Patent Application
20240010083
The present technology relates to charging systems for electric vehicles (“EV”s) and in particular to apparatus and methods for managing cables for delivering charging current to electric vehicles.
Electric vehicles (EVs), which may be battery electric or plug-in hybrid vehicles of any sort, including personal cars and trucks, commercial and fleet vehicles, industrial equipment (such as forklifts), aircraft, aircraft service vehicles, delivery drones, watercraft, and the like, are typically charged by a charging system configured to deliver electrical charging current to the EV by way of a charging cable.
A typical EV charging system includes an electric power source connected to supply electrical power to an electrical relay and control unit known as Electric Vehicle Supply Equipment (EVSE), which in turn may be connected to charge one or more EVs by one or more charging cables.
A typical EVSE receives signals from an EV indicating when the EV is ready to receive charging current and interprets those signals, then either connects or disconnects the power source to the charging cable connected to the vehicle. An EVSE may also have other functions such as determining charge priority between two or more EVs and switching power on or off to selected EVs accordingly, and indicating the status and energy transfer rate of the charging circuit.
Most currently available EV charging equipment includes a charging cable that lies on the ground while connected between a charging station and an EV. To connect an EV to a charging station a user must typically pull a charging cable connected to the charging station toward the EV and connect the cable to a charging receptacle of the EV. After charging is complete the user may coil and hang the charging cable. Charging cables can be heavy, especially when long and designed to carry high charging currents and can be dirty especially if deployed on the ground.
With ever increasing adoption of EVs for commercial and personal use, ever-increasing numbers of parking spaces will require access to a charging station. Many households already have, or will soon have an EV regularly parked and needing to be charged in their driveways and garages, and many of these households will soon add a second EV.
Suitably locating an EV charging station can be challenging because the charging station needs a source of electrical power, needs to be located reasonably close to an area where an EV may be parked during charging and needs to include a structure suitable for mounting components of the charging station. This problem can be further complicated where it is desired to situate the charging station to allow two or more vehicles to be simultaneously connected for charging. The charging station should be installed in a way that can accommodate different EVs that may have charging receptacles at different locations on the EV as well as different orientations of the EV (e.g. one driver may prefer to back into a charging spot while another may prefer to drive forward into the charging spot).
Accordingly, there is a need for charging stations that include cables that can reach a wide area around the charging stations. Many existing charging stations approach this need by providing long cables, which are meant to be manually stowed at the station (eg. by looping over a hook) when not in use. In use, the cable normally lies on the ground between the station and the vehicle. These stations have the disadvantage of being inconvenient for the user, requiring that the cable (which are typically quite heavy, and may be wet and/or dirty) be coiled up and stowed. In practice, charging cables are frequently left on the ground creating a messy appearance, a tripping hazard, a barrier to mobility-limited users (wheelchair, walking aid, or scooter), and also creating a situation where the cable and plug is at risk of being run over and damaged. This approach is also limited by the maximum cable length of 25 feet currently allowed for many EVSEs.
Some existing charging stations include a mechanical retractor attached via a small diameter tension cable to the larger, heavier charging cable at a point along the charging cable length. The retractor may support a portion of the charging cable up off the ground and close to the station until a user pulls the charging cable away from the station. This approach has the added complexity of a retractor which typically relies on springs, counterweights, or other mechanical means to apply tension to the retractor cable. Also, the length of charging cable that can be controlled and held off the ground is typically limited by the height of the station structure.
Retractor-type cable reels are available that directly spool the charging cable onto a reel until pulled out by the user. Charging cables are typically quite heavy and often have a diameter greater than 0.5 inch, requiring a relatively heavy and complex retractor to stow sufficient length of charging cable. Such charging cable retractor reels suffer the disadvantages of cost, complexity, and weight.
One type of existing charging station, the Tesla ‘Supercharger’, has a short cable that can be more easily stowed within the station, but requires the user to back the vehicle in to within a specific distance of the station (optionally using driving assist features specific to the vehicle and station), and can only accommodate vehicles with the charge receptacle at the left rear of the vehicle. This approach is limited to particular vehicles and parking orientations.
Although modern charging software typically prevents the driver from driving away with the vehicle connected to the charger, there are other situations in which excess tension may be applied to the charging cable, for example becoming tangled with a moving vehicle, rough usage, abuse such as a person climbing or swinging on the cable, or vandalism. Similarly, abuse loads may be applied to part of the charging station other than the cable, for example a person stepping or climbing on the station structure or using the station structure to support weight other than the weight of the charging cable.
U.S. Pat. No. 10,308,122 Rodriguez shows an industrial charging station including a base unit containing electrical supply equipment and an arm through which charging cables pass pivoting about a horizontal pivot axis, with heavy counterbalance weights used to ease operation.
U.S. Pat. No. 8,925,885, Ishii et al. shows an articulated arm with horizontal pivot axes, gravity compensation apparatus, a parallelogram mechanism, and a charging plug directly attached to the end of the last arm segment.
U.S. Pat. No. 8,373,389, Badger shows an articulated overhead arm that positions a charging plug. The arm has swivel joints that provide 6 degrees of freedom between the base and the end of the arm.
U.S. Pat. No. 5,306,999, Hoffman shows charging stations that include a base and articulated arms with parallelogram mechanisms. A charging plug is directly coupled to the last arm segment. Hoffman also shows an embodiment with a vertical tube enclosing a portion of a charging cable, the tube being connected to the base by a coil spring thus allowing the tube to move to a non-vertical position in a conical range when the cable is pulled, and biased to return to the vertical position when the cable is released.
This arrangement has no predetermined force or travel limit, other than the elastic deformation or breaking limits of the components and their attachment means.
US Patent Publication No. US2015/0060611, Takahashi et al. shows a wall-mounted articulated overhead arm having rectangular tube section arms and magnet catches to hold the arms in a stowed position. A charge cable extends through bores extending along the arms. The plug end of the charge cable hangs from a hole in a distal end of the arm.
WO202235319 A1, Van Den Brande et al. shows an overhead arm with a horizontal pivot axis, having a sliding carriage in a vertical base and a support member. This unit folds to a vertical non-functional state.
WO202143897 A1, MacDonald shows a vertically stowing arm having a sliding mechanism.
WO202147762 A1, Tueschen et al. shows a single pivoting arm supporting a charging cable, with a spring or counterweight mechanism biasing the arm to a stowed position. A cable slides through an opening on a distal end of the arm.
The inventors have recognized a need for EV charging stations that include features for improved cable management as well as other enhancements.
The present invention has a number of aspects. While these aspects have synergies when combined they also have benefit when applied individually. Without limitation, the present invention includes:
The present technology has example application in an improved EV charging station that has a base unit attached to a structure and an electrical power source, an arm portion that extends from a support (e.g. the base unit, the structure or another support). The arm carries a charging cable. A portion of the charging cable hangs from a distal end of the arm and terminates at a charging plug. The arm may be mounted to the support via a pivot joint, such that the arm is movable by pivoting around an axis of the pivot joint in a selected range. Example embodiments of the present technology include one or a combination of any two or more of the following features:
One aspect of the present technology provides an electric vehicle charging station, comprising an electrical power supply cable, a control unit connectable to receive electrical power from the power supply cable, a charging plug adapted to connect to an electric vehicle, a charging cable having a proximal end connected to the control unit and a distal end connected to the charging plug, a base portion mountable to a structure, and an arm projecting from the base portion and supporting at least a portion of the charging cable, the arm having a proximal end coupled to the base portion and a distal end spaced apart from the base portion, the electric vehicle charging station further comprising one or more of:
Another aspect of the present technology provides a cable assembly useful for electric vehicle charging, The cable assembly comprises an arm comprising a mount configured to attach the arm to a structure such that the arm projects outwardly from the structure. A cable is supported by the arm and has a free end extending from a distal end of the arm. The cable is releasably attached to the arm by a force limiting mechanism. The force limiting mechanism is operative to allow the cable to be separated from the arm in response to tension pulling the free end of the cable in a direction such that a force component in a direction transverse to the arm has a magnitude exceeding a threshold. A plug may be provided at an end of the cable for charging an EV.
In some embodiments the arm is formed with a longitudinally extending channel that has an opening facing outwardly of the arm, the cable extends along the channel, and the force limiting mechanism comprises one or more members that block the cable from being pulled out of the channel through the opening.
In some embodiments the channel extends along a lower surface of the arm.
In some embodiments the force limiting mechanism comprises an elongated panel that covers the opening of the channel.
In some embodiments the one or more members support a light emitting strip that extends along the channel.
In some embodiments the panel is held to the arm by push-in rivets spaced apart along a length of the channel.
In some embodiments the panel comprises laterally-projecting flexible tab portions, the channel includes first and second recesses on opposing sides of the channel and the panel is held to the arm by engagement of the flexible tabs of the panel with the recesses on the opposing sides of the channel.
In some embodiments the force limiting mechanism comprises a breakaway conduit attached to the arm by releasable fasteners configured to allow the breakaway conduit to pull away from the arm in response to the force component acting on the breakaway conduit.
In some embodiments the releasable fasteners are selected from push in rivets or magnets or adhesive pads or hook and loop fasteners.
In some embodiments the threshold is 45 kg force or less.
In some embodiments the arm is coupled to the mount by a coupling that comprises a mechanical fuse, the mechanical fuse configured to deform or break to allow the distal end of the arm to drop to a dropped position in response to a moment caused by downward force on the arm wherein the arm remains in the dropped position until the arm is reset or the mechanical fuse is replaced. In some embodiments in moving from a normal position to the dropped position the distal end of the arm is lowered by no more than 30 centimeters.
In some embodiments the arm remains in the dropped position until the arm is reset or the mechanical fuse is replaced.
In some embodiments the arm is coupled to the mount by a pivot assembly configured to allow the arm to pivot about a substantially vertical axis.
In some embodiments the pivot assembly comprises a bias mechanism connected to bias the arm toward a stowed position.
In some embodiments the arm lies parallel to a face of the structure when the arm is in the stowed position.
In some embodiments the pivot assembly comprises a mechanical fuse, the mechanical fuse configured to deform or break to allow a pivot axis of the pivot assembly to shift from a normal vertical orientation to an inclined orientation in response to a moment caused by downward force on the arm exceeding a threshold moment.
In some embodiments the pivot assembly comprises first and second spaced apart bearings that define the pivot axis wherein the mechanical fuse holds the first bearing in a position such that the pivot axis is vertical and deformation or breaking of the mechanical fuse allows transverse movement of the first bearing relative to the second bearing such that the pivot axis is movable to an angle that is inclined to vertical. In some embodiments the second bearing is a spherical bearing. In some embodiments the first bearing is slidable along a slot that extends transversely relative to the pivot axis and the mechanical fuse comprises a member that blocks the first bearing from sliding along the slot until a compression or tension force on the mechanical fuse exceeds a threshold. In some embodiments the mechanical fuse comprises a deformable circlip.
In some embodiments the pivot assembly is configured so that the pivot axis remains in the inclined position until the arm is reset or the mechanical fuse is replaced.
In some embodiments the cable assembly comprises a mechanical fuse, the mechanical fuse configured to deform or break to allow an angle of the arm relative to a pivot axis of the pivot assembly to shift downward from a normal orientation to a changed orientation in which the distal end of the arm is lowered in response to a moment caused by downward force on the arm exceeding a threshold moment. In some embodiments the mechanical fuse is located between a bearing of the pivot assembly and a support member on the arm and the mechanical fuse is in a line of force transmission between the support member and the bearing. In some embodiments the mechanical fuse is normally in compression and is configured to be reduced in length upon being deformed or broken. In some embodiments the mechanical fuse is normally in tension and is configured to be increased in length upon being deformed or broken.
In some embodiments the cable assembly comprises an electrical switch that is arranged to change state in direct or indirect response to the mechanical fuse deforming or breaking. In some embodiments the electrical switch is connected to control application of charging current through the cable and the change of state of the electrical switch causes the supply of charging current to be interrupted.
In some embodiments the arm comprises at least one intermediate pivot joint configured to allow a distal portion of the arm to be pivoted relative to a proximal portion of the arm. In some embodiments the intermediate pivot joint comprises a mechanical fuse, the mechanical fuse configured to deform or break to allow the distal portion of the arm to move to a dropped position in response to a moment caused by downward force on the distal portion of the arm wherein the distal portion of the arm remains in the dropped position until the distal portion of the arm is reset or the mechanical fuse is replaced.
In some embodiments the cable assembly comprises a charging plug attached to a distal end of the cable.
In some embodiments the cable is a first cable and the cable assembly also comprises a second cable supported by the arm, releasably attached to the arm and having a free end extending from a distal end of the arm.
In some embodiments the second cable is releasably attached to the arm by the force limiting mechanism.
In some embodiments the second cable is releasably attached to the arm by a second force limiting mechanism, the second force limiting mechanism operative to allow the second cable to be separated from the arm in response to tension pulling the distal end of the second cable in a direction such that a force component in a direction transverse to the arm has a magnitude exceeding a second threshold.
In some embodiments the cable assembly comprises Electric Vehicle Supply Equipment (EVSE), mounted to the arm and connected to supply charging current to an electric vehicle by way of the cable. In some embodiments the EVSE is configured to charge one electric vehicle and includes a connector plug for adding a module to charge a second electric vehicle by way of a second cable supported by the arm.
In some embodiments the cable assembly comprises a motion sensor and/or a proximity sensor and/or a camera located on the arm. In some embodiments the motion sensor and/or the proximity sensor is located near a distal end of the arm.
In some embodiments the cable assembly comprises a light and a control circuit operative to turn on the light in response to an output signal from the motion sensor and/or the proximity sensor.
In some embodiments the cable assembly comprises a camera located on the arm at or within 1.2 meters of the distal end of the arm. In some embodiments a wireless data transmitter is connected to transmit image data from the camera to a user.
In some embodiments a charging plug support is coupled to the free end of the cable, the charging plug support comprising a cradle configured to receive and support a plug. The charging plug support may comprise a hook dimensioned to receive and support one or more loops of the cable. In some embodiments the charging plug support is slidably attached to the free end of the cable. In some embodiments the charging plug support comprises a cable receiving portion comprising a plurality of elements that define a bent path for the cable through the cable receiving portion.
Another aspect of the present technology provides a cable assembly useful for electric vehicle charging. The cable assembly comprises an arm, a mount configured to attach the arm to a structure such that the arm projects outwardly from the structure; and a cable supported by the arm and having a free end extending from a distal end of the arm. The arm is coupled to the mount by a coupling that comprises a mechanical fuse, the mechanical fuse configured to deform or break to allow the distal end of the arm to drop to a dropped position in response to a moment caused by downward force on the arm wherein the arm remains in the dropped position until the arm is reset or the mechanical fuse is replaced.
In some embodiments, in moving from a normal position to the dropped position the distal end of the arm is lowered by no more than 15 centimeters.
In some embodiments the arm remains in the dropped position until the arm is reset or the mechanical fuse is replaced.
In some embodiments the arm is coupled to the mount by a pivot assembly configured to allow the arm to pivot about a substantially vertical axis.
In some embodiments the pivot assembly comprises a bias mechanism connected to bias the arm toward a stowed position.
In some embodiments the arm lies parallel to a face of the structure when the arm is in the stowed position.
In some embodiments the pivot assembly comprises a mechanical fuse and the mechanical fuse is configured to deform or break to allow a pivot axis of the pivot assembly to shift from a normal vertical orientation to an inclined orientation in response to a moment caused by downward force on the arm exceeding a threshold moment.
In some embodiments the pivot assembly comprises first and second spaced apart bearings that define the pivot axis wherein the mechanical fuse holds the first bearing in a position such that the pivot axis is vertical and deformation or breaking of the mechanical fuse allows transverse movement of the first bearing relative to the second bearing such that the pivot axis is movable to an angle that is inclined to vertical.
In some embodiments the second bearing is a spherical bearing.
In some embodiments the first bearing is slidable along a slot that extends transversely relative to the pivot axis and the mechanical fuse comprises a member that blocks the first bearing from sliding along the slot until a compression or tension force on the mechanical fuse exceeds a threshold.
In some embodiments the mechanical fuse comprises a deformable circlip.
In some embodiments the cable assembly comprises an electrical switch that is arranged to change state in direct or indirect response to the mechanical fuse deforming or breaking. In some embodiments the electrical switch is connected to control application of charging current through the cable and the change of state of the electrical switch causes the supply of charging current to be interrupted.
Another aspect of the present technology provides apparatus having any new and inventive feature, combination of features, or sub-combination of features as described herein.
Another aspect of the present technology provides methods having any new and inventive steps, acts, combination of steps and/or acts or sub-combination of steps and/or acts as described herein.
Further aspects and example embodiments are illustrated in the accompanying drawings and/or described in the following description.
It is emphasized that the invention relates to all combinations of the above features, even if these are recited in different claims.
The accompanying drawings illustrate non-limiting example embodiments of the invention.
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive sense.
Movable portion 8 includes arm 15 and distal end fitting 10. Cable 11 is fixed to distal end fitting 10. Arm 15 includes a straight cylindrical proximal end portion 15A having axis 16, and a distal end portion 15C connected to proximal end portion 15A by a bent section 15B so that distal end portion 15C extends away from mounting bracket 13. Arm 15 may be made of 304 stainless steel tubing of about 2.25 inch outside diameter and about 0.188 inch wall thickness.
Plug 17 terminates charging cable 11, and establishes electrical connections to vehicle 1 when inserted into receptacle 19 of vehicle 1 (see
Clip 25 is attached to cable 11 at a suitable height from the ground 3. The position of clip 25 along cable 11 may be adjustable. For example, clip 25 may be held in place along cable 11 by a friction fit, an adjustable clamp or the like. In a stowed position, plug 17 may hang from clip 25. The length of cable 11 and reach of arm 15 are selected to provide the desired range of possible locations of plug 17 from fixed portion 7. Typically the length of cable 11 extending from end fitting 10 is selected such that cable 11 does not rest on the ground surface 3 when stowed in clip 25, however a longer cable 11 may be used. Clip 25 may additionally support one or more loops (see
In the embodiment of
In some embodiments, pivot joint 55 includes a mechanical fuse which releases in the event that a force on the mechanical fuse exceeds a threshold. The mechanical fuse may be included in a mechanism that supports arm 15 and configured to release if more than a threshold amount of force, such as an abuse load in the direction of arrow 4, is applied at a distal end of arm 15. The mechanical fuse may, for example, comprise a member that is deformed (resiliently or inelastically) or breaks in response to application of a force on the member that exceeds a threshold.
Release of the mechanical fuse may result in pivot axis 16 of arm 15 shifting. For example, the mechanical fuse may hold a bearing or other component that defines the pivot axis in place until the mechanical fuse is deformed or broken as a result of a force on the bearing or other component in a direction transverse to the pivot axis. The mechanical fuse may be constructed in such a manner that a component must be replaced or a reset procedure must be performed to restore the pivot axis to its original orientation.
In alternative embodiments, alternative mechanical fuses such as shear pins, shear circlips, serrated plates, plastic inserts having shear webs, and fasteners with a preselected tension failure load range are provided to keep bearing 31 in place until an overload force is applied to arm 15.
Hole 18 passes through both walls of arm 15. The axis of hole 18 lies in midplane 51 of arm 15 (see
Inner bearing 31 has flange portion 36, cylindrical boss 38, and through inner bore 34. Bore 34 is a sliding fit over the outside diameter of proximal end portion 15A of arm 15. Outer bearing 29 includes flange portion 28, slot 33 through flange 28, hollow cylindrical boss 30, slotted holes 32 through both walls of boss 30, and threaded hole 52. The outer diameter of boss 30 is a sliding fit in bore 12. Slot 33 has a width selected to be a sliding fit with the outer diameter of boss 38 and a length greater than the width, allowing inner bearing 31 to slide in slot 33 for a selected distance in a direction normal to axis 16, for example, about % inch. The centrelines of slotted hole 32 and threaded hole 52 lie in the midplane of the width of slot 33.
Circlip 35 has screw hole 50, bore 24 and slot 26. Circlip 35 may be made of spring steel. Limit switch 53 is mounted to circlip 35. The outer diameter of boss 38 is a sliding fit in bore 24. The width of slot 26 is less than the outside diameter of boss 38. Axis 22 is perpendicular to axis 16, intersects the axis of hole 50, and lies in the midplane of the width of slot 26 and the plane of the bottom surface of circlip 35.
The width of slot 26 is selected along with the thickness, material properties, and outside profile of circlip 35 such that inner bearing 31 is slidable through slot 26 along the direction of axis 22 when a force above a predetermined threshold is applied to inner bearing 31 along the direction of axis 22. The resulting strain in the material of circlip 35 is selected to be within the elastic range of the material of circlip 35. When assembled, cross pin 39 passes through slotted holes 32 and hole 18 and is retained by cotter pin 41. Screw 37 fixes circlip 35 to outer bearing 29 via holes 50 and 52, thus outer bearing 29, circlip 35, screw 37, cross pin 39, and cotter pin 41 form an assembly that rotates together with arm 15 about axis 21. Axis 22 and the midplane of the width of slot 33 always remain coincident with midplane 51 of arm 15 (see
Base end fitting 47 has upper cylindrical boss 40, flange portion 42, lower cylindrical boss 44, and notch 46. Boss 40 is press-fit into the inner diameter of arm 15, such that the maximum amount of torque from torsion spring 27 can be transmitted via fitting 47 to arm 15. Boss 44 is a sliding fit into the inner bore of spherical bearing 49. Base end fitting 47 also has a through bore along axis 16 having a diameter greater than that of cable 11, so that cable 11 may pass through base end fitting 47. The outer diameter of spherical bearing 49 is a push-fit into bearing seat 45. Bearing seat 45 is a push-fit into bore 14 and has notch 48 that aligns with notch 20 when installed to allow an end of torsion spring 27 to pass through to engage in notch 20. Bearings 29 and 31 may be made from acetal. Bearing seat 45 and base end fitting 47 may be made from stainless steel.
When assembled, axis 16 is nominally coincident with axis 21, one end of torsion spring 27 engages notch 46, and the opposite end of torsion spring 27 passes through notch 48 to engage notch 20. Any torque generated in torsion spring 27 is therefore transmitted from mounting bracket 13 to arm 15. The relative angular position between notch 20 and notch 46 about axis 21 at a stowed position, along with the free (no torque) relative angular position between the ends of torsion spring 27 are selected to apply a selected preload torque biasing arm 15 towards the stowed position as shown in
Referring also to
Charging station 6 is mounted to a structure 5 at a selected location relative to a parking area for vehicle 1 to provide the desired range of locations that can be reached with plug 17. The user unhooks plug 17 from clip 25 and takes plug 17 to receptacle 19 of vehicle 1, which may be in a variety of locations relative to the fixed portion 7 of station 6 depending on the type of vehicle and orientation it is parked in, and distance it is parked from structure 5.
Movable portion 8 of station 6 operates in a ‘follow me’ manner, in that when cable 11 is moved from a free-hanging position to a position where the center of gravity of cable 11 is a distance from arm midplane 51, arm 15 overcomes bias torque due to torsion spring 27 and swings out to a deployed position at angle 2. Upon returning plug 17 to clip 25 and allowing cable 11 to hang free in plane 51, arm 15 returns to a stowed position as shown in
The user may adjust the position of clip 25 on cable 11 to a comfortable distance from the ground surface 3 by sliding cable 11 through flexible portions 121 and 122 of clip 25. Typically, the length of the free hanging portion of cable 11 is selected such that cable 11 does not touch the ground when plug 17 is stowed in clip 25 as shown, however in some cases a longer cable 11 may be used or the user may wish to stow cable 11 further from the ground. In these cases, the user may hang a loop of cable 11 in hook portion 133 of clip 25. Similarly, in the alternative embodiment of
When an abuse load is applied to arm 15 creating a moment in midplane 51 that exceeds a selected threshold (for example, a downward force on arm 15 in the direction of arrow 4 due to a user pulling excessively on cable 11, or hanging or stepping on arm 15) and acts in a direction such that inner bearing 31 is urged to move out of engagement with circlip 35, inner bearing 31 slips though circlip 35 against the resilient forces applied by circlip 35, inner bearing 31 slides upwards on arm 15, cross pin 39 slides in slotted holes 32 and arm 15 moves through an angular motion in midplane 51 until inner bearing 31 hits the end of slot 33 and arm 15 is in a overloaded position as shown in
This creates an immediate tactile, audible indication and a persisting visual indication that too much load has been applied to arm 15. The threshold may be selected to be less than the load at which structural failure of station 6 or the attachment of station 6 to structure 5 could occur.
In the overloaded position shown in
Arm 15 remains in the overloaded position shown in
Optional sensor 127 communicates with EVSE 9 and senses motion in the vicinity of EVSE 9, for example when vehicle 1 or a user moves into a certain range around EVSE 9, EVSE 9 may turn light 128 on. Sensor 127 may also be used as a security monitor, communicating to the user's cellphone or home computer network or an alarm monitoring service via optional wireless transceiver 130.
EVSE 9 may additionally control light 128 to indicate state and fault conditions, for example by illuminating steady green when current is flowing to vehicle 1, steady red when current is not flowing, and flashing red for a fault condition such as overload on arm 15 resulting in limit switch 53 being triggered. Motion sensing functions of sensor 127 may also be used to detect when a vehicle is parked in a suitable position relative to the charging station by sensing the position of a selected feature of the vehicle. EVSE 9 may be configured to operate light 128 in a distinctive manner (e.g. by flashing light 128 and/or setting light 128 to a particular colour such as green) to indicate a vehicle position within a selected range of suitable positions.
In some embodiments the cable is received in a downward facing groove or recess that extends longitudinally along the arm and the breakaway mechanism comprises one or more retaining members that hold the charging cable in the groove or recess. In some embodiments the breakaway mechanism comprises one or more retaining members (such as a channel member, straps, or the like) that hold the charging cable against an outer face of the arm. The retaining members may be affixed to the arm by attachments that release and/or the retaining members may themselves break or separate to allow the charging cable can come away from the arm if an applied force exceeds a threshold. Any embodiments of the present technology, including embodiments as illustrated in
Pivot joint 304 and EVSE 225 are attached to structure 300. Arm 302 is pivotally attached to pivotjoint 304. Charging cable 308 is connected to EVSE 225 and is supported by arm 302 along substantially all the length of arm 302. EVSE 225 is connected to power source 306.
The material and diameter of shear pin 68 may be selected to provide the desired range of bending moment that will trigger the force limiting means. Different shear pins may be selected to provide a suitable range of moment 324 for various lengths of arm 302 and attachment arrangements of pivot joint 304 to structure 300.
One of ordinary skill in the art will recognize that various other means of elastic or inelastic force limitation may be applied as a mechanical fuse in place of fusible link 67 and shear pin 68, a few examples being sprung latches, circlips, or serrated plates held in engagement by spring force. The mechanical fuse may, for example be configured to be crushed, stretched, bent, broken apart, and/or released from holding another member or the like.
Washer stack 336 may be made up of one or more steel Belleville washers. Different spring rates for stack 336 and different angles and engagement depth of the serrations of plate 332 and washer 334 may be selected to provide the desired range of moment 324 that allows arm 302 to move to overloaded state 302′ shown in
Compared to the embodiment shown in
Arm 302 of charging station 299 pivots out from structure 300 when a user pulls cable 308 towards a vehicle. If the user applies an abuse load to cable 308 causing a downward pull reaching a predetermined range (for example if a child climbs or swings on cable 308), cable 308 pulls down progressively from arm 302 to a state 314′ thereby limiting the amount of abuse load that can be applied to cable 308 to a level which may be below selected load limits of the other components of charging station 299 and/or the attachment of station 299 to structure 300. In this particular example, the user must reinsert rivets 312 to restore cable 308 and conduit 314 from breakaway state 314′ to their normal use state.
In the case of an abuse load reaching a predetermined range being applied directly to arm 302 (for example, a person climbing or stepping directly on arm 302), shear pin 68 shears and pivot joint 304 moves abruptly to a tilted-down position such as overloaded state 302′ thereby warning the user that an excessive load has been applied. The predetermined range of load that moves arm 302 to overloaded state 302′ may be selected to be below a load that will detach joint 304 from structure 300. The user must replace shear pin 68 to reset pivot joint 304 and move arm 302 back from overloaded state 302′ to a normal use state. The change of position from a normal use state to state 302′ may be selected to be visually noticeable and sufficient to provide a tactile and audible feedback upon overload, while still maintaining a selected clearance to the ground (so that arm 302 does not contact a vehicle parked below).
In this particular example, arm 302 may be about 60 inches (about 2 m) long and may tilt toward the ground by about 5 degrees when moving from the normal use state to overloaded state 302′, resulting in the distal end (the end opposite joint 304) of arm 302 moving about 5 inches (about 12.5 cm) downward. The abuse load required to move arm 302 into overloaded state 302′ in this example may be about 150 pounds force (about 70 kg force) applied at the distal end of arm 302.
In the alternative embodiment shown in
Arm 151 rotates about the cylindrical axis of pivot tube 166. Power supply cable 154 passes through ceiling mount 152 and pivot tube portion 166 of ceiling mount 152 thus a portion of the longitudinal centreline of power supply cable 154 lies substantially on the axis of rotation of arm 151. Breakaway fitting assembly 210, optional illumination light unit 162, and optional EVSE 170 snap-fit into extrusion 159. Primary charge cable 156, optional 110V cable 129, and optional secondary charge cable 157 friction-fit into breakaway fitting 210. Optional low voltage cable 106 connects electrically to indicator light and sensor unit 161 and illumination light unit 162.
Access cover 175, supply cable shroud 176, and output cable shroud 177 may snap-fit to enclosure 171, and in turn shrouds 176 and 177 and enclosure 171 may snap-fit to extrusion 159 (see
Cables 106, 129, 156, and 157 (and also power supply cable 154 seen in
Connections between controller 199 and board 200 are made as required for relay and ground fault detection operation with typical low voltage signal wiring and connectors (not shown). Optional secondary charge controller unit 173 includes secondary EVSE controller 202, secondary power distribution board 203, male board edge connector 204, and other components typical to existing single charge circuit EVSEs including a relay, a ground fault detection loop for charge output power, and wire connection terminals for charge output power. Power connection is made between primary charge controller unit 172 and secondary charge controller unit 173 via board edge connectors 201 and 204. In some embodiments secondary charge controller unit 173 is configured as a plug-in module such that EVSE 170 may be easily upgraded to provide a second charge controller for a second EV.
Referring also to
Upper bearing 187 may be push or press fit into fitting 158 and lower bearing 182 may be push or press fit into adjuster 179. Both bearings 182 and 187 may, for example, be trade number 6807 ball bearings. Adjuster 179 is a sliding fit in fitting 158. Adjustment screw 180 threads into adjuster 179, and is retained axially within fitting 158 by circlip 181. Referring also to
Illumination light unit 162 includes backing strip 188, LED light strip 189, and lens 190, and snaps into the groove features of extrusion 159, thus forming an enclosed conduit for 110V cable 129, primary charge cable 156, secondary charge cable 157, and low voltage cable 106 along the length of extrusion 159. Cover strip 185 (see
Retainer 214 has removable portion 218, which can be cut away to allow retainer 214 to hold a second cable. Retainers 213 and 214 form set 219. Additional retainers may be added to set 219 to fit various diameters of charge cables in single and dual cable configurations. Referring also to
In the position shown in
If an abuse load is applied as a downward pull on cables 156, 157, or 129 or any combination of these (for example a person hanging on or climbing the cables), breakaway fitting 210 pulls out of arm 151. If tension continues, the cables pull light unit 162 out of arm 151. The allowable downward pull on cables 156, 157, or 129 may be selected to be less than the threshold load required to shear circlip 181.
If an abuse load is applied directly to arm 151 creating a downwards bending moment 191 in arm 151 beyond a selected threshold (for example by a person applying weight directly to arm 151 rather than cables 156, 157, or 129), circlip 181 shears and arm 151 tilts noticeably downward as adjuster 179 hits the limit of travel in fitting 158. The selected shear load capacity of circlip 181 may be selected in relation to the selected length of arm 151.
EVSE 170 may be operated with primary charge controller unit 172 and charge cable 156 only, and with cable retainer 214 in breakaway fitting assembly 210, then expanded later to add an optional second charge output for a second vehicle by plugging secondary charge controller unit 173 into unit 172, adding cable 157, and cutting away section 218 of cable retainer 214 or selecting an alternative cable retainer from set 219 as required to fit the number and diameter of charging cables. Optional light and sensor control unit 174 and wireless transceiver 130 may be programmed to activate light unit 162 when motion is sensed by indicator light and sensor unit 161. The indicator light portion of unit 161 may be activated by signals from controllers 199 and 202 to indicate the status of EVSE 170.
Torsion spring 229 has one end which engages spring seat 230 and another end which bears against fitting 232. Spring seat 230 is a push fit onto pin 233 and is rotationally locked to D-section pivot pin 233, which in turn is rotationally locked to wall bracket 237. Thus spring 229 applies torque to fitting 232 acting to keep arm 221 in the stowed position shown in
Wall bracket 237 includes two instances each of keyhole shaped hole 256 and slotted hole 257, allowing a person working alone to install arm 220 by preinstalling at least two and up to four flanged bolts (not shown), hanging arm 220 (preassembled to wall bracket 237) on the bolts, lightly tightening the bolts, optionally adjusting arm 220 to be level horizontally, and then tightening all four bolts.
Wall bracket 237 includes a plurality of bend relief slots 264. The size of slots 264 may be selected, along with the thickness and material properties of bracket 237, such that bracket 237 permanently deforms at a predetermined range of load on wall pivot joint 224. For example, the range of load required to deform bracket 237 may be selected to be less that the range of load causing the bolted attachment of bracket 237 to a structure to fail.
Operation of the embodiment shown in
Articulated arm 220 operates in an articulated ‘follow me’ manner, in that when cable 235 is moved a sufficient distance from a free-hanging position, distal arm 222 overcomes bias torque of elbow joint torsion spring 250 and swings out from proximal arm 221. As the user continues to move cable 235 away from wall pivot joint 224, proximal arm 221 swings out from the stowed position overcoming bias torque from spring 229. Upon returning the charge cable 235 to clip 25 and allowing cable 235 to hang free, arms 221 and 222 return to their stowed position. Magnitude of bias torques due to springs 229 and 250 relative to each other may be chosen to provide deployment from the stowed position in a predictable order, distal arm 222 first and then proximal arm 221. Overall magnitude of bias torques due to springs 229 and 250 may be chosen to return arm 220 to the stowed position unassisted, or may be less, requiring the user to lightly assist the return to the stowed position.
In a similar manner to that shown in
In a similar manner to that shown in
Referring particularly to
The cable breakaway and mechanical fuse features described may, for example, be designed according to the following non-limiting example. Arms 221 and 222 may both be about 48 inches (122 cm) long. Breakaway fitting 210 may pull out of the distal end of arm 222 at a downward pull on cable 235 of 30 to 40 pounds-force (13 to 18 kg force) or more. An abuse load may be defined as a force acting downwards on the distal end (the end opposite elbow 223) of arm 222. Circlip 254 may shear (and screw 253 may break in tension, in the configuration shown in
In a similar manner to the embodiment described in
In the embodiment shown in
From the description above, a number of advantages of some embodiments of the charging station become evident, some of which are particularly, but not exclusively, adapted to residential use. The charging station may, for example have any combination of the following features:
Charging stations as described herein may be developed and adapted for residential use and may provide the ability to position a charging cable overhead over the majority of the area of the parking space (thereby keeping the charging cable off the ground), provide progressive warning to the user of excess load being applied to the cable or the structure of the station, and provide indication that persists after such loads are released that an overload has occurred, without excess mechanical complexity or weight.
Although the description above contains specificities, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of several embodiments. For example, the mechanical fusible links shown could have other shapes, materials, or attachment means that provide elastic or non-elastic limits to motion into the overload indicating condition. Mounting structure could be provided with the station, for example as a pedestal or post mounted to the ground near a parking space. Arm structures could have various forms without a single planar midplane, but still have a rotation plane passing through a distal load application point and a pivot axis, in which moments due to abuse loads lie and which follows the motion of the arm throughout its deployment range.
Where a component (e.g. a joint, plug, sensor, controller, assembly, device, circuit, etc.) is referred to herein, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
Electronic controllers in some embodiments of the invention are implemented using specifically designed hardware, configurable hardware, programmable data processors configured by the provision of software (which may optionally comprise “firmware”) capable of executing on the data processors, special purpose computers or data processors that are specifically programmed, configured, or constructed to perform one or more steps in a method as explained in detail herein and/or combinations of two or more of these. Examples of specifically designed hardware are: logic circuits, application-specific integrated circuits (“ASICs”), large scale integrated circuits (“LSIs”), very large scale integrated circuits (“VLSIs”), and the like. Examples of configurable hardware are: one or more programmable logic devices such as programmable array logic (“PALs”), programmable logic arrays (“PLAs”), and field programmable gate arrays (“FPGAs”). Examples of programmable data processors are: microprocessors, digital signal processors (“DSPs”), embedded processors, graphics processors, math co-processors, general purpose computers, server computers, cloud computers, mainframe computers, computer workstations, and the like. For example, one or more data processors in a control circuit for a device may implement methods as described herein by executing software instructions in a program memory accessible to the processors.
Unless the context clearly requires otherwise, throughout the description and the
Words that indicate directions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “left”, “right”, “front”, “back”, “top”, “bottom”, “below”, “above”, “under”, and the like, used in this description and any accompanying claims (where present), depend on the specific orientation of the apparatus described and illustrated. The subject matter described herein may assume various alternative orientations. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.
Where a range for a value is stated, the stated range includes all sub-ranges of the range. It is intended that the statement of a range supports the value being at an endpoint of the range as well as at any intervening value to the tenth of the unit of the lower limit of the range, as well as any subrange or sets of sub ranges of the range unless the context clearly dictates otherwise or any portion(s) of the stated range is specifically excluded. Where the stated range includes one or both endpoints of the range, ranges excluding either or both of those included endpoints are also included in the invention.
Certain numerical values described herein are preceded by “about”. In this context, “about” provides literal support for the exact numerical value that it precedes, the exact numerical value ±5%, as well as all other numerical values that are near to or approximately equal to that numerical value. Unless otherwise indicated a particular numerical value is included in “about” a specifically recited numerical value where the particular numerical value provides the substantial equivalent of the specifically recited numerical value in the context in which the specifically recited numerical value is presented. For example, a statement that something has the numerical value of “about 10” is to be interpreted as: the set of statements:
Specific examples of systems, methods and apparatus have been described herein for purposes of illustration. These are only examples. The technology provided herein can be applied to systems other than the example systems described above. Many alterations, modifications, additions, omissions, and permutations are possible within the practice of this invention. This invention includes variations on described embodiments that would be apparent to the skilled addressee, including variations obtained by: replacing features, elements and/or acts with equivalent features, elements and/or acts; mixing and matching of features, elements and/or acts from different embodiments; combining features, elements and/or acts from embodiments as described herein with features, elements and/or acts of other technology; and/or omitting combining features, elements and/or acts from described embodiments.
As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any other described embodiment(s) without departing from the scope of the present invention.
Any aspects described above in reference to apparatus may also apply to methods and vice versa.
Any recited method can be carried out in the order of events recited or in any other order which is logically possible. For example, while processes or blocks are presented in a given order, alternative examples may perform routines having steps, or employ systems having blocks, in a different order, and some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or subcombinations. Each of these processes or blocks may be implemented in a variety of different ways. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed in parallel, simultaneously or at different times.
Various features are described herein as being present in “some embodiments”. Such features are not mandatory and may not be present in all embodiments. Embodiments of the invention may include zero, any one or any combination of two or more of such features. All possible combinations of such features are contemplated by this disclosure even where such features are shown in different drawings and/or described in different sections or paragraphs. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible). This is the case even if features A and B are illustrated in different drawings and/or mentioned in different paragraphs, sections or sentences.
It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, omissions, and sub-combinations as may reasonably be inferred. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
This application claims priority from U.S. application No. 63/161,814 filed 16 Mar. 2021 and entitled ELECTRIC VEHICLE CHARGING STATION WITH CABLE MANAGEMENT AND OVERLOAD WARNING MEANS which is hereby incorporated herein by reference for all purposes. For purposes of the United States of America, this application claims the benefit under 35 U.S.C. § 119 of U.S. application No. 63/161,814 filed 16 Mar. 2021 and entitled ELECTRIC VEHICLE CHARGING STATION WITH CABLE MANAGEMENT AND OVERLOAD WARNING MEANS.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CA2022/050401 | 3/16/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63161814 | Mar 2021 | US |
