CHARGING CABLE MANAGEMENT SYSTEM

Abstract

The present invention concerns a charging cable management system, which is motorized and is applied in electric vehicle charging equipment, or other applications that require this type of solution. The developed charging cable management system allows extending or retracting a suspension cable that assists the user in the task of mobilizing and moving an electric charging cable for charging electric vehicles, preventing it from touching the ground when not in use. In addition, the charging cable management system allows the use and mobilization of charging cables with greater longitudinal amplitude, minimizing the efforts associated with carrying out these tasks by the user.

Claims

1. Electric vehicle charging cable management system, comprising: a motorized winding system (101) of a suspension cable (103), characterized in that the motorized winding system (101) comprises: a longitudinal U-shaped rail (1031) with two ends, inside which a guide (1038) comprising a vertical hole passing through its central core runs longitudinally and which is physically and mechanically adapted to the shape of the rail (1031) allowing its free displacement between the two ends, wherein the base of said rail (1031) comprises a longitudinal cutout coincident with the positioning and alignment of the vertical hole of the guide (1038), the rail (1031) comprising at one of its ends a first offset sensor (1034), and at the opposite end a second offset sensor (1039); a U-shaped bracket (1036) comprising a threaded shaft (1035), a motor (1014) and limit switch sensors A and B (10351, 10352), the threaded shaft (1035) mechanically adapted to the bracket (1036) comprises a movable guide (1037), the motor (1014) mechanically adapted to the threaded shaft in order to promote its rotation is fixed to the bracket (1036), the limit switch sensors A and B (10351, 10352) fixed to the bracket (1036) are positioned so as to determine the positioning of the movable guide (1037), and the rail (1031) is fixed to said bracket (1036); a reel (1033), positioned above the rail (1031) and mechanically adapted to the threaded shaft (1035) in order to accompany its rotational movements, comprising a mechanical fastening means; and a suspension cable (103) fixed at one of its ends to the reel (1033) by said mechanical fastening means, crosses simultaneously the longitudinal cutout of the rail (1031) and the hole of the guide (1038), comprises at its other end a bracket of the suspension cable (105) mechanically fixed by a clamping system; wherein the motorized winding system (101) is adapted to control the provision of said suspension cable (103) that guarantees support and suspension of the electric vehicle charging cable.

2. (canceled)

3. System, according to claim 1, characterized in that the motor (1014) is mechanically adapted to the threaded shaft (1035) by means of a rotor (10141).

4. System, according to claim 1, characterized in that the first and second offset sensors (1034, 1039) detect the contact of the guide (1038) with the respective end of the rail (1031) promoting the activation of the motor (1014).

5. System, according to claim 1, characterized in that the contact of the guide (1038) with the first offset sensor (1034) promotes the rotation of the motor (1014) in one direction, and the contact of the guide (1038) with the second offset sensor (1039) promotes the rotation of the motor (1014) in the same direction corresponding to the unwinding of the suspension cable (103).

6. System, according to claim 1, characterized in that the limit switch sensors A and B (10351, 10352) detect the contact of the movable guide (1037) that runs along the threaded shaft (1035) with the ends of the bracket (1036).

7. System, according to claim 1, characterized in that the reel (1033) promotes the winding or unwinding of the suspension cable (103) through the action generated by the motor (1014).

8. System, according to claim 1, characterized in that the contact of the movable guide (1037) with the limit switch sensor A (10351) or with the limit switch sensor B (10352) identifies the winding or unwinding position of the cable (103) on the reel (1033).

9. System, according to claim 1, characterized in that it comprises an outer housing (1032) with an open groove at its base that allows the suspension cable (103) to pass through and be handled.

10. System, according to claim 1, comprising: a control system (1017) consisting of a signal acquisition and processing unit (10171), a processing and control unit (10172) and an output signal for motor control (10173); a command system (1013); and a DC power supply (1011).

11. System, according to claim 1, characterized in that it comprises a sensor system (1016) composed of motor current sensors (10350) and connector rest sensors (10353).

12. System, according to claim 1, characterized in that the control system (1017) receives signals from the sensor system (1016) through the signal acquisition unit (10171), performing signal processing in the processing unit (10172) which sends the output signal (10173) to the command system (1013) of the motor (1014).

13. System, according to claim 1, characterized in that the output signal (10173) actuates the command system (1013) through the use of an H-bridge, which promotes the rotation of the motor (1014) in a direction, thus closing a MOSFET circuit Q3-Q2, or promotes rotation of the motor (1014) in the reverse direction thus closing a MOSFET circuit Q1-Q4.

14. Electric vehicle charging system (100) comprising: at least one electric vehicle charging cable management system as described in claim 1, and at least one charging cable (102) with a charging connector (104); wherein the charging cable (102) is supported by the suspension cable (103) of the motorized winding system (101) ensuring that it does not come into contact with the ground when not in use.

15. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] For an easier understanding of the present application, figures are herein attached, which represent embodiments which however are not intended to limit the art herein disclosed.

[0045] FIG. 1 shows an electric vehicle charging system wherein: [0046] 100charging station; [0047] 101motorized winding system; [0048] 102charging cable; [0049] 104charging connector; [0050] 200user.

[0051] FIG. 2 shows an electric vehicle charging system wherein: [0052] 100charging station; [0053] 101motorized winding system; [0054] 102charging cable; [0055] 104charging connector; [0056] 200user.

[0057] FIG. 3 shows an electric vehicle charging system wherein: [0058] 100charging station; [0059] 101motorized winding system; [0060] 102charging cable; [0061] 103suspension cable; [0062] 104charging connector; [0063] 105suspension cable bracket; [0064] 200user.

[0065] FIG. 4 schematically shows an electric vehicle charging system wherein: [0066] 100charging station; [0067] 101motorized winding system; [0068] 102charging cable; [0069] 103suspension cable; [0070] 104charging connector; [0071] 105suspension cable bracket; [0072] 200user.

[0073] FIG. 5 depicts the block diagram making up the motorized winding system, wherein: [0074] 101motorized winding system; [0075] 1011power supply; [0076] 1012overcurrent protection; [0077] 1013command system; [0078] 1014DC motor; [0079] 10141mechanical system, rotor; [0080] 1016sensor system; [0081] 1017control system.

[0082] FIG. 6 depicts the mechanical components making up the motorized winding system, wherein: [0083] 105suspension cable bracket; [0084] 1014DC motor; [0085] 10141rotor; [0086] 1031rail; [0087] 1032system housing, [0088] 1033reel; [0089] 1034first offset detector/sensor; [0090] 1035threaded shaft; [0091] 1036bracket; [0092] 1037movable guide; [0093] 1039second offset detector/sensor.

[0094] FIG. 7 depicts the mechanical components making up the suspension cable offset detection system, wherein: [0095] 103suspension cable; [0096] 105suspension cable bracket; [0097] 1031rail; [0098] 1034first offset detector/sensor; [0099] 1038suspension cable guide; [0100] 1039second offset detector/sensor.

[0101] FIG. 8 depicts in detail the mechanical components making up the suspension cable offset detection system, wherein: [0102] 1031rail; [0103] 1034first offset detector/sensor; [0104] 1038suspension cable guide; [0105] 1039second offset detector/sensor.

[0106] FIG. 9 depicts in detail the mechanical components making up the retracted or extended cable detection system, wherein: [0107] 1035threaded shaft; [0108] 1036bracket; [0109] 1037movable guide; [0110] 10351limit switch detector/sensor A; [0111] 10352limit switch detector/sensor B;

[0112] FIG. 10 depicts the diagram of the motorized winding system (101), wherein: [0113] 1016sensor system; [0114] 10350motor current sensors; [0115] 10351limit switch detector/sensor A; [0116] 10352limit switch detector/sensor B; [0117] 10353connector rest detector/sensor; [0118] 1034first offset detector/sensor; [0119] 1017control system; [0120] 10171signal acquisition and processing unit; [0121] 10172processing and control unit; [0122] 10173output signal for motor control; [0123] 1011DC power supply; [0124] 1013command system; [0125] 1014DC motor.

[0126] FIG. 11 depicts the electrical component applied to the motor. Reference numbers represent: [0127] 301clockwise rotation movement; [0128] 302immobilized motion; [0129] 303counterclockwise rotation movement; [0130] 1014DC motor.

[0131] FIG. 12 depicts the mechanical component, wherein: [0132] 103suspension cable; [0133] 1014DC motor; [0134] 10141mechanical system, rotor; [0135] 1035threaded shaft; [0136] 1033reel.

[0137] FIG. 13 depicts the diagram of the charging cable management system states, describing its method of operation.

DESCRIPTION OF EMBODIMENTS

[0138] Referring to the figures, some embodiments are now described in more detail, which are not intended, however, to limit the scope of the present application.

[0139] With reference to FIG. 1, the charging connector (104) is inactive and placed in the rest bracket of the charging station (100), causing the charging cable (102) to be retracted and the cable suspension (103) completely wound onto the reel (1033) of the motorized winding system (101).

[0140] In this case, there is no tension or offset in the suspension cable (103) to activate the charging cable management system.

[0141] In FIG. 2, the first interaction of the user (200) with the charging station (100) is depicted. Here, the user (200) pulls the charging connector (104) towards the electric vehicle, the charging cable (102) being suspended in the air without coming into contact with the ground.

[0142] At this first moment, through the first and second offset detectors (1034, 1039), the motorized winding system (101) detects that more charging cable (102) is being requested by the user (200).

[0143] In FIG. 3, the suspension cable (103) is responsible for guaranteeing the lift and support of the charging cable (102), preventing it from coming into contact with the ground when the user (200) moves the charging connector (104) towards the vehicle to be loaded. In this case, as long as offset detection is made by first and second offset detectors (1034, 1039), the motorized winding system (101) will unwind the suspension cable (103) from the reel (1033).

[0144] In FIG. 4, the motorized winding system detects (101), through the first and second offset detectors (1034, 1039), that no more charging cable (102) is being requested, and since the suspension cable (103) is vertical to the charging station (100), first and second offset sensors (1034, 1039) will not activate. Thus, the motor (1014) is immobilized, and the suspension cable bracket (105) is responsible for guaranteeing the lift of the charging cable (102), allowing sufficient slack and tension for the user (200) to guarantee the insertion of the charging connector (104) in the vehicle.

[0145] The charging cable management system solution proposed by the present invention, as shown in FIG. 5, is composed of the motorized winding system (101), which comprises a DC power supply (1011), a command system (1013), control system (1017), overcurrent protection (1012), a DC motor, DC (1014) with gearbox, a mechanical system, rotor (10141) and sensor system (1016).

[0146] The innovation of the solution proposed by the present invention involves the use of a direct current operating motor (1014) to promote the winding and unwinding of the suspension cable (103) that supports the charging cable (102), allowing the latter to have greater extension and consequent greater reach. The suspension cable (103) supports the charging cable (102) through the suspension cable holder (105) The motor (1014) is mechanically connected to a reel (1033) where the suspension cable (103) is wound and unwound. An exploded view of the motorized winding system (101) developed is shown in FIG. 6.

[0147] The motorized winding system (101) allows the application and operation with different types of charging cables (102) such as CCS and CHAdeMO of different diameters and weights, either cooled or not. The proposed motorized winding system (101) has the possibility to change the necessary parameters to compensate for the different charging cables (102) and maintain speed and ease of use regardless of the type of charging cable.

[0148] To ensure that the suspension cable (103) is released only when requested, a mechanism has been developed that determines, through the positioning of said suspension cable (103), whether the user (200) is pulling the electric charging cable (102). FIG. 7 illustrates this suspension cable offset detection mechanism (103).

[0149] In that sense, when the user (200) pulls the charging cable (102) towards the vehicle, the suspension cable (103) that crosses the guide (1038) slides in the rail (1031) illustrated in FIG. 7 and FIG. 8. When the guide (1038) touches one of the ends of the rail (1031), the first and second offset detectors (1034, 1039) are activated, causing the control system (1017) and command system (1013) to actuate the motor (1014).

[0150] In order to ensure that the suspension cable (103) movement is detected, regardless of where the user (200) is and when pulling the charging cable (102), the groove incorporated in the rail (1031) has been designed in such a way that the suspension cable (103) always slides until one of the first and second offset detectors (1034, 1039) triggers.

[0151] As soon as the first and second offset detectors (1034, 1039) of the rail (1031) are activated by contact with the guide (1038), the motorized winding system (101) validates the status of the limit switch sensors A and B (10351, 10352) installed on the bracket (1036) as shown in FIG. 9.

[0152] To ensure that the motor (1014) stops the rotation movement of its axis when the suspension cable (103) is fully unwound, or fully wound, a mechanism has been created that, through a movable guide (1037), which travels a threaded shaft (1035) rotating in synchrony with the motor shaft (1014) through mechanical communication performed by a rotor (10141), causes the movable guide (1037) to abut one of points A or B, as shown in FIG. 9, triggering each of the limit switch sensors A or B (10351, 10352), respectively the limit switch sensors at points A or B (10351, 10352).

[0153] If the suspension cable (103) is fully wound, the movable guide (1037) abuts one of the identified points (A or B) and triggers one of the limit switch sensors A or B (10351 or 10352). Likewise, in case the suspension cable (103) is fully unwound, the movable guide (1037) will abut the opposite point (A or B), triggering the other limit switch sensor A or B (10351 or 10352).

[0154] In this way, the motorized winding system (101) analyzes the status of the limit switch sensors A and B (10351, 10352) to determine whether the suspension cable (103) is fully wound on the reel (1033) or fully extended on the vertical position to the charging station (100), and together with the two first and second offset sensors (1034, 1039), it validates whether the release of more charging cable (103) is being requested and whether there are conditions to comply with the user's request (200).

[0155] The sensor system (1016), referred to in FIG. 10, is composed of: motor current sensors (10350), which validate whether its operation is taking place within normal operating patterns; limit switch sensors A and B (10351, 10352), which provide information to the motorized winding system (101) on the winding status of the suspension cable (103) about the reel (1033); first and second offset sensors (1034, 1039), in joint action, allow to validate whether or not there is a suspension cable (103) release request; and rest sensor (10353) of the charging connector (104) on the charging station rest bracket (100), determines the initial and final operating condition of the charging cable management system, so that the motorized winding system (101) dispenses or winds the suspension cable (103).

[0156] The way in which the motor (1014) retracts or extends the suspension cable (103), depends on the control signals that close or open the circuits of the electric bridge H where it is inserted, as illustrated in FIG. 11.

[0157] First and second offset sensors (1034, 1039), limit switch sensors A and B (10351, 10352) and rest sensor (10353), send the signal with their status to the control unit (1017), which receives them through the signal acquisition unit (10171), the signal processing being performed by the processing unit (10172) which will determine and send the output signal (10173), which will act on the H-bridge of the command system (1013) illustrated in FIG. 11, wherein the motor (1014) promotes the rotation of its axis to one side, closing circuit Q3-Q2 (MOSFET) or to the other, closing circuit Q1-Q4 (MOSFET).

[0158] In mechanical terms, the basic concept of the charging cable management system of the present invention involves the use of a model with a motor (1014) associated with a reel (1033), which pulls or releases a weight according to the rotational direction of the motor axis (1014).

[0159] In the proposed model, the motor is connected to a rotor (10141), which changes the relationship between speed and torque.

[0160] The angular speed in the rotor (10141) decreases in ratio (W2<W1) and the torque increases in ratio (T2>T1) due to the gear ratio R=(N2/N1). The ratio between rotor (10141), torque and angular speed is as follows:

W2=W1/R

T2=T1R

[0161] Which means that the higher the rotor gear ratio (10141), the higher the torque, the lower the angular speed, in this case the system is able to move a heavier object, yet at a lower speed.

[0162] The threaded output shaft (1035) of the rotor (10141) is coupled to a reel (1033), where the suspension cable (103) is wound or unwound.

[0163] Considering the particular application of this solution proposed by the present invention in charging electric vehicles, FIG. 13 shows the functional flowchart of the charging cable management system and its conditional operating method.

[0164] According to the flowchart shown in FIG. 13, when the motorized winding system (101) detects that the charging connector (104) is not installed on the charging station's rest bracket (100), through information from the rest sensor (10353), the motorized winding system (101) validates the status of the first and second offset detectors (1034, 1039), to assess whether the charging cable (102), and in particular the suspension cable (103), is being pulled by the user (200). If first and second offset detectors (1034, 1039) are triggered, then the motorized winding system (101) will validate whether there is suspension cable (103) to supply or retrieve. This information is determined through the data from the limit switch sensors A and B (10351, 10352). If the availability condition of the suspension cable (103) is verified, the motorized winding system (101) will actuate the rotation movement of the central shaft of the motor (1014), in order to provide (unwind) the suspension cable (103). As long as there is a suspension cable (103) available and it is detected that the charging cable (102) is being pulled and the charging connector (104) is not at rest, the motor shaft (1014) rotates in the rotation direction which promotes the provision of the suspension cable (103).

[0165] When the user (200) stops pulling the charging cable (102), there is no longer angling of the suspension cable (103) inside the rail (1031), which leads the first and second offset sensors (1034, 1039) to no longer being activated. Since the contacts of the first and second offset sensors (1034, 1039) are not closed, the motor shaft (1014) will then be immobilized by stopping its rotation. Similarly, when there is no more suspension cable (103) available, the threaded shaft (1035) of the motor (1014) will stop through the contact actuation of the limit switch sensors A and B (10351, 10352).

[0166] Then, the motorized winding system (101) validates whether the charging connector (104) is connected to the vehicle for charging the electric vehicle. If the condition is verified, the threaded shaft (1035) of the motor (1014) remains immovable, and there is no need to supply more suspension cable (103).

[0167] If the vehicle is not in the charging period, the motorized winding system (101) assesses whether the charging session has already been completed. In the event that the charging connector (104) returns to the resting position, then the charging session is considered to be completed and the motorized winding system (101) proceeds to the phase of validating the presence of suspension cable (103) to retract.

[0168] This is carried out by reading the limit switch sensors A and B (10351, 10352) and if there is a suspension cable (103) to retract, the motorized winding system (101) incorporates a timer, which allows the user (200) time to step away so that the system retracts the suspension cable (103) safely.

[0169] The suspension cable (103) is retracted, while the charging connector (104) remains in the rest position and there is suspension cable (103) to retract. As soon as the motorized winding system (101) detects, through limit switch sensors A or B (10351, 10352) that the suspension cable (103) is fully wound, then the cycle ends, and the threaded shaft (1035) of the motor (1014) is immobilized.

[0170] When the vehicle has finished charging and the rest sensor (10353) placed in the charging connector rest bracket (104) is not activated, a message is sent to the user (200), shown on a display at the charging station (100), requesting him/her to place the charging connector (104) in the resting position on the charging station (100) The system immobilizes the threaded shaft (1035) of the motor (1014) until the charging connector (104) is placed on the rest bracket in the resting position by the user (200).

[0171] The motor drive circuit (1014), as illustrated in FIG. 11, is based on an electrical converter with H-bridge configuration. This converter allows driving the motor (1014) clockwise or counterclockwise according to the MOSFET states (Q1, Q2, Q3, Q4), as well as controlling the rotation speed of the motor (1014) using the Pulse-Width Modulation (PWM) technique. To establish the PWM pulse width, a closed loop current control system is used. The reference current used for controlling the motor (1014) is adapted to the weight of the charging cable (102), thus limiting the torque of the motor (1014) to what is essential to move the charging cable (102).

[0172] To immobilize the motor (1014) in a given position, a state is induced in transistors such that the poles of the motor (1014) are short-circuited, forcing the existence of a countermovement torque of the rotor, causing the immobilization thereof. This is done by running Q1 and Q3, or else Q2 and Q4.

[0173] The present description is of course in no way restricted to the embodiments presented herein and a person of ordinary skill in the art may provide many possibilities of modifying it without departing from the general idea as defined in the claims. The preferred embodiments described above are obviously combinable with each other. The following claims further define preferred embodiments.