Sliding Conductor Rail With Narrow Slot for Safe EV Charging
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Solution Overview
Problem
Existing electrical sliding pavement conductive connection devices for electric vehicles face challenges in providing safe and efficient high-power charging for heavy-duty vehicles, particularly in high-traffic areas, due to limitations in electric protection and power capability, requiring complex and expensive power switching systems and not supporting large current shoe contact surfaces for rapid charging.
Innovation Solution
A conductive connection device with a pavement conduit featuring a vertical slit and inclined overhang contact surfaces, allowing dynamic and static charging with at least three cables connected to the ground, including a mechanism for controlled pressure on current shoes and a flexible metal structure for easy installation, enabling high-power transfer in dense traffic conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vertical slit with width less than 12mm is used in the conduit, then electric protection is enhanced by preventing finger penetration, but the contact surface area for current shoes is reduced
Solution Approach 1:
The patent implements a nested structure where the current shoe assembly with contact surfaces is positioned inside the conduit cavity, which itself is within the pavement structure. The inclined overhang contact surfaces are nested within the cavity space, allowing large contact areas to be achieved within the constrained slit width by utilizing the three-dimensional cavity volume rather than expanding the slit opening.
Solution Approach 2:
The patent transitions from a two-dimensional contact surface problem to a three-dimensional solution by creating an inclined overhang contact surface that extends into the cavity depth. This allows the contact surface area to be increased by utilizing the vertical and depth dimensions of the cavity rather than simply widening the horizontal slit opening.
2Productivity
If high power transmission is implemented for rapid charging, then charging speed is improved, but complex and expensive power switching systems are required
Solution Approach 1:
The patent enables the electrical connection system to serve itself by using the natural mechanical pressure from the current shoes against the inclined overhang contact surfaces to maintain reliable electrical contact. The system utilizes the self-aligning geometry of the inclined surfaces and the natural downward force of the current shoe assembly to ensure consistent pressure and connection without requiring external switching control systems.
Solution Approach 2:
The patent extracts and eliminates the complex power switching system from the overall charging infrastructure by relying on the passive electrical connection through the inclined contact surfaces. The high power transmission is achieved through the direct conductive connection enabled by the mechanical pressure of the current shoes on the contact surfaces, removing the need for active switching components.
3Power
If large current shoe contact surfaces are provided for high power transmission, then power capability is improved, but the device structure becomes more complex
Solution Approach 1:
The patent applies local quality by concentrating the contact surface optimization at the inclined overhang surfaces within the cavity, where the electrical contact is most critical. The rest of the conduit structure maintains a simple cylindrical form, allowing large contact surfaces to be achieved locally without increasing the overall device complexity. The inclined surfaces are precisely formed only where needed for electrical contact.
Solution Approach 2:
The patent merges the structural support function and the electrical contact function into a single integrated inclined overhang surface. The contact surfaces serve both as the structural element defining the cavity geometry and as the electrical contact interface, eliminating the need for separate contact components and reducing overall device complexity while maintaining large contact area.
4Extent of automation
If the conduit is designed for dynamic charging with vertical entry, then automation is improved, but the rotation of current shoe assemblies is increased
Solution Approach 1:
The patent provides beforehand cushioning by designing the inclined overhang contact surfaces to naturally guide and limit the rotation of current shoe assemblies during the vertical entry process. The inclined geometry pre-determines the rotation path and limits it to less than 60 degrees, cushioning against excessive rotation that would complicate the mechanism while still enabling automated dynamic charging operation.
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 solution provides safe and efficient high-power charging for multiple vehicles in dense traffic, reducing the need for complex power switching systems and enhancing electric protection, allowing for reduced battery size and weight in heavy-duty trucks, while maintaining safety and reliability.
Implementation Method 1
the cavity containing at least two electrical contact surfaces connected to a fixed current source, the contact surfaces being recessed from direct access through the slit and positioned in inclined overhang
Data Source
AI summary
Conductive, dynamic and static connection device for electrical supply of electrically propelled vehicles comprising one current collector on board the vehicles, and one fixed conduit, comprising a vertical slot, opening into a cavity of the conduit to receive, vertically or horizontally, the current collector, the cavity containing electrical contact surfaces connected to a source, the contact surfaces being recessed from direct access through the slot, the electrical conductive supply comprises at least three conductors, one of which is “ground”, the vertical slot of the fixed conduit having a width “L” of less than 12 mm preventing the introduction of fingers in the slot, and in case the current collector is entering the conduit vertically, the collector comprises two current shoe assemblies articulated on a longitudinal horizontal axis, the rotation around the longitudinal horizontal axis between the vertical retrieval position and the contact position being less than 60 degrees.