Underbody Charging Box Layout for Durable EV Fleet Docking
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Solution Overview
Problem
Conventional pin-type electrical connectors used in charging systems are insufficiently durable for frequent use, particularly in applications requiring thousands of connections and disconnections, such as fleets of electric vehicles, leading to potential durability issues.
Innovation Solution
A charging system that includes a charging box mounted to the underside of a vehicle, which connects to a charge coupler using larger, robust electrical contacts, and utilizes near-field communication or other wireless protocols to ensure safe and efficient charging without manual intervention, allowing for autonomous alignment and contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pin-type electrical connectors are used for charging, then the charging system can be established, but the durability is insufficient for frequent use
Solution Approach 1:
The patent extracts the connector from the vehicle and places it in the docking station instead. The vehicle has a simple charging port that receives the connector from the station, eliminating the need for durable connectors on the vehicle while maintaining frequent connectivity capability
Solution Approach 2:
Instead of the vehicle carrying the connector that plugs into the station, the invention inverts this arrangement by having the station carry the connector that plugs into the vehicle. This reversal transfers the wear and durability requirements to the stationary component rather than the mobile one
2Reliability
If manual connection of electrical connectors is required, then charging can be performed, but safety risks from unintended contact with energized contacts exist
Solution Approach 1:
The system performs preliminary alignment and positioning actions before electrical contact is made. The vehicle autonomously maneuvers into the docking station and aligns its charging port with the station's connector, ensuring proper positioning before energization occurs
Solution Approach 2:
The system incorporates feedback mechanisms to detect when the vehicle is properly positioned and when electrical contacts are securely made. This feedback controls the energization sequence, ensuring safety by confirming proper alignment before applying power
3Ease of operation
If charging infrastructure is distributed at numerous locations, then convenience is improved, but the duration and availability of charging may be limited
Solution Approach 1:
The docking station is designed as a universal charging infrastructure that can serve multiple vehicles sequentially. The station incorporates both the connector and the charging equipment in one location, allowing any vehicle with a compatible port to access charging at that specific location
Data Source
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AI summary
A system for charging one or more batteries of a vehicle may include a charging box mounted to a vehicle to facilitate connection to a charge coupler from under the vehicle. The charge coupler may be configured to provide an electrical connection between an electrical power source and the charging box. A vehicle including the charging box may maneuver to a position above the charge coupler, after which electrical contacts of the charging box and the charge coupler may be brought into contact with one another. The charge coupler and/or the charging box may be configured to provide electrical communication between the electrical power source and the one or more batteries, so that the electrical power source may charge one or more of the batteries. Thereafter, the electrical contacts may be separated from one another, and the vehicle may maneuver away from the charge coupler.