Overhead EV Charging Gantry for Automatic Coil Alignment
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Solution Overview
Problem
Current wireless charging systems for electric vehicles require ground-based installations, which are susceptible to interference from water, debris, and wear, and necessitate precise alignment, making them inefficient and requiring user intervention, especially for fleet charging where multiple vehicles need to be charged simultaneously.
Innovation Solution
A gantry-like overhead structure that maneuvers a power transmitting coil in x, y, and z directions to align with a power receiving coil integrated into the electric vehicle's hood, enabling automatic and efficient wireless charging without the need for ground-based installations, allowing for charging of multiple vehicles parked side-by-side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ground-based charging pads are used for wireless charging, then wireless charging capability is achieved, but the system becomes susceptible to interference from water, debris, and wear
Solution Approach 1:
The patent inverts the conventional ground-based charging approach by placing the charging coil overhead instead of underneath. The vehicle passes through an overhead gantry structure containing the charging coil, eliminating contact with ground-level contaminants like water, debris, and wear from vehicle traffic. This spatial inversion resolves the reliability issue while maintaining wireless charging functionality.
Solution Approach 2:
The patent transitions from a two-dimensional ground-based charging pad to a three-dimensional overhead gantry structure. By moving the charging coil vertically above the vehicle path and enabling movement in x, y, and z directions, the system creates a new spatial dimension for charging, avoiding ground-level interference while maintaining effective charging distance.
2Productivity
If ground-based charging pads are used, then wireless charging is enabled, but precise alignment is required which reduces efficiency and requires user intervention
Solution Approach 1:
The patent employs dynamic positioning systems that actively adjust the overhead charging coil's position in real-time during the charging process. Sensors detect the vehicle's location and the charging coil automatically adjusts its x, y, and z coordinates to maintain optimal alignment, eliminating the need for manual user intervention and ensuring consistent charging efficiency throughout the vehicle's passage.
Solution Approach 2:
The system incorporates feedback mechanisms where sensors monitor the relative position between the overhead charging coil and the vehicle's receiving coil. This feedback information is used by control systems to automatically adjust the charging coil's position, ensuring precise alignment without requiring user intervention and maintaining high charging efficiency throughout the charging cycle.
3Ease of manufacture
If ground-based charging pads are installed, then charging infrastructure is established, but modification of concrete or pavement is required
Solution Approach 1:
The patent inverts the installation approach by placing the charging infrastructure overhead rather than embedded in the ground. This eliminates the need for concrete or pavement modification while still providing stable structural support through existing overhead structures like gantries or bridges, significantly simplifying installation.
Solution Approach 2:
The overhead charging system is divided into modular components including the gantry structure, charging coil assembly, and positioning systems. This segmentation allows for flexible installation on existing structures without requiring ground modification, and enables easy maintenance or relocation of individual modules independently.
4Ease of operation
If overhead gantry structure is used, then alignment issues are eliminated, but device complexity increases
Solution Approach 1:
The overhead gantry structure is designed to perform multiple functions: supporting the charging coil, providing structural stability, housing positioning mechanisms, and incorporating sensing systems. This multi-functionality consolidates what would otherwise be separate systems into a single integrated structure, reducing overall system complexity despite the added capability for automated alignment.
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
This solution provides a convenient, efficient, and scalable method for wireless charging, eliminating alignment issues and interference concerns, while enabling automatic operation and simultaneous charging of multiple vehicles, thus enhancing the adoption of electric vehicles by simplifying the charging process.
Implementation Method 1
The basic principle behind wireless charging for electric vehicles is electromagnetic induction. It involves transferring energy between two coils: a transmitter coil (installed in a charging pad or ground-based infrastructure) and a receiver coil (integrated into the EV). When the transmitter coil is supplied with electricity, it generates a magnetic field. This magnetic field induces an alternating current in the receiver coil, which is then converted back into direct current electricity to charge the EV's battery.
Data Source
AI summary
A wireless charging system and method for an electric vehicle, includes a gantry-like overhead structure for maneuvering in vertical and horizontal directions a power transmitting coil mounted on a charging line (e.g., rod or cable) suspended from the gantry-like overhead structure to a power receiving coil mounted to a surface (e.g., hood) of an electric vehicle (EV) for wireless charging of the EV. The gantry-like overhead system can move along a track to charge multiple vehicles (e.g., fleet vehicles) parked side-by-side in a parking structure. Movement of the gantry-like system can be automatic based on input from at least one sensor to a controller included in the wireless charging system.