SYSTEM FOR CONDUCTIVE RECHARGING OF AN ELECTRIC

VEHICLE

Technical field

This invention relates to a system for conductive recharging of an electric vehicle.

In particular, the invention is used for the recharging of electricity storage systems of electric vehicles, for example batteries, for uses in home/residential contexts, or in the urban context, both private and public.

Background art

Currently, the recharging systems for electric vehicles, as the latter require the transfer of significant quantities of electricity, are usually of a conductive type, that is to say, in which the connection between the charger and the vehicle is carried out by conduction by means of a physical contact between conducting materials.

In fact, the inductive technology is not currently applicable to the sector of systems for recharging electric vehicles, that is to say, where the presence of a physical contact between the charger and the vehicle to be recharged is not necessary.

The prior art systems for recharging electric vehicles therefore generally consist of plug-in connections.

In short, therefore, the electric vehicle is connected by a user to the respective recharging system using a special wiring.

The known system allows a suitable recharging of an electric vehicle but has major drawbacks.

A first major drawback is due to the presence of the wiring, whether it is placed close to the recharging system or forms an integral part of the accessories of the vehicle (in the latter case, the dimensions of the wiring will occupy useful space for loading the vehicle). Another major drawback is due to the fact that, since the connection by wiring is a manual operation to be performed by the user, once the vehicle has been positioned in the specific recharging area (for example, the relative garage), if the user forgets to connect the electric vehicle to the respective recharging system the vehicle will not be ready at the subsequent use to perform its functions since the batteries will not have been adequately recharged.

Disclosure of the invention

In this context, the technical purpose which forms the basis of the invention is to provide a system for recharging an electric vehicle which overcomes the above-mentioned drawbacks of the prior art.

In particular, the aim of this invention is to provide a recharging system for an electric vehicle which is fully automatic and which does not require any intervention by a user to start the recharging step.

A further aim of the invention is to provide a recharging system for an electric vehicle which does not occupy any useful space for loading the vehicle.

A further aim of the invention is to provide a recharging system for an electric vehicle which allows a margin of tolerance in the mutual positioning between the electric vehicle and the system.

The technical purpose indicated and the aims specified are substantially achieved by a recharging system for an electric vehicle according to the invention.

Brief description of the drawings

Further features and advantages of this invention are more apparent in the non-limiting description of a preferred but non-exclusive embodiment of a recharging system an electric vehicle, as illustrated in the accompanying drawings, in which:

- Figure 1 shows a schematic view of an embodiment of a recharging system for an electric vehicle according to this invention in a first condition of use;

- Figure 2 shows a schematic view of a recharging system for an electric vehicle according to this invention in a second condition of use;

- Figure 3 schematically shows a coupling between a recharging system according to the invention and an electric vehicle and

- Figure 4 shows a schematic view of a device for transmitting electrical energy included in a recharging system according to the invention;

- Figure 5 shows a schematic view of an embodiment of a coupling between an electric vehicle and a recharging system according to the invention;

- Figure 6 is a schematic top view of the electricity transmission device of Figure 4 and

- Figure 7 shows a detail of the electricity transmission device of Figures 4 and 6.

Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, the numeral 1 denotes a recharging system for an electric vehicle 100, in particular for home/residential use, or in an urban context, both public and private, according to the invention.

The recharging system 1 for an electric vehicle 100 comprises in its basic embodiment a main body 2 suitable for being positioned on the floor of an area suitable for recharging the vehicle 100.

The expression “area suitable for recharging the electric vehicle 100” means, for example, a private or public garage or automobile spaces suitable for the purpose.

Advantageously, the main body 2 of the recharging system 1 can self- propelled (for example, installed on a robot) or be fixed to the floor in such a way that it does not move when surmounted by the electric vehicle 1 to be recharged. The main body 2 is configured to be connected to an electrical power source, for example by means of a special wiring, of known type which is not shown in the drawings.

Once located in the recharging area, the main body 2 can be surmounted at least partly by the vehicle 100 to be recharged so as to place the vehicle 100 above the main body 2.

The main body 2 comprises an electricity transmission device 5 designed to transfer electricity from the above-mentioned source and the energy storage system installed on the electric vehicle 100 being recharged.

The transmission device 5 comprises lifting means 14 for moving at least one conductive element 8, 9, 28, 29, 30 (preferably five contacts to which predetermined functions can be attributed: positive and negative in the case of direct current supply or phase and neutral in the case of alternating current supply) from a first lowered position (shown in Figure 1 ) to a second raised position (shown in Figure 2).

The second, raised position is such that the at least one conductive element 8, 9, 28, 29, 30 can enter into physical contact (and, therefore, electrical) with at least one respective conductive element 108, 109, 128, 129, 130 located in the lower platform of the electric vehicle 100 being recharged and connected with the energy storage system of the vehicle (for example, a battery pack or the like).

The elements 108, 109, 128, 129, 130 constitute a device for receiving electricity for the vehicle 100.

The transfer of energy is therefore of the conductive type.

Advantageously, the conductive elements 8, 9, 28, 29, 30 of the recharging system 1 are in the form of a plate or bar.

Advantageously, moreover, the conductive elements 108, 109, 128, 129 of the vehicle 100 are in the form of a pin.

It should be noted that the pin shape can be made for the conductive elements 8, 9, 28, 29, 30 of the transmission device 5 and at the same time the plate or bar shape can be made for the conductive elements 108, 109, 128, 129, 130 of the receiving device 105 of the vehicle 100.

More generally speaking, the importance from the technical point of view is that a conductive transmission and/or receiving element with a planar shape corresponds to a conductive transmission and/or receiving element with a pin shape.

Advantageously, when the transmission device 5 is in the lowered position (Figure 1 ), it is located completely inside said main body 2.

This configuration is convenient because it avoids the possibility of any obstacle when the vehicle 100 surmounts the main body 2 to obtain the correct mutual positioning.

With regard to the mutual positioning step between the recharging 1 system and the vehicle 100, with reference to Figure 5, a first embodiment is shown in which the main body 2 comprises at least a first pair of emitters 6a, 6b of a respective light beam 16a, 16b positioned in such a way as to emit the above-mentioned beam inclined by a same angle relative to the direction X, that is to say, the ideal direction of forward movement of the vehicle 100 relative to the recharging system 1.

The light beam 16a, 16b, 17a, 17b may advantageously be of the laser type.

The light beam 16a, 16b. 17a, 17b can also consist of a coherent or incoherent type of light, in the visible spectrum or in the invisible spectrum. Advantageously, the light beams 16a, 16b, 17a, 17b are emitted at a height above ground of between 1 cm and 20 cm, preferably between 3 cm and 12 cm.

The power of the emitters 6a, 6b, 7a, 7b is such that the respective light beams emitted 16a, 16b, 17a, 17b reach at least 2 metres without distortions of the beam itself.

Preferably, the recharging system 1 comprises a further second pair of emitters 17a, 17b positioned downstream of the direction of forward movement X of the vehicle 100 relative to the recharging system 1.

The recharging system also comprises a communication device 19, operating by means of any radio technology and able to exchange information with a respective on-board communication device 1 19 of the vehicle 100.

By using the above-mentioned light beams 16a, 16b, 17a, 17b and the exchange of information between the devices 19, 1 19 the driver of the vehicle is provided (for example, on any on-board display) with information relative to the ideal trajectory to be followed in order to obtain a perfect mutual recharging positioning.

It is clear that when this invention refers to mutual positioning between the vehicle 100 and the recharging system 1 it means mutual positioning between the conductive elements 8, 9, 28, 29, 30 (of the main body 2) and the conductive elements 108, 109, 128, 129, 130 (of the vehicle 100), or in any case between the transmission device 5 of the recharging system 1 and the receiving device 105 of the vehicle 100.

During operation, when the vehicle 100 approaches into the radius of action of the communication devices 19, 1 19, it starts to transmit information regarding, for example, the dimensions, the geometry (including the distance between the tyres of each axle) and the speed of the vehicle 100.

Advantageously, at the end of the recognition step between the devices 19 and 1 19, the recharging system 1 sends a command for switching on a display unit of the vehicle 100 in such a way as to allow the driver to see, for example through a front video camera, the recharging system 1.

Continuing the approach, when one of the two light beams 16a, 16b interferes with one of the two tyres 39a, 39b, by knowing the intersection point, the angle between the light beam itself and the direction of forward movement X, the recharging system 1 determines the distance of the vehicle 100 (that is to say, the position of the receiving device 105) since its position on the vehicle 100 was received during the first communication between the devices 19, 119).

When the vehicle 100 continues its forward movement, the second light beam 16b also interferes with the respective tyre 39a, 39b; by acquiring this information, the recharging device 1 is able to determine the position of the vehicle 100 relative to itself including the mutual inclination.

At this point, the recharging system 1 communicates the first information regarding the ideal trajectory, for example on a display unit on-board the vehicle 100, so as to indicate to the driver how to act on the steering to obtain a correct positioning.

Advantageously, if there is also a further pair of light emitters 7a, 7b, these can acquire a second measurement, after the vehicle 100 has continued to move forward, again based on the interference of the light beams 17a, 17b with the tyres 29a, 29b, in such a way as to further optimise the mutual positioning between the system 1 and the vehicle 100.

In particular, according to an embodiment, the second pair of emitters 17a, 17b emits a respective beam in a direction perpendicular to the direction X in such a way as to determine the correct centring of the vehicle 100 relative to the recharging system.

For this purpose, there can also be a single further emitter 17a or 17b as the information relating to the geometry of the vehicle 100 and, therefore, the positioning of the receiving device 105 on the vehicle 100 has already been processed by the recharging system 1 in the first step of moving the vehicle 100 using the communication devices 19, 1 19.

Alternatively, or in addition, the emitters 6a, 6b, 7a, 7b can be movable on an axle in such a way as to follow the forward movement of the vehicle 100 and provide a sort of instantaneous scanning of the positioning relative to the recharging system 1.

Other embodiments of mutual positioning systems are applicable to the invention such as, for example, those described in Italian patent applications 1020180000005423, 1020180000005432 and

1020180000006614 in the name of the same Applicant, the content of which is considered entirely incorporated by reference in this application. Once the recharging system 1 identifies the correct positioning of the vehicle 100 it communicates the start of the recharging procedure or sends information for correction of the relative position to be made by the driver or by means of autonomous driving commands.

As shown in Figures 4, 6 and 7, the main body 2 advantageously comprises at least one protective cover 12 positioned externally and all around the conductive elements 8, 9, 28, 29 and 30.

The cover 12 is, for example, of the concertina type and is configured to move vertically together with the conductive elements 8, 9, 28, 29 and 30 along the direction indicated by the arrow F.

In particular, the conductive elements 8, 9, 28, 29, 30 directly guide the movement of the protective cover 12, for example by a mechanical electrically insulating connection.

The cover 12 can comprise an electrically conductive coil, for example made of metal material, and is configured for the connection to earth of the vehicle 100.

The cover 12 therefore performs the twofold function of:

- protection against contact with the components 5, 105 designed for the electrical connection and transfer, that is to say, where the voltage is dangerous and

- the earth contact, that is, the earthing of the vehicle 100.

Advantageously, the cover 12 comprises earth conductor means designed to enter into contact with a respective earth positioned on the vehicle 100 when the cover 12 is lifted.

Alternatively, as shown in Figures 6 and 7, the earth connection can be integrated in the conductive element 30, preferably positioned in a central zone relative to the four conductive elements 8, 9, 28, 29 and isolated from them electrically.

More in detail, Figure 4 shows a possible embodiment of a system 14 for lifting the conductive elements 8, 9, 28, 29, 30.

The system can comprise lifting means 14 (for example, of the pantograph type as illustrated in Figure 4 with electric, pneumatic or hydraulic operation) connected to a supporting plate 18 of the conductive elements

8, 9, 28, 29, 30 by means of a ball joint 19.

The ball joint 19 allows the possible misalignment of the conductive elements 8, 9, 28, 29, 30 with the respective lifting means 14.

The misalignment allows, in turn, the contact of the conductive elements 8,

9, 28, 29, 30 and the respective contacts 108, 109, 128, 129, 130 of the vehicle 100 to be optimised.

To allow a greater misalignment tolerance of the lifting means 14 it can be mounted in a movable fashion on a respective horizontal guide.

With reference to Figure 4, the lifting means 14 (and all the components fixed to it) can move along the direction G relative to the main body 2.

It is important to consider that the perfect parallelism between the contacts 8, 9, 28, 29, 30 with 108, 109, 128, 129, 130 is lost even if only one of the four tyres is more deflated than the others.

The ball joint 19 makes it possible to overcome this type of problem.

In order to guarantee a greater physical (and, therefore, electrical) adhesion between the conductive elements 8, 9, 28, 29, 30 with the respective contacts 108, 109, 128, 129, 130 of the vehicle 100 the device for transmitting electricity 5 also comprises at least one electromagnet 31 configured to enter into physical and magnetic contact with a respective ferromagnetic contact 131 formed on the receiving device 105 of the vehicle 100.

According to an alternative embodiment, the at least one electromagnet 31 is included in the receiving device 105 and the respective ferromagnetic contact element is included in the transmission device 5.

Preferably, the main body 2 comprises a protective hatch 15 for protecting the at least one conductive element 8, 9, 28, 29, 30 when the lifting means 14 are in the lowered position.

This avoids any possible obstacle to the forward movement of the vehicle 100 above the main body 2.

Advantageously, the at least one conductive element 8, 9, 28, 29, 30 comprises at least one temperature sensor for measuring the temperature of the conductive element 8, 9, 28, 29, 30 when it is in contact with the respective conductive element 108, 109, 128, 129, 130 of the vehicle 100.

If the temperature sensor detects a temperature above a threshold value, the recharging system 1 prevents or limits the supply of current since the electrical contact of the conductive type is not optimum.

According to a possible operational example, an electric vehicle 100 approaching the recharging system 1 places the communication device 19 in radio communication with the communication device of the vehicle 1 19 which starts to exchange information regarding at least the dimensions and geometries of the vehicle.

After completing the recognition step between the devices 19, 119 the vehicle 100 continuing to move forward will ensure that firstly one tyre 39a and then the other 39b (or both at the same time, in the case of a perfect alignment) will interfere with the respective light beam 16a, 16b emitted by the respective emitters 6a, 6b.

From these interferences, the recharging system 1 is able to exactly calculate much information relative to the vehicle 100, in particular the positioning relative to the recharging system 1 and its speed of forward movement.

As the forward movement continues, according to the preferred embodiment which also comprises a second pair of emitters 7a, 7b, located downstream of the first 6a, 6b, the recharging system 1 performs a second measurement of the position of the vehicle 100.

From the first recognition step the recharging system 1 starts to send information relative to any trajectory corrections which the driver must perform in order to achieve a correct and perfect alignment with the recharging system 1.

Once the recharging system 1 determines a perfect alignment it gives consent for the start of the recharging procedure.

If, on the other hand, the recharging system 1 determines an incorrect positioning of the vehicle 100 relative to the main body 2, it signals to the user the need to perform a new positioning.

In the event of correct positioning, the protective hatch 15 of the main body opens and leaves adequate space for lifting the conductive elements 8, 9, 28, 29, 30 and the cover 12 towards the lower surface of the vehicle 100, that is, towards the respective contacts 108, 109, 128, 129, 130.

The conductive element 30 is the first component to come into contact with the vehicle 100 (in particular with a respective earth contact 130).

In fact, as shown in Figure 4, the conductive element 130 is at a vertical height greater than the conductive elements 108, 109, 128, 129 and an elastic means is advantageously mounted which can yield once in contact with the respective earth contact 130 of the vehicle 100.

During this step, the recharging system 1 performs a first check of the contact resistance of the earths.

If this check gives a positive result then the recharging system 1 continues with the completion of the lifting of the conductive elements 8, 9, 28, 29 to place them in contact with the respective conductive elements 108, 109, 128, 129 of the vehicle.

Once the above-mentioned conductive elements have entered into mutual contact the recharging system 1 energises the at least one electromagnet 31 in such a way as to generate an electromagnetic force which guarantees the adhesion between the contacts 8-108, 9-109, 28-128 and 29-129.

In this situation, if, for example, the vehicle moves in a minimal manner or is lightened (for example, during an unloading of goods from the vehicle) the perfect adhesion between the contacts 8-108, 9-109, 28-128 and 29- 129 and, therefore, the positive recharging operation, is guaranteed.

The recharging system 1 checks the contact resistance of the conductive elements 8-108, 9-109, 28-128 and 29-129.

If this check also gives a positive result, the recharging system 1 communicates to the vehicle 100 the values of the relative voltage or power available for picking up during recharging.

At this point, if there is a correspondence of the values provided by the recharging system 1 with respect to those of the vehicle 100 the recharging step starts.

Once the recharging cycle is finished, the recharging system 1 lowers the cover 12 and the conductive elements 8, 9, 28, 29, 30.

If a situation occurs in which the supply of electricity is interrupted during the recharging step of the vehicle 100, the recharging system 1 can comprise a battery or a generic system for storing electricity, which, controlled by suitable sensors, allows the disengaging of the recharging system 1 from the vehicle 100.

In particular, the battery allows the lowering of the lifting means 4 and, therefore, the disengaging of the vehicle 100 from the recharging system 1 .

The features of a system 1 for recharging an electric vehicle 100 according to the invention are clearly described above, as are the advantages with respect to the prior art.

In particular, an important advantage consists in the fact that a recharging system 1 according to the invention allows the operation for recharging an electric vehicle 100 to be performed without the need for the user to carry out operations of a manual type.

In particular, the positioning of the vehicle 100 over the main body is sufficient to ensure that the recharging operation starts.

In this way, the possibility that the user forgets to connect the vehicle 100 to the respective recharging station once he/she has returned, for example, to their home is avoided.