Underground EV Charging Connector with Spring Alignment
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges with heavy and cumbersome liquid-cooled cables, vulnerable connectors, and the need for expensive robotic systems for handling high-power charging, which are difficult for humans to manage safely and efficiently.
Innovation Solution
A charging arrangement where the first charging connector is positioned underneath the electrical vehicle, allowing for simple and automated connection by driving the vehicle over a charger component with a spring-based mechanism that provides flexibility for vertical, horizontal, and rotational movement, eliminating the need for complex actuation systems and reducing cable weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooled charge cables are used for high power charging, then heat dissipation is improved and conductors can be thinner, but cable weight increases and handling becomes difficult
Solution Approach 1:
The patent extracts the cooling function from the cable itself by implementing a charging station with active cooling capability. The cooling system is separated from the cable and integrated into the stationary charging infrastructure, allowing the cable to be lighter while still providing effective heat management through the station's cooling apparatus.
Solution Approach 2:
The patent introduces an intermediary cooling system at the charging station that mediates between the power transmission function and heat dissipation requirements. This intermediary system handles the thermal management burden, allowing the cable to focus on electrical conduction without carrying excessive weight for cooling purposes.
2Productivity
If charge current is increased for faster charging, then charging speed is improved, but cable thickness and weight increase
Solution Approach 1:
The patent replaces the mechanical solution of thicker cables with higher current capacity with an electrical/electronic solution implemented at the charging station. The station incorporates power management and cooling systems that enable high current transmission through lighter cables by actively managing thermal constraints and electrical load distribution.
Solution Approach 2:
The patent changes the operating parameters at the charging station level rather than at the cable level. By adjusting voltage, current, and cooling parameters at the station, the system achieves high charging speeds through optimized electrical parameters rather than through physically heavier cables.
3Reliability
If robotic systems are used for connector handling, then connector damage is reduced, but system cost increases and safety risks to humans arise
Solution Approach 1:
The patent implements a self-aligning connector system where the charging connectors are designed to automatically align and connect through simple vehicle movement. The ground-based connector positioning system provides guidance features that enable automatic engagement without requiring complex robotic manipulation, reducing both cost and safety risks while maintaining reliable connection.
Solution Approach 2:
The patent employs dynamic positioning capabilities at the ground-based connector rather than fixed positioning. The connector can adjust its position in real-time to accommodate vehicle movement and alignment variations, enabling reliable connection through controlled movement rather than requiring precise robotic placement.
4Area of stationary object
If overhead mounting is used for charging station, then space utilization is improved, but connector alignment precision becomes more difficult
Solution Approach 1:
The patent introduces guiding elements and alignment features as intermediary components between the overhead mounting structure and the charging connectors. These intermediaries provide mechanical guidance and positional reference that maintain alignment precision despite the overhead mounting configuration, bridging the gap between space-efficient mounting and precise connector positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, safe, and cost-effective high-power charging without the need for expensive robotic systems, allowing for flexible positioning and reduced risk of connector damage, while maintaining effective electrical contact even if the vehicle is not perfectly aligned.
Implementation Method 1
The spring allows a vertical, horizontal and rotational movement of the second charging connector within a certain range
Data Source
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AI summary
The invention relates to a charging arrangement for an electrical vehicle (2), comprising the electrical vehicle (2) and a charger component (3), whereby the electrical vehicle (2) comprises a first charging connector (1) arranged underneath the electrical vehicle (2) for receiving electrical energy to charge the electrical vehicle (2), whereby the first charging connector (1) comprises at least two vehicle contacts (16) which are spaced apart from each other and extend both in longitudinal direction of the electrical vehicle (2) and from the electrical vehicle (2) towards ground (6), and the charger component (3) comprises at least one spring (7) attached to ground (6) and a second charging connector (4) for providing electrical energy to the electrical vehicle (2), whereby the second charging connector (4) is attached to the at least one spring (7), the spring force allowing a vertical, horizontal and rotational movement of the second charging connector (4), the second charging connector (4) comprises at least two charging contacts (8) corresponding to the at least two vehicle contacts (16) and at least three intermediate elements (9), each charging contact arranged recessed between two adjacent intermediate elements (9), the at least two charging contacts (8) and/or the at least three intermediate elements (9) extend in a longitudinal direction such that, by inserting the first charging connector (1) onto the second charging connector (4), electrical connection is established between the first charging connector (1) and the second charging connector (4).