Pantograph Charging Head with Ball-and-Socket Joint for Electric Bus
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Solution Overview
Problem
Existing connection systems for charging electric bus batteries require precise maneuvering of the vehicle and often rely on complex and unreliable aiming devices, especially in adverse weather conditions, to ensure correct connection of high-current contacts, which complicates the charging process and reduces operational safety and comfort.
Innovation Solution
A connection system featuring a head with a ball-and-socket joint mounted on a pantograph, equipped with prismatic dielectric holders and slidably mounted electrical brushes, which connects with a platform having dielectric strips and driving mechanisms, allowing for flexible alignment and reducing the need for precise vehicle positioning, and includes communication contacts for circuit continuity checks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex aiming devices are used to ensure correct connection of high-current contacts, then connection reliability is improved, but device complexity increases and reliability decreases in adverse weather conditions
Solution Approach 1:
The patent removes complex aiming devices from the system entirely. Instead, it uses a pantograph mechanism with a head that can be manually positioned by the driver, and the connection is achieved through direct mechanical contact between the head and platform contacts, eliminating the need for complex optical or electronic aiming systems.
Solution Approach 2:
The system allows the driver to directly operate the pantograph head positioning without requiring complex automated aiming systems. The driver manually adjusts the head position to align with the platform, and the self-aligning nature of the ball-and-socket joint facilitates reliable connection without additional complexity.
2Measurement precision
If precise vehicle maneuvering is required for correct connection, then connection accuracy is improved, but ease of operation deteriorates and operational safety reduces
Solution Approach 1:
The patent employs a pantograph mechanism with a ball-and-socket joint that provides dynamic adjustment capability. The head can be manually positioned in multiple directions and angles, allowing the driver to easily align it with the platform without requiring precise vehicle maneuvering. The mechanism absorbs positioning errors through its degrees of freedom.
Solution Approach 2:
The system changes the positioning parameters from requiring precise vehicle location to allowing manual adjustment of the head position. The ball-and-socket joint enables angular and positional adjustments, transforming the problem from one of precise vehicle maneuvering to one of simple manual alignment.
3Productivity
If high power charging stations are constructed for fast recharging, then charging speed is improved, but operational safety and comfort deteriorate due to increased human attendance requirements
Solution Approach 1:
The system enables the driver to independently operate the charging connection process by manually positioning the pantograph head and establishing contact with the platform. This self-service capability eliminates the need for additional personnel or complex safety systems, maintaining operational safety while enabling fast charging.
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 enables safe, reliable, and ergonomic charging of electric buses by allowing for flexible alignment and reducing the complexity of the connection process, eliminating the need for precise vehicle positioning and complex aiming systems, thus improving operational safety and efficiency.
Implementation Method 1
the head is connected with the lifting mechanism through a ball-and-socket joint
Implementation Method 2
Inside the dielectric holders 1a the electrical brushes 1as, 1bs, 1cs, and 1ds are mounted slidably on springs S
Implementation Method 3
The head 1, thanks to its being mounted through the ball-and-socket joint 2, has the number of degrees of freedom required for its correct connection with the platform 4
Data Source
AI summary
Design of a connection system for charging batteries of a vehicle, according to the invention comprises a head (1) connected with a lifting mechanism (3) through a ball-and-socket joint (2). The head (1) of basically prismatic shape is formed by mechanically connected dielectric holders of a PE contact segment (1a), a positive pole high-current contact segment (1b), a negative pole high-current contact segment (1c) and a communication contact segment (1d), and inside each holder respective electrical brushes (1as, 1bs, 1cs, and 1ds) are mounted slidably on springs (S). The electrical brushes (1as, 1bs, 1cs, and 1ds) in their extreme positions protrude from the holder surfaces, furthermore the brushes (1as) of the PE contact segment (1a) protrude from the top surface of the head (1), whereas the brushes (1bs) of the positive pole high-current contact segment (1b), the brushes (1cs) of the negative pole high-current contact segment (1c) and the brush (1ds) of the communication contact segment (1d) protrude from two opposite side surfaces of the head. The platform (4) is constituted by a body (4a) inside which at least one dielectric strip (4b) is mounted in parallel to the opposite sides of the body (4a) and slidably in the direction perpendicular to these sides of the body. The strip (4b) is connected with a driving mechanism (4c) mounted in the body (4a). The strip holds (4b) a negative pole high-current contact rail (4b1), a positive pole high-current contact rail (4b2), and a communication contact rail (4b3). The inner surface (4pw) of the wall which covers the body (4a) from above is electrically conductive. When the strip (4b) is in such a position that it is in contact with the side surface of the head (1), the brushes (1bs) of the positive pole high-current contact segment (1b), the brushes (1cs) of the negative pole high-current contact segment (1c) and the brush (1ds) of the communication contact segment (1d) are in contact with the surface of the positive pole high-current contact rail (4b2), the surface of the negative pole high-current contact rail (4b1) and the surface of the communication contact rail (4b3), respectively.