GB2559188A

GB2559188A - Charging station

Info

Publication number: GB2559188A
Application number: GB1701545.4A
Authority: GB
Inventors: Manners John; Manners William; Dominik Moczek Aleksander
Original assignee: A Tech Fabrications Ltd
Current assignee: A Tech Fabrications Ltd
Priority date: 2017-01-31
Filing date: 2017-01-31
Publication date: 2018-08-01
Also published as: GB201701545D0

Abstract

A charging station 301 for a vehicle (e.g. an autonomous guided vehicle 101) has a marker detector 304 (e.g. optical barcode reader) that detects one or more markers 108 (e.g. optical barcodes) associated with a vehicle when the vehicle enters and leaves the charging station, in order to determine a period of time during which the vehicle has undergone charging in the charging station. The charging station also includes a charging mechanism that connects to a vehicle for transferring charge to an energy storage unit of the vehicle. The charging mechanism may include a connection plate 303 that is: connectable to a power supply; and provides an electrical connection with a corresponding connection plate 107 of the vehicle. The charging station connection plate may be located on a charging stand 302 and positioned such that an electrical connection between the charging station connection plate and the vehicle connection plate is provided when the vehicle enters the charging station and occupies a predetermined charging position. Guidance elements (e.g. floor mounted position guides 304) may be used to guide the vehicle to the predetermined charging position.

Description

(54) Title of the Invention: Charging station Abstract Title: Vehicle charging station (57) A charging station 301 for a vehicle (e.g. an autonomous guided vehicle 101) has a marker detector 304 (e.g. optical barcode reader) that detects one or more markers 108 (e.g. optical barcodes) associated with a vehicle when the vehicle enters and leaves the charging station, in order to determine a period of time during which the vehicle has undergone charging in the charging station. The charging station also includes a charging mechanism that connects to a vehicle for transferring charge to an energy storage unit of the vehicle. The charging mechanism may include a connection plate 303 that is: connectable to a power supply; and provides an electrical connection with a corresponding connection plate 107 of the vehicle. The charging station connection plate may be located on a charging stand 302 and positioned such that an electrical connection between the charging station connection plate and the vehicle connection plate is provided when the vehicle enters the charging station and occupies a predetermined charging position. Guidance elements (e.g. floor mounted position guides 304) may be used to guide the vehicle to the predetermined charging position.

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Application No. GB1701545.4

RTM

Date :19 July 2017

Intellectual

Property

Office

The following terms are registered trade marks and should be read as such wherever they occur in this document:

Microsoft

Windows

Intellectual Property Office is an operating name of the Patent Office www.gov.uk/ipo

Charging Station

Technical Field

The present invention relates to a charging station for transferring charge to an energy storage unit of a vehicle.

Background

Vehicles powered by electrical energy sources are well known and widely used. For example, in industrial settings, such as factories and warehouses, electric vehicles are often used for moving items from place to place.

In such environments electric vehicles may be preferable for a range of reasons. For example unlike vehicles powered by a combustion engines there are little or no exhaust emissions from electric vehicles. Such emissions are undesirable in an enclosed space.

Electric vehicles are typically powered by battery units which become depleted of energy as the vehicle is used. It is commonplace therefore in places where electric vehicles are deployed to also find battery charger equipment for charging electric vehicle batteries.

A user of such electric vehicles may rent or buy battery units and/or charger equipment from battery equipment suppliers. The user of the electric vehicles may rent or buy battery units based on the claimed performance of the batteries.

However, although the user may typically oversee the charging of the batteries on a day25 today basis, they may be provided with no mechanism by which they can independently monitor the performance of battery units being used.

Summary of the Invention

In accordance with a first aspect of the invention, there is provided a charging station for a vehicle comprising a charging mechanism connectable to a vehicle for transferring charge to an energy storage unit of the vehicle, wherein the charging station further includes a marker detector, said marker detector arranged to detect one of one or more markers associated with a vehicle when the vehicle enters the charging station and to detect the one of the one or more markers on the vehicle when the vehicle leaves the charging station, thereby enabling a period of time during which the vehicle has undergone charging in the charging station to be determined.

Optionally, the charging mechanism is connected to a vehicle when the vehicle enters the charging station and occupies a predetermined charging position.

Optionally, the charging mechanism includes a connection plate for providing an electrical connection with a corresponding connection plate of a vehicle, wherein said connection plate of the charging station is connectable to a power supply.

Optionally, the connection plate is located on a charging stand and positioned such that when a vehicle enters the charging station and occupies a charging position, an electrical connection is provided between the connection plate of the charging station and the corresponding connection plate of the vehicle.

Optionally, the charging station comprises guidance elements to guide a vehicle to the predetermined charging position.

Optionally, the charging station is arranged such that a vehicle can enter the charging station and move into the predetermined charging position in a first direction and leave the charging station in a second direction.

Optionally, the second direction is opposite the first direction.

Optionally, the charging station further comprises a stop positioned to prevent a vehicle moving in the first direction past the predetermined charging position.

Optionally, the charging station is arranged such that a vehicle can enter the charging station and move into the predetermined charging position in a first direction and leave the charging station in the first direction thereby moving through the charging station.

Optionally, the charging stand and connection plate are on a first side of the charging station, and the charging station comprises a further charging stand with further connection plate positioned on a second side of the charging station, wherein the second side is opposite the first side.

io Optionally, the marker is an optical barcode and the marker detector is an optical barcode reader.

Optionally, the marker detector is connectable to a computer system and is operable to convey information to the computer system indicating a time at which a vehicle enters the charging station and a time at which the vehicle leaves the charging station

Optionally, the vehicle is an autonomous guided vehicle.

In accordance with embodiments of the invention, a technique is provided that enables a user to conveniently determine an amount of charge transferred to the battery of a vehicle. This provides a number of advantages. For example, a user can compare the amount of charge transferred to a battery of a vehicle with the observed performance of the vehicle to independently assess the state of the vehicle’s battery. This allows faulty or older batteries to be readily identified. Additionally or alternatively, a user can choose to provide a predetermined amount of charge to a vehicle’s battery rather than charging it to a maximum level. This may reduce energy consumption and energy costs.

Various aspects and features of the invention are defined in the claims.

Brief Description of Figures

Certain embodiments of the present invention will now be described hereinafter, by way of example only, with reference to the accompanying drawings in which:

Figure 1 provides a schematic diagram of an autonomous guided vehicle adapted for use in a charging station in accordance with certain embodiments of the invention;

Figure 2 provides simplified schematic diagram of a charging station arranged in accordance with certain examples of the invention;

io

Figure 3 provides simplified schematic diagram of a charging station arranged in accordance with certain examples of the invention;

Figure 4 provides a schematic diagram of an autonomous guided vehicle adapted for use in 15 a charging station in accordance with certain embodiments of the invention;

Figure 5 provides a simplified schematic diagram of a charging station arranged in accordance with certain examples of the invention, and

Figure 6 provides a schematic diagram showing an electrical implementation of connection plates of an AGV and charging stand.

In the drawings like reference numerals refer to like parts.

Detailed Description

Figure 1 provides a schematic diagram of an autonomous guided vehicle (AGV) 101 adapted for use in a charging station in accordance with certain embodiments of the invention.

The AGV 101 includes a main body 102, a steerable drive wheel 103, a pair of rear stabiliser wheels 104 and a forklift unit 105.

The main body 102 houses a battery unit for powering the AGV along with electric motors for driving and steering the steerable drive wheel 103 and operating the forklift unit 105. The main body 102 also houses controlled electronics for controlling the operation of the AGV 101.

In the example shown in Figure 1, the AGV 101 also includes a sensor unit 106 for monitoring the position of a guidance track. In operation, the AGV 101 can proceed along a predetermined path by following such a guidance track.

The AGV 101 further includes a connection plate 107 positioned on the side of the main body 102. The connection plate 107 is coupled to a charging unit within the main body 102 which itself is coupled to the battery unit. This arrangement is such that when the connection plate 107 is brought into suitable contact with a corresponding connection plate of an AGV charging station, charge can flow from the connection plate of the AGV charging station to the battery unit of the AGV 101 via the AGV connection plate 107 and the charging unit. In this way the battery unit of the AGV 101 can be recharged.

Suitable connection plates are known in the art and typically comprise a nylon base with electrical conducting parts made from a suitable conducting material such as brass.

The AGV 101 further includes a marker 108. The marker can be provided by an optical code marker such as a barcode label positioned on the side of the AGV.

Figure 2 provides a simplified schematic diagram of a charging station 201 arranged in accordance with certain examples of the invention. The charging station 201 is arranged to operate in conjunction with an AGV to charge the battery unit of the AGV as described above.

In operation, an AGV of the type described with reference to Figure 1 enters the charging station 201 forklift unit first in the direction indicated by the arrow. Typically, fork legs of the forklift unit are in a lowered position when the AGV enters the charging station 201.

In some AGV implementations, the connection plate may be positioned in different locations. For example, in some implementations, a battery unit and charging plate of the AGV is mounted on the forklift unit itself. In such implementations, when the AGV enters the charging station, the forklift unit is set at a height to ensure that the connection plate can contact a connection plate of the charging station. The connection plate of the charging station is explained in more detail below.

As the AGV enters the charging station each fork leg of the forklift unit is guided by a fork guidance element 202. Each fork guidance elements 202 typically presents a spaced opening to receive the tip of each fork leg and then defines a narrowing passage along which the fork leg travels as the AGV moves into the charging station 201. The spaced opening is typically sized such that despite typical variances in the position of the AGV, and thus the fork legs, arising due to the AGV entering the charging station in differing positions, the tip of each fork leg will still enter the fork guidance elements. The narrowing passage ensures that as the AGV moves into the charging station 201, it moves towards a predefined charging position. The fork legs are prevented from moving beyond a desired point by a fork stop unit 203.

The charging station 201 further includes a pair of floor mounted position guides 204 which engage with the sides of the AGV as it enters the charging station. The floor mounted position guides 204, equipped for example with roller units, allow movement of the AGV into and out of the charging station but minimise lateral (side to side) movement of the AGV as it enters the charging station 201. In combination, the floor mounted position guides 204, the fork guidance elements 202 and the fork stop unit 203 ensure that when the AGV has fully entered the charging station (e.g. the tips of each fork leg are in contact with fork stop unit 203) it occupies a precise charging position. The charging position is such that the connection plate of the AGV is in secure electrical contact with a connection plate 205 of a charging stand 206 of the charging station. The connection plate 205 of the charging station 101 is coupled to a charging unit which is itself coupled to a charging power supply (not shown). When the AGV is in the charging position, charge from the charging power supply is transferred to the battery unit of the AGV via the charging unit of the charging station, the connection plate 205 of the charging stand 206, the connection plate of the AGV and the charging unit of the AGV.

The charger station 201 further includes a charger shelf 207 which is arranged such that equipment such as a charging unit, connectable to the charging stand 206 can be conveniently placed on it.

It will be understood that a charging station such as that depicted in Figure 2 allows an AGV to re-charge its battery unit autonomously. For example, the charging station may be positioned on a guidance track that is followed by the AGV. When the control electronics of the AGV determines that its battery unit is running low on charge, the AGV is controlled to enter the charging station and move into the charging position. When the control electronics of the AGV determines that the battery unit is fully charged, the AGV exits the charging station.

The AGV can detect that it is in the charging position by a position detector on the AGV detecting a position marker on the charging station. Such a position marker and position detector can be provided by any suitable means. For example, if the AGV is equipped with a magnetic field detector for following the guidance track, the position marker can be a metallic element with a magnetically encoded position marker detectable by the magnetic field detector. Alternatively, the AGV could be provided with a suitably positioned microswitch which is activated by a suitably positioned indent or catch mounted on the charging station, when the AGV is in the charging position.

Referring again to Figure 2, the charging station 201 is further provided with a marker detector 208. In examples in which the marker is a barcode label, the marker detector 208 is an optical barcode scanner. Such optical barcode scanners are well-known in the art.

In accordance with examples of the invention, the marker on an AGV is positioned such that when the AGV enters the charging station it is detected by the marker detector 208 and is detected again by the marker detector 208 when the AGV leaves the charging station.

Every time the marker detector 208 detects a marker, it communicates a detection signal to a computer system 209 connected to the marker detector 208.

The computer system 209 can be a system based on a conventional personal computer (PC) running a conventional operating system such as Microsoft Windows. The connection between the computer system 209 and the marker detector 208 can be provided by any suitable data connection that enables data to be exchanged between a device and a computer system. For example, the data connection can be based on one of a USB connection, parallel port connection, serial port based connection or Ethernet connection. In certain implementations, the data connection can be based on a wireless connection, rather than a wired connection.

The detection signal includes an identifier which is read by the marker detector 208 from the marker. The identifier is encoded on the marker and typically identifies the AGV.

The computer system has a program running thereon that is arranged to log the point in time at which the marker is first detected (indicating that the AGV has entered the charging station 201) and log the point in time when the marker is detected again (indicating that the AGV has left the charging station). In this way, the computer program can generate a charging time value corresponding to the period of time that the AGV has been charged by the charging station 201.

The charging station 201 delivers charge to the AGV battery unit at a predetermined constant rate. This is typically controlled by the charging unit of the charging station.

The program running on the computer system is provided with a charging rate variable. The charging rate variable corresponds to the charge rate of the charging station 201.

Using the charging time value, and the charging rate variable, the program running on the computer system 209 can calculate a total charge value. The total charge value is an estimate of the total charge provided from the charging station 201 to the battery unit of the AGV. The computer program is further arranged to generate a charging record which associates an identifier associated with the AGV (based on the identifier from the marker) with the total charge value. Further data may be included in the data record such as a date and time at which the charging operation commenced and finished. For implementations in which a plurality of AGVs are deployed in a location, a series of such data records can be generated showing the charge provided from the charging station to the battery units of different AGVs.

In certain examples, the charging station is arranged to allow AGVs to enter the charging station in one direction and depart the charging station in the same direction. An example of such a charging station is depicted in Figure 3.

Figure 3 provides a schematic diagram of a charging station 300 which corresponds to that shown in Figure 2, except that the elements that would otherwise prevent the AGV from proceeding through the charging station (e.g. the fork guidance elements with the narrowing passage, the charger shelf and the fork stop unit) are omitted.

In keeping with the charging station depicted in Figure 2, the charging station depicted in 301 includes a charging stand 302 with connection plate 303 and a marker detector 304 connectable to a computer system (for clarity a computer system connected to the marker detector 304 is not shown). The charging station 301 includes a set of floor mounted position guides 305 for holding an AGV in a charging position to receive charge from the charging stand 302.

In order to conveniently implement a charging arrangement using the type of charging station depicted in Figure 3, an AGV to be charged typically includes two markers, for example two bar code labels. In certain examples, these markers can be positioned on the side of the AGV such that when the AGV enters the charging station, a first marker is read by the marker detectors and when the AGV exits the charging station the second marker is read. An example of such an arrangement is shown in Figure 4.

Figure 4 provides a schematic diagram of an AGV 401 corresponding to that shown in Figure 1 except that a first marker 402 and a second marker 403 are positioned on the side of the AGV 401, rather than a single marker. As will be understood, in the event that the AGV 401 enters the charging station 301, forklift unit first, the first marker 402 will be detected by the marker detector 304. When the AGV is charged and leaves the charging station 305, again forklift unit first, the second marker 403 will be detected by the marker detector 304. Thus, as detailed above, when the marker detector 304 detects the first marker, this is indicative of an AGV entering the charging station 301 and a detection signal is communicated to the computer system. When the marker detector detects the second marker, this is indicative of the AGV leaving the charging station and another detection signal is communicated to the computer system. Operating as detailed above, the computer program running on the computer system can thereby generate a charging record.

Figure 5 provides a schematic diagram of a charging station 501 in accordance with certain embodiments of the invention. As can be seen from Figure 5, the charging station 501 includes a first charging stand 502 with connection plate 503 and a corresponding first marker detector 504. However, the charging station 501 includes a second charging stand 505 with second marker detector 506. The charging station 501 includes a first set of floor mounted position guides 507 for holding an AGV in a first charging position to receive charge from the first charging stand 502 and a second pair of floor mounted position guides 508 for holding an AGV in a second charging position for receiving charge from the second charging stand 505.

As will be understood, by virtue of the provision of the second charging stand 505 and marker detector 506, in the charging station 501 depicted in Figure 5, AGVs configured as indicated in Figure 4, can enter and exit the charging station in a first direction “direction 1” or the opposite direction “direction 2”.

Figure 6 provides a schematic diagram depicting an electrical implementation of the charging station and the AGV when the AGV is in the charging position.

As shown in Figure 6, the connection plate 601 of the AGV comprises two “small” brushes 602 (typically a positive brush and a negative brush) and two “big” brushes 603 (typically a positive brush and a negative brush). Correspondingly, the connection plate 604 of the charging station comprises two “small” brushes 605 (typically a positive brush and a negative brush) and two “big” brushes 606 (typically a positive brush and a negative brush).

When the AGV moves into the charging position, a microswitch 607 suitably mounted on the charging station is activated. If the connection plate 601 of the charging station and the connection plate 604 of the AGV are correctly aligned (thus causing the microswitch 607 to be activated), then, as can be seen from Figure 6, a circuit is completed allowing current from a low voltage output of a charging power unit 608 to flow through the small brushes 602 of the charging station and the small brushes 605 of the AGV. This current energises a first relay 609 in the charging station and a second relay 610 in the AGV. Energising the first relay 609 and the second relay 610 completes a circuit connecting the battery unit of 611 the AGV to high voltage output of the charging power unit 608. This allows charging current to flow into the battery of the AGV.

In accordance with this arrangement, two safety features are implemented. Firstly, the charging operation only begins if the microswitch 607 is activated. As described above, the microswitch is positioned so that it is only activated if the AGV is in the charging position (thus ensuring that the brushes of the charging station are not exposed). Secondly, once the microswitch is activated, only the small brushes on the charging station connected to a low voltage output are initially energised. This means that if for some reason the microswitch 607 is activated without the AGV being in the correct charging position (potentially leaving the connection plate of the charging station exposed) then the only “live” brush is the low voltage small brush of the charging station.

It will be understood that modifications can be made to the embodiments of the invention described above.

The examples provided above have been described mainly in terms of the markers being provided by an optical barcode on a label and correspondingly, the marker detector being provided by an optical barcode scanner. However, it will be understood that any suitable means can be used to provide the marker and marker detector, for example an RFID tag and an RFID tag reader.

The examples provided above have been described mainly in terms of the vehicle being an AGV, however, techniques according to examples of the invention can be employed for other types of battery powered vehicles, including human controlled vehicles, such as human controlled forklift trucks and human controlled electric passenger cars.

In certain examples of the invention, a conventional charging station can be retro-fitted with suitable equipment (for example a marker detector connectable to a suitably arranged computer system)

Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of the features and/or steps are mutually exclusive. The invention is not restricted to any details of any foregoing embodiments. The invention extends to any novel one, or novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader’s attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

1. A charging station for a vehicle comprising a charging mechanism connectable to a vehicle for transferring charge to an energy storage unit of the vehicle, wherein the charging station further includes a marker detector, said marker detector arranged to detect one of one or more markers associated with a vehicle when the vehicle enters the charging station and to detect the one of the one or more markers on the vehicle when the vehicle leaves the charging station, thereby enabling a period of time during which the vehicle has undergone charging in the charging station to be determined.

2. A charging station according to claim 1, wherein the charging mechanism is connected to a vehicle when the vehicle enters the charging station and occupies a predetermined charging position.

3. A charging station according to claim 2, wherein the charging mechanism includes a connection plate for providing an electrical connection with a corresponding connection plate of a vehicle, wherein said connection plate of the charging station is connectable to a power supply.

4. A charging station according to claim 3, wherein the connection plate is located on a charging stand and positioned such that when a vehicle enters the charging station and occupies a charging position, an electrical connection is provided between the connection plate of the charging station and the corresponding connection plate of the vehicle.

5. A charging station according to any of claims 2 to 4 comprising guidance elements to guide a vehicle to the predetermined charging position.

6. A charging station according to any previous claim, according to any of claims 2 to 5, wherein the charging station is arranged such that a vehicle can enter the charging station and move into the predetermined charging position in a first direction and leave the charging station in a second direction.

7. A charging station according to claim 6, wherein the second direction is opposite the first direction.

8. A charging station according to claim 6 comprising a stop positioned to prevent a vehicle moving in the first direction past the predetermined charging position.

9. A charging station according to any of claims 2 to 5 wherein the charging station is arranged such that a vehicle can enter the charging station and move into the predetermined charging position in a first direction and leave the charging station in the first direction thereby moving through the charging station.

10. A charging station according to claim 9 depending on claim 4, wherein the charging stand and connection plate are on a first side of the charging station, and the charging station comprises a further charging stand with further connection plate positioned on a second side of the charging station, wherein the second side is opposite the first side.

11. A charging station according to any previous claim, wherein the marker is an optical barcode and the marker detector is an optical barcode reader.

12. A charging station according to any previous claim, wherein the marker detector is connectable to a computer system and is operable to convey information to the computer system indicating a time at which a vehicle enters the charging station and a time at which the vehicle leaves the charging station

13. A charging station according to any previous claim, wherein the vehicle is an autonomous guided vehicle.

Intellectual

Property

Office

Application No: GB1701545.4 Examiner: Mr Gareth John