Heated Charging Contact Rail for Stable EV Fast Charging

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Solution Overview

Problem

Fast charging systems for electric vehicles face issues with electric arcs and disrupted connections due to relative movement and high electrical resistance, especially in humid weather, leading to premature wear of charging contact elements and potential charging process interruptions.

Innovation Solution

A fast charging system with a heating device to control the temperature of charging contact elements, preventing frost, ice, and humidity, and a positioning device that compensates for vehicle movement and misalignment, ensuring a stable and cost-effective electroconductive connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the contact device is inserted vertically into the charging contact device, then the contact position can be reached accurately, but electric arcs occur due to high electrical resistance and relative movement during charging

Engineering Contradiction:

Improvecontact position accuracyVSAvoidcharging connection stability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

Instead of inserting the contact device vertically into the charging contact device as in prior art, the patent inverts the approach by having the charging contact device inserted into the contact device. This inversion changes the relative movement dynamics and contact geometry, reducing electric arc formation while maintaining positioning accuracy through the positioning device

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the contact geometry from punctiform (point contact) to strip-shaped contact surfaces. This parameter change increases the contact area, reduces electrical resistance, and minimizes electric arcs during the charging process, thereby improving connection stability

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If the contact elements have a small contact surface, then the contact device structure is simplified, but electric arcs occur due to high electrical resistance

Engineering Contradiction:

Improvecontact device structureVSAvoidelectrical connection stability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies local quality by making the charging contact elements have strip-shaped contact surfaces while keeping the contact elements simpler. This localized improvement in contact surface geometry reduces electrical resistance and electric arcs at the critical contact interface without significantly complicating the overall device structure

Inventive Principle:

Principle #3Local quality

3Productivity

If the charging process continues during vehicle movement, then charging efficiency is maintained, but relative shift between contact elements causes electric arcs and wear

Engineering Contradiction:

Improvecharging efficiencyVSAvoidcontact element durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces a positioning device that dynamically adjusts and compensates for relative movements between the contact device and charging contact device during charging. This dynamic compensation maintains stable contact and prevents electric arcs even when the vehicle moves, allowing continuous charging without compromising contact element durability

Inventive Principle:

Principle #15Dynamics

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

The system ensures a safe and uninterrupted charging process by maintaining contact element temperature and stabilizing the connection, reducing wear and tear, and allowing for efficient high-current charging.

Implementation Method 1

the charging contact device having a heating device by means of which the temperature of the charging contact elements is controllable

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20230415588A1Rapid charging system and method for electrically connecting a vehcile to a charging station

Publication Date: 2023.12.28 SCHUNK TRANSIT SYST GMBH

AI summary

The invention relates to a fast charging system for electrically driven vehicles, in particular electric busses or the like, and to a method for forming an electroconductive connection between a vehicle and a stationary charging station by means of a contact device, a charging contact device (10) and a positioning device, the contact device or the charging contact device being disposed on a vehicle, the charging contact device being electrically connectable to the contact device in a contact position, the contact device being positioned in a longitudinal and/or transverse direction with respect to the charging contact device and being moved to the contact position by means of the positioning device, the charging contact device having a charging-contact-element carrier (12) comprising charging contact elements (13), the charging-contact-element carrier being formed as a longitudinal rail disposed in a moving direction of the vehicle, the charging contact elements each forming a strip-shaped charging contact surface, the contact device having a contact element carrier comprising contact elements, the contact elements each forming a contact surface which is smaller than the charging contact surface, the contact elements being electrically connectable to the charging contact elements for forming respective contact pairs in the contact position, the charging contact device having a heating device (35) by means of which the temperature of the charging contact elements is controllable.