A. Field of the Invention
The present invention relates to methods and apparatus for charging batteries of all-electric and hybrid vehicles. More particularly, the invention relates to a novel system comprised of a method and apparatus which utilize existing electrical power supplied to municipal street lights, parking meters and the like, to charge vehicle batteries, and which relegates paying for charging power to a vehicle mounted apparatus.
B. Description of Background Art
Air pollution resulting from increasing numbers of vehicles powered by internal combustion engines has prompted people worldwide to utilize alternative vehicles. The latter include all-electric vehicles which utilize electric traction motors powered by “on-board” batteries mounted in the vehicle. Hybrid vehicles also use electric motors powered by on-board batteries as a prime mover, but have a small, low-power, low-pollution internal combustion engine which may be used to power the vehicle and to re-charge the batteries if they become substantially discharged while the vehicle is in use.
Both hybrid and all-electric vehicles require that their on-board batteries be re-charged on a regular basis. Re-charging is most often done at a home base of the vehicle, via a cable which is connected at an inner end to a battery charger module located in the vehicle. The outer end of the cable is terminated by a standard electrical power plug which may be connected to utility power mains by inserting the plug in a conventional electric power receptacle, or by a special conversion box or charging apparatus.
With the increasing use of vehicles powered by on-board batteries, there has been an increased demand for charging facilities that enable the operator of an electrically powered vehicle to re-charge vehicle batteries when the vehicle is away from the user's residence or home base. In response to this demand, some governmental agencies have built building and maintaining charging stations for electric vehicles is quite high, which is probably a major reason why such facilities are literally few and far between.
As the number of electric vehicles in regular use increases, problems faced by city governments and vehicle users alike because of an insufficient number of public charging stations available to the users of electric vehicles are rapidly increasing. Accordingly, it would be desirable for governmental agencies to be enabled to utilize existing elements of municipal power grids to provide large numbers of needed electrical vehicle re-charging stations, and at a minimal cost to the government. The desirability of providing a method and apparatus for delivering electricity to charge batteries of electric vehicles which included a large number of charging stations that could use already existing municipal facilities such as street lights and parking meters to thus minimize capital investment outlays by a municipality, was a motive for the present invention.
An object of the present invention is to provide a system for charging batteries of electrically powered vehicles parked on city streets and roads.
Another object of the invention is to provide an electric vehicle battery charging system which utilizes electrical power supplied to municipal fixtures such as parking meters and street lights as a source of battery charging current.
Another object of the invention is to provide a system for charging batteries of electric vehicles which includes an accessory power interface module that is readily retro-fittable to an existing street light, parking meter or other such fixture which is supplied with electrical power from municipal power grid mains, to thus enable the fixture to function as an electric vehicle battery charging station while still performing its original intended function such as illuminating a street or receiving parking fees.
Another object of the invention is to provide a system for charging batteries of electric vehicles from municipal power mains, which uses an accessory power receptacle that is readily retro-fittable to an existing municipal facility or fixture such as a parking meter or street light, and which uses vehicle-mounted apparatus components that enable a municipality to obtain payment for electricity supplied to charge vehicle batteries, without requiring installation of payment authorization and accounting equipment at the existing municipal facility.
Another object of the invention is to provide a system for charging batteries of an electric vehicle parked on a street or road from curbside parking meters or street lights, which are modified to function as curbside electric vehicle battery charging stations by the addition of a keyed power output receptacle that will output electrical charging power only to a complementarily keyed plug which is connected through a vehicle charger cable to a vehicle-mounted apparatus that enables power to be drawn from the receptacle only if pre-payment has been made to a municipality or other authorized vending agency.
Another object of the invention is to provide a system for charging batteries of an electric vehicle from a parking meter or street light while the vehicle is parked, using a keyed plug at the end of a vehicle charger cable which extends from the vehicle into a keyed receptacle that extends from the parking meter or street light, the apparatus including a vehicle-mounted safety interlock module which prevents the vehicle from moving while plugged in, yet enables operation of battery-operated vehicle accessories such as air conditioning, radio and lights in the parked vehicle.
Another object of the invention is to provide a system for charging batteries of an electric vehicle from parking meters or street lights which generates a parking and/or charging payment authorization affirming message that is shown on a display device visible from outside the vehicle, and/or accessible by a wireless transponder interrogation device useable by payment enforcement authorities.
Another object of the invention is to provide a system for charging batteries of an electric vehicle which has at the end of a vehicle charger cable that extends from the vehicle multi-terminal electrical plug that has a non-contacting keying device which cooperates with a complementary keying device in a charging power output electrical receptacle located at the end of an electrical cable which is connected to power mains conductors in parking meter or street light, to enable flow of electrical power from the receptacle cable to the vehicle charger cable only if the vehicle charger cable plug keying device presents a correct code to the receptacle.
Another object of the invention is to provide a system for charging batteries of an electric vehicle which utilizes a plug at the end of a vehicle-mounted charging cable that contains a non-contacting keying device which cooperates with a complementary keying device in a power receptacle at the end of a cable that extends from a parking meter or street light to cause an actuator within the receptacle to move an obstructing cover plate which covers the entrance opening of the receptacle to a non-obstructing location which enables the vehicle cable plug to be inserted into the power source receptacle.
Various other objects and advantages of the present invention, and its most novel features, will become apparent to those skilled in the art by perusing the accompanying specification, drawings and claims.
It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the characteristics of the invention described herein are merely illustrative of the preferred embodiments. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to details of the embodiments described. I do intend that equivalents, adaptations and modifications of the invention reasonably inferable from the description contained herein be included within the scope of the invention as defined by the appended claims.
Briefly stated, the present invention comprehends a system for charging batteries of electrically powered vehicles, which utilizes electrical power supplied to existing municipal facilities or fixtures such as street lights and parking meters. According to the invention, a municipal fixture such as a parking meter or street light powered by electrical power mains and located close to the side of a street or road is minimally modified or retrofitted to enable the facility or fixture to function as an electrical vehicle charging station, while the fixture can continue to perform its intended function as a street light, parking meter, etc. The minimal modification includes adding a charging station electrical cable to a fixture which is to be modified and connecting conductors at the inner end of the charging station cable in parallel with load ends power mains conductors within the fixture which are connected at supply ends thereof to a municipal electrical power grid.
The charging station cable which is retrofitted to a municipal fixture includes a novel keyed tamper-resistant and weather-resistant charging power output electrical receptacle located at the outer, load end of the charging station cable. The charging power output receptacle contains an electro-mechanical or solid state electronic contactor, and a novel arrangement of keyed conductive and non-conductive pins, which enable electrical power to be drawn from the receptacle only by a correctly keyed plug of novel design and construction, the plug comprising another part of the invention.
According to the invention, only vehicles which have had installed at the time of manufacture or as an after-market accessory novel vehicle mounted components of the system comprising an On-Board Charge Control System may obtain electrical power from a keyed power receptacle. The On-Board Charge Control System includes electrical and electronic components mounted within a vehicle which are connected to a vehicle charger electrical cable that is terminated at an outer, input end thereof by the novel keyed plug.
Vehicle-mounted components of the On-Board Charge Control system according to the invention include a Charging Current Controller module which controls charging current supplied to an existing main or master bank of batteries that power the vehicle, as well as auxiliary batteries. The Charging Current Controller module provides an electrical charge authorization or charging station access signal to an electromagnetic or solid state electronic power contactor relay located within an Automatic Power Off (APO) module that is connected in series with the vehicle charger cable and a main, master battery bank within the vehicle.
The charge authorization signal actuates the APO power contactor relay to thus enable charging current to flow from the charging station power output receptacle to the vehicle batteries only if a prepaid, magnetically or electronically encoded charge card such as a SIM card issued by a municipality or other authorized agency is inserted into a card reader slot in the Charging Current Controller module.
The Charging Current Controller module deducts from a prepaid money balance on the charge card money amounts proportional to the product of electric charging power drawn from an electric vehicle charging station, multiplied by a predetermined cost per unit of power.
As long as a positive money balance remains on the charge card, the APO will be enabled by a signal from the Charging Current Controller module to conduct current from the charging station receptacle mounted on the street light or parking meter to the vehicle in which the apparatus is mounted.
According to the invention, electrical current from a municipal facility or fixture such as a parking meter or street light is paid for in advance by an electrical vehicle user, and as current flows to the vehicle, an electrical power meter or coulomb charge meter in the vehicle deducts from a money credit balance on a charge card an amount equal to the product of power or charge outputted to the vehicle, multiplied by the rate in dollars, e.g., yuan, yen, etc. per unit of charge or power. When the money balance on the charge card decreases to zero, the charging station access enable signal provided to the power contactor relay in the APO by the Charging Current Controller module is removed, preventing any further current to be drawn by a particular vehicle from the charger receptacle.
The Charging Current Controller module in the vehicle also has an excess charge or “battery overflow” sensor input port which disables charging power by removing the charge enable signal to the APO, if an excess charge, charge rate or over-voltage sensor connected to the vehicle batteries and input to the Charging Current Controller module detects an excess battery charge rate, excess battery charge or over-voltage condition.
In a preferred embodiment of an electric vehicle charging apparatus and system according to the present invention, the vehicle is provided with one or preferably two auxiliary batteries. The auxiliary batteries are used to power automobile accessories such as lights, radio and air-conditioner, for the safety, convenience and comfort of occupants of a vehicle, while the master battery for powering the vehicle traction motor is being charged.
Also according to the invention, provision is made for charging one or more selected auxiliary batteries, when, for example, the vehicle is parked at a parking meter which has been modified to function as a charging station . Thus, in a preferred embodiment of the invention, selected combinations of the master battery, first auxiliary battery, or first and second auxiliary batteries can be charged by operating selector switches located on a control panel of the Charging Current Controller Module. For example, a first, master battery charge switch can be operated to enable charging the master battery of a vehicle at a relatively high current rate, at a first high dollar per hour rate, of, for example, two dollars per hour. Similarly, if it is desired to charge one or both auxiliary batteries, the control panel of the Charging Current Controller Module can be provided with second and third switches for enabling intermediate charging currents to flow to both or one auxiliary batteries at, for example, one dollar per hour or 50 cents per hour, respectively.
According to the invention, the On-Board Charge Control System mounted in a vehicle includes a safety interlock mechanism to prevent electrical power from being supplied to the vehicle traction motor while the vehicle charging plug is inserted into the charging station street receptacle. In a preferred embodiment, the safety interlock mechanism is implemented by a vehicle Drive Enable module connected in series with the vehicle battery and traction motor controller. The vehicle Drive Enable module prevents current from flowing to the vehicle drive motor unless the plug at the end of the vehicle charger cable is removed from the street charging station receptacle and inserted into a similarly constructed receptacle on the Charging Current Controller Module, which provides an enabling signal to the Drive Enable module only when the plug is inserted into the receptacle of the Charging Current Controller Module.
Preferably, the system for charging electric vehicle batteries from street lights and parking meters according to the present invention includes a verification device which enables police, meter maids or other payment enforcement personnel to confirm that a vehicle connected to a charging station is authorized to receive electrical power from the charging station. The verification device in one embodiment of the invention consists of a visual display device which is mounted inside the vehicle and viewable through a window of the vehicle by enforcement personnel. The display device can confirm that the vehicle is receiving power which has been paid for, and is legally entitled to be parked at a metered location. Optionally, an on-board component of the street charging system apparatus can include a wireless transponder which operates at radio or infrared frequencies and can be interrogated by enforcement personnel on foot or in a patrol vehicle, using a radar gun-type of transponder interrogation device, to confirm that a vehicle is authorized to receive charging power.
The electric vehicle charging system according to the present invention may optionally include an enhancement such as an additional electronic interlock relay located with the power outlet receptacle, which requires the presence of correctly coded RFID chip in the plug at the end o the vehicle charger cable, to enable current to flow to the plug. Also, the receptacle may optionally include an obstructing security cover plate which covers the entrance opening to the receptacle against rain, snow and the like, and further secures the receptacle against being tampered with or subjected to unauthorized use. In this embodiment, the security cover plate is operable by an electro-mechanical actuator such as an electric motor or solenoid within the receptacle, which is energized by electronic sensing and control circuitry only when a correctly coded mechanical, magnetic or electronic key such as an RFID chip is presented to the receptacle.
For further security, the power cable disposed between the power main and power receptacle may be shortened, and the receptacle hard-mounted to the standard of a parking meter or light pole.
Also, the charging system according to the present invention may optionally include an inductive magnetic coupler connected in a series with the vehicle charger cable.
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Vertical rear bulkhead 47 of receptacle body 36 has extending perpendicularly inwardly from front face 47A thereof a plurality of electrically conductive sockets or ferrules 48, 49, 50, 51, 52 and 53.
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Preferably, magnetic coil coupler 93 contains within secondary housing 99 thereof current limiting and over-voltage protection circuitry which ensures that only suitably limited voltages and currents are supplied to on-board vehicle charge control system 23.
As will now be explained, the novel design and construction of receptacle 27 and plug 35 according to the present invention provide a secure means of conducting electrical power supplied by street power mains to conductors 79 and 80 of charging station cable 24 to conductors 89 and 90 of vehicle charger cable 29.
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(1) Plug 35 is inserted into recess 38 of receptacle 27.
(2) There is an electrically conductive path between neutral wire 90 of vehicle charger cable 29 and lower middle pin 51 of plug 35.
(3) Pin 71 of plug 35 is inserted into socket ferrule 71 of receptacle 27 and makes electrical contact with socket 51.
(4) Pin 68 of plug 35 is inserted into socket ferrule 48 of socket ferrule 48 of receptacle 27 and makes electrical contact with socket 48.
(5) Pin 69 of plug 35 is inserted into socket ferrule 49 of receptacle 27 and makes electrical contact with socket 49.
(6) There is an electrically conductive jumper wire 102 electrically conductively connected between pins 68 and 69 of plug 35.
Also, a complete electrical path between hot wire 79 of charging station cable 24 and hot wire 89 of vehicle charger cable 29 may be provided if the following conditions are met:
(1) Plug 35 is inserted into recess 38 of receptacle 27 sufficiently far for interlock pin 74 in the right side 59 of body 54 of the plug to be aligned with bore 76 in right inner side wall 45 of receptacle 27.
(2) A key is inserted into key slot 75 of plug 35 and turned to thereby extend interlock pin 74 into bore 76 sufficiently far for the pin to operate an electrical contactor switch 103 which is connected in series with hot wire 79 of charging station cable 24, and upper right-hand socket ferrule 52 of receptacle 27, thus closing a circuit between input terminal 104 and switched output terminal 105 of the contactor switch.
(3) An electrically conductive path is established between switched output terminal 105 of contactor 103 and socket ferrule 50 of receptacle 27, in the following manner.
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(1) From hot power mains conductor 79 through key operated contactor switch 103 and resistance R1.
(2) Through coded length socket and pin pairs 72-52A, 73-53A, respectively.
(3) Through input terminals 118, 119 and coil 124 of relay 117.
(4) Through conducive socket pin pairs 48A-68, 69-49A, and jumper wire 102.
(5) Through resistance R2 to conductor 80 connected to power mains neutral conductor 80.
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FIGS. 2 and 9-12 illustrate additional structural and functional details of the system 20 for charging electric vehicles according to the present invention.
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Charging Current Controller Module 28 contains a card reader, such as a magnetic or electronic card reader 170 of a design and construction well-known to those skilled in the art, which will output a logic true charge authorization signal as long as a pre-paid money balance remains encoded on a special pre-paid charge card 168. Charging Current Controller Module 28 also contains a contactor 164 which closes an electrical circuit between input charging current power port 165 of switches 161-163, output port 166 of the Charging Current Controller Module, and input terminal port 167 of batteries 31, 32 and 33.
As long as prepaid charge card 168 contains a money balance, contactor 164 of Charging Current Controller Module 28 enables charging current selected by closing switches 161, 162 and 163 to flow into batteries 31, 32 and 33, respectively.
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Optionally, parking charge paid indicator 154 may be supplemented or replaced by a Radio Frequency Identification (RFID) chip which is included in charge card 168. With this option, charge authorization personnel such as police or meter maids may use a hand-held or patrol vehicle-mounted radio frequency transponder interrogation device, similar to a radar speed gun, to interrogate a vehicle being charged at a street charging station, confirm identity of a charging card 168, and confirm that a positive money balance remains on the card. The structure and function of such verification system are well known to those skilled in the art, and are in wide use as components of electronic toll collection (ETC) systems, such as the FasTrak system used in the State of California in the United States.
In another optional modification of a vehicle charging system 20 according to the present invention, charge authorization, and actuation of charging power enabling contactor relay 117 in receptacle 27, may be accomplished by using a communication and control system using communications between satellite and radio-frequency transceivers located in either or both a vehicle and receptacle 27. Such satellite based communication and control systems are well known to those skilled in the art, and are in wide use in the United States and other countries to provide roadside assistance to operators of vehicles equipped with special radio transceivers which can communicate through orbiting space satellites with a central control station, and marketed under the name OnStar.
Another optional modification of the charge system 20 according to the present invention includes a modified receptacle 27 which has a movable cover plate or door which covers the sockets of the receptacle from weather and tampering, the door being operable by an electro-mechanical actuator such as an electric motor or solenoid only if a properly coded magnetic card or RFID chip is presented to the receptacle.
Another optional modification of the charge system according to the present invention includes relocating at least the charge-card authorization mechanism of the charge controller module 28 shown in