Segmented Charge Rail for Safe Automatic Vehicle Charging
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Solution Overview
Problem
Charging of parked road vehicles requires manual cable connection, which is inconvenient and limits flexibility, especially for heavy vehicles that need to be moved quickly, and poses safety risks due to locked cable sockets.
Innovation Solution
A charge rail system with electrically isolated segments (charging control, DC-, DC+, and PE) that allows for automatic connection and disconnection without leaving the vehicle cockpit, featuring a CCS arrangement and safety mechanisms like curtain protection and sensors to prevent accidents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cable connection is used for charging, then charging can be performed, but flexibility is reduced and driver convenience is worsened
Solution Approach 1:
The charge rail system enables automatic connection and disconnection without requiring manual intervention from the driver. The vehicle's charge pickup arrangement automatically engages with the charge rail segments, and the system self-regulates the charging process through control pilot signals, eliminating the need for driver involvement in cable handling.
Solution Approach 2:
The patent replaces the mechanical cable connection system with an electrical contactless charging system. The charge rail uses electrical segments that establish contact through a charge pickup arrangement, eliminating the need for physical cable manipulation and mechanical locking mechanisms.
2Reliability
If cable socket is locked to the vehicle, then safety is improved, but flexibility is reduced
Solution Approach 1:
The charge rail system implements dynamic connection and disconnection capabilities. The charge pickup arrangement can automatically engage with the charge rail segments when needed and disengage when the vehicle needs to move, providing both safety during charging and flexibility for vehicle relocation without locked sockets.
Solution Approach 2:
The charge pickup arrangement acts as an intermediary between the vehicle and the charge rail segments. It establishes electrical contact for charging while allowing the vehicle to be moved when charging is not required, mediating between the need for secure connection and the need for flexibility.
3Ease of operation
If driver leaves cockpit to connect cable, then charging connection is established, but time is lost and productivity is reduced
Solution Approach 1:
The charge pickup arrangement automatically performs the connection function without requiring the driver to leave the cockpit. The system detects when the vehicle is positioned for charging and automatically establishes electrical contact with the charge rail segments, maintaining driver presence and operational continuity.
Solution Approach 2:
The charge pickup arrangement is pre-positioned on the vehicle and automatically engages with the charge rail segments when the vehicle approaches the charging position. This preliminary positioning eliminates the need for manual cable connection steps and reduces charging setup time.
4Reliability
If charge rail segments are electrically isolated, then safety is improved, but device complexity increases
Solution Approach 1:
The charge rail is divided into multiple electrically isolated segments (positive voltage, negative voltage, control pilot, protective earth). Each segment is independently controlled and can be selectively activated, improving safety by preventing unintended current flow while managing complexity through modular design.
Solution Approach 2:
Different segments of the charge rail have different electrical properties and functions. The control pilot segment operates at low voltage for signaling, while the DC segments operate at high voltage for power transfer. This local differentiation of electrical characteristics enhances safety while maintaining manageable system complexity.
Data Source
AI summary
A charge rail for charging a parked road vehicle is provided. The charge rail comprising: a charging control segment; a first charging segment; a second charging segment; and a Protective Earth, PE, segment. The segments are arranged one after another along a longitudinal extension of the charge rail, are electrically conducting, and are mutually electrically isolated from each other. The charge rail further comprising a base supporting the segments.