WO2019113143A1

WO2019113143A1 - Overhead evse with cable management

Info

Publication number: WO2019113143A1
Application number: PCT/US2018/063964
Authority: WO
Inventors: James S. Bianco; John Fahy; David B. PALMER
Original assignee: Control Module, Inc.
Priority date: 2017-12-05
Filing date: 2018-12-05
Publication date: 2019-06-13

Abstract

An overhead EVSE is adapted for mounting to a fixed elevated location, a pole or an overhead track. The EVSE system employs a receptacle having an inside surface which defines a truncated cone having a large diameter first end and a reduced diameter second end. The second end has an opening through which the power cable bi-directionally passes. A drive pulley is employed to drive the cable to an extended and a retracted direction. The drive pulley operation is automatically controlled by a controller. The cable is extendable from a home position to an assist position and is extendable to an extended position for connection with an EV. In a retracted position, the cable is coiled against the receptacle inside surface with the coils having a progressively diminished coil diameter. The overhead EVSE may be mounted to a track. In one embodiment, the overhead EVSE functions as a shuttle displaceable along a track.

Description

OVERHEAD EVSE WITH CABLE

MANAGEMENT

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the priority of U.S. Provisional Patent Application Nos. 62/594,720 filed on December 5, 2017 and U.S. 62/739,397 filed on October 1 , 2018.

BACKGROUND

[0002] This disclosure relates generally to overhead charging installations which manage the cable and connector employed to charge the battery power supply of an electric vehicle. More particularly, this disclosure relates to an overhead charging station which functions to lower and raise an electric cable connecting the electric vehicle service equipment (EVSE) and to lower and to extend the electrical cable connector to connect with the battery power charging unit of the electric vehicle (EV).

[0003] The present disclosure is directed to an overhead charging system which mitigates the wear on the electric cable that is prone to occur with very large numbers of cycles of extending and retracting the cable. The present disclosure is also directed to providing installation flexibility by allowing for on-site setting of the initial compliance height of the cable connector upon initially lowering the connector for grasping and usage to connect with the EV battery supply.

SUMMARY

[0004] For the overhead EVSE systems disclosed herein, the power cables are stored internally and are lowered automatically when authorized. The cables are therefore kept off the ground, out of the elements and out of the reach of vandals and unauthorized individuals. When the EVSE is authorized for charging, the cable is lowered to a height that fully complies with the ADA standard. The user can then extend the cable and connector by simply pressing the proximity switch located on the connector to cause the cable drive motor to extend the cable with little or no additional required force. The user then extends the cable until it reaches the inlet port of the electric vehicle. Once the power connector has been connected to the vehicle inlet port, charging can begin when authorization or payment is made. The power cable is off of the ground during the charging cycle. When the charging cycle is completed, the power cable is disconnected from the electric vehicle power cable and connector, and the cable and connector will automatically be driven to its storage position which is preferably located high above the ground.

[0005] Briefly stated, in one preferred embodiment, an overhead EVSE system comprises an EVSE module connectable to an external power source. A power cable communicates with the EVSE module and terminates in a connector. A storage receptacle or tub for the cable has an inside diameter which is configured as a truncated cone having an enlarged diameter at one end and a reduced diameter at a second end. The second end defines an opening through which the cable bi-directionally passes. A drive pulley drives the cable in both an extending and a retracting direction. The drive pulley is automatically controlled by a controller. The cable is extendable from a home position to a connector assist position and is drivably extendable from the assist position to an extended connector position. The cable is also retractable to a retracted position wherein the cable is coiled against the storage receptacle inside surface to form coils which have a progressive staggered descending diameter.

[0006] The inside surface of the receptacle is preferably coated with a non-stick material. A strain relief assembly is interposed between the EVSE module and the coiled cable. The strain relief assembly comprises a member which is rotatable relative to a fixed position to allow limited rotation of the cable. A height adjustment system is employed for setting the height of the assist position. The height adjustment system, in one embodiment, comprises a cam having at least one lobe mounted to a shaft which rotates the drive pulley and a pulse generator which generates pulses in response to detecting the rotating lobes of the cam and a counter which counts the pulses. In one embodiment, the height adjustment system further employs a dip switch for setting the number of pulses which define the assist position.

[0007] A button on the connector is employed for selectively extending the cable. A button may be employed on the connector wherein upon disconnecting the connector from the EV charging system and releasing the button, the cable is retractable to the home position.

[0008] In another disclosed embodiment, an overhead EVSE employs a housing which is mounted to a pole or post at an elevated position. The housing encloses a coil receptacle defining a truncated cone. The reservoir has a central axis which is vertical and a lower panel of enlarged diameter parallel to an upper panel of reduced diameter which also defines an opening. The cable passes bi- directionally through the opening and is driven into the receptacle so as to form a stack of coils of descending diameter with the largest coil being supported on the lower panel.

[0009] The overhead EVSE system includes a communication module. The communication module wirelessly communicates with a remote device for actuating the charging operation.

[0010] An overhead EVSE system in another disclosed embodiment comprises a housing mounted to or suspended from an elevated structure. The housing has a lower opening. An EVSE module is disposed in the housing and is connectable to an external power source. A power cable communicates with the EVSE module and terminates in an EV connector. A storage receptacle is disposed in the housing and has an interior surface defining a truncated cone having an enlarged diameter at the first end and a reduced diameter at the second end which defines an opening through which the cable bi-directionally passes. A driver selectively drives the cable in an extending and a retracting direction. A drive control module controls the driver so that the cable is extendable from a connector home position to a connector assist position and extendable from the assist position to an extended connector position and is retractable through the opening to a retracted position wherein the cable is coiled against the receptacle inside surface in coils having a progressively staggered diameter.

[0011] An electrical connect module is disposed in the housing and selectively disconnects electrical power between the EVSE module and the external power source. A vehicle detector is optionally mounted for communication with the EVSE module. A communication module is mounted to the housing.

[0012] A display/data router module is disposed adjacent a lower portion of the housing. A GFCI control module is mounted to the housing. A power cable guide and home sensor is disposed at the lower opening of the housing. The receptacle defines a central axis and the central axis is disposed at an acute angle to a vertical plane through the housing.

[0013] In one embodiment, the housing is mounted to a suspended track. The housing may be mounted in a fixed position to the track. The housing may also be mounted to the track by four trolley assemblies, each comprising a pair of rollers, wherein the housing is displaceable along the track.

[0014] An overhead EVSE system comprises an overhead track and an EVSE assembly mounted to the track and disposed below the track. The EVSE assembly comprises an EVSE module, a power cable which communicates with the EVSE module, a storage receptacle having an interior conical surface, a driver assembly and a controller which automatically controls the driver assembly. The storage receptacle is preferably disposed in a canted relationship to the track.

[0015] The track comprises a pair of parallel rails and the EVSE assembly is mounted to the rails at a fixed position. The parallel rails each have opposed channels and the EVSE assembly comprises a mounting plate fixedly secured to the rails by a plurality of fasteners each threaded to a nut bridging opposed channels of a rail.

[0016] In another embodiment, each rail forms a pair of parallel longitudinally extending edges and the EVSE assembly comprises a mounting plate which is secured by a plurality of trolley units each having a pair of rollers which roll along the edges. Each trolley unit comprises a U-shaped yoke which mounts a pair of rollers. Each yoke is fastened to the mounting plate.

[0017] A sensor unit assembly optionally extends from the EVSE assembly and mounts a sensor for sensing the presence of an EV below the overhead EVSE system. The EVSE assembly may also comprise a quick disconnect/connect assembly which electrically selectively disconnects and connects the external power source to the EVSE module. The EVSE assembly comprises a housing which is slidably displaceable along the track. The housing defines a slot providing visual access to LEDs of a data router module disposed in the housing. The housing also mounts a light which indicates that the overhead EVSE is ready for usage.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Fig. 1 is a side view, partly in section, partly in phantom and partly in schematic, illustrating an overhead EVSE with the connector in the home position;

[0019] Fig. 1A is a side elevational view, partly in section, partly in phantom and partly in schematic, illustrating the overhead EVSE of Fig. 1 with the connector in a standard compliant position;

[0020] Fig. 1 B is a side elevational view, partly in section, partly in phantom and partly in schematic, together with an operator’s hand grasping the connector and illustrating the connector in an extended position;

[0021] Fig. 1 C is a side elevational view, partly in section, partly in phantom and partly in schematic, of the overhead EVSE of Fig. 1 together with an EV and the connector illustrated in the extended position connected to the EV battery power supply for charging;

[0022] Fig. 2 is an enlarged side sectional view of a cam assembly employed in the overhead EVSE of Fig. 1 ;

[0023] Fig. 3 is a frontal view, portions removed and portions illustrated in schematic, and further illustrating a relief strain feature for the overhead EVSE of Fig. 1 ; [0024] Fig. 4 is an enlarged view of the strain relief feature of Fig. 3, portions shown diagrammatically

[0025] Fig. 5 is a perspective view of the housing employed in the overhead EVSE of Fig. 1 ;

[0026] Fig. 6 is an isometric view of an overhead EVSE;

[0027] Fig. 6A is an enlarged front view of an instruction plate for the

EVSE of Fig. 6

[0028] Fig. 7 is a side elevational view, partly annotated and partly diagrammatic, of an overhead EVSE with a representative operator holding a cell phone;

[0029] Fig. 8 is a front elevational view of an overhead EVSE with a representative operator and a portion of the EV with the cable in an extended position;

[0030] Fig. 9 is an enlarged interior view of an overhead EVSE with the cover removed, portions being shown in phantom and portions removed;

[0031] Fig. 10 is an enlarged fragmentary perspective view of a rail mount for an overhead EVSE;

[0032] Fig. 11 is an enlarged fragmentary sectional view illustrating a mounting assembly for an EVSE;

[0033] Fig. 12 is a perspective view of a portion of the assembly of Fig. 11 ;

[0034] Fig. 13 is an enlarged fragmentary perspective view of a system mount for an overhead EVSE;

[0035] Fig. 14 is a cross-sectional view of a trolley mount assembly for an overhead EVSE as mounted to the rail of Fig. 13;

[0036] Fig. 15 is an enlarged perspective view of a trolley unit employed in the trolley mount assembly of Fig. 14;

[0037] Fig. 16 is an exploded fragmentary perspective view of a mounting plate portion of the overhead EVSE and a tandem rail installation together with an optional vehicle sensor assembly, partly broken away;

[0038] Fig. 17 is an exploded perspective view, partly annotated to illustrate a connect/disconnect wiring feature, of an overhead EVSE and the mounted plate assembly portion and tandem rails as mounted in place for the plate and rails of Fig. 16;

[0039] Fig. 18 is an enlarged view of the circled portion A of Fig. 17;

[0040] Fig. 19 is an enlarged view of the circled portion B of Fig. 17;

[0041] Fig. 20 is an exploded perspective view of a fixedly mounted overhead EVSE portion and tandem rails of Fig. 17 together with a cover for the overhead EVSE;

[0042] Fig. 20A is an enlarged view of the circled portion A of Fig. 20;

[0043] Fig. 21 is a perspective view of the mounted overhead EVSE and tandem rail assembly of Fig. 20;

[0044] Fig. 22 is a representative side elevational view of a trolley mounted overhead EVSE connected to an EV;

[0045] Fig. 23 is a rear elevational view of the trolley mounted EVSE and connected EV of Fig. 22;

[0046] Fig. 24 is a rear elevational view, partly in diagram, illustrating a dual trolley mounted overhead EVSE installation together with two connected EVs;

[0047] Fig. 25 is an exploded perspective view of a portion of a trolley mounted overhead EVSE unit of Fig. 22;

[0048] Fig. 26 is a perspective view, partly diagrammatic, illustrating how the trolley mounted EVSE of Fig. 22 is mounted to a track;

[0049] Fig. 27 is a fragmentary perspective view, partly diagrammatic, of a track and a trolley mounted EVSE; and

[0050] Fig. 28 is a fragmentary end view of the trolley mounted EVSE of Fig. 27.

DETAILED DESCRIPTION

[0051] With reference to the drawings wherein like numerals represent like parts throughout the several figures, an overhead EVSE is generally designated by the numeral 10. The overhead EVSE 10 functions to connect an EVSE module 500 to the battery power charging unit of an EV via an extendable and a retractable cable 102 having a connector 100 at its terminus.

[0052] The connector 100 is preferably a J-1772 connector, although a Tesla^™ or a European standard connector, such as a Mennekes^® (Type 2) connector (with other modifications), may also be employed. The connector has a button 108 which is easily depressed by the operator’s thumb at 110 to allow the cable to be extended, as will be further described. When the button is released after disconnecting from the EV, the cable will be retracted from the connected position illustrated in Fig. 1 C to the home position illustrated in Fig. 1.

[0053] It will be appreciated that, as will be further described below, the cable/connector will be extended downwardly to the standard assist position designated as position 109 in Fig 1A. From there, the cable can be extended by pressing on the button 108 and manually pulling the cable, such as illustrated in Fig. 1 B, to ultimately connect the connector with the EV.

[0054] Power is supplied to the EVSE module 500 through a connecting cable over lines 503 and 504 via filter 506 together with the ground wire 505. The power lines to the cable 102 enter into a coiling reservoir or storage receptacle 400 which has a truncated conical geometry, as best illustrated in Fig. 5. Angle 401 , in one embodiment, is approximately 6°. The enlarged rear diameter portion of the tub has an end plate 404 against which the trailing coil 102A engages. A strain relief 405 is interposed across the proximity line 507C, the pilot 507B and the power and ground wires to the cable. The front of the reservoir 400 includes an end plate 403 which has an enlarged opening surrounded by a Teflon^™ grommet 402.

[0055] The EVSE module 500 preferably has connectors 103 and 104 for the power lines, 105 for the ground, 106 for the pilot and 107 for the proximity line. The EVSE also has a connector 306 for a pulse register 507D. Connector 307 connects the motor 306 to the motor controller 507E. The home position signal is sensed by micro-switch 202 disengaging from arm 201 (Fig. 1 ) resulting from the top of the connector 100 raising the collar 200. The home position signal communicates via connector 204 to input 507F. [0056] The interior of the housing has a Teflon^™ or other anti-stick coating so that the cable may freely slide along the interior tub as the cable is being wound and unwound for retraction and extension, as will be further described. Because of the truncated conical geometry of the tub, the coils will tend to lay and coil in an orderly fashion since sheet each succeeding coil has a slightly smaller diameter than the preceding coil and will tend to engage against the inside of the housing. Alternative configurations of the tub which receive and engage the coiled cable in a progressive staggered descending diameter relationship are also possible.

[0057] The motive force assembly 300 for extending and retracting the cable comprises a motor 301 which drives a drive pulley 301 A driven by shaft 302. The motor is automatically controlled by controller 507E. Tension on the cable is maintained by guide rollers 303A, 303B, 303C and 303D, as best illustrated in Figs. 1A-1 C.

[0058] A three-load cam 303 is mounted to shaft 302 in fixed relationship with the shaft and drive pulley. The cam has lobes 303A, 303B and 303C which are engaged by a micro switch 304 of pulse generator 305. The pulse generator 305 generates pulses which are communicated at input 507D to the control module 507.

[0059] A data router module 600 communicates over line 610 with EVSE 500. The data router module 600 includes a dip switch bank 602. A representative individual dip switch for setting the ADA height at the initial installation is designated by 604. The data router module also includes an on/off button 606 and LEDS 608. The ADA or the assist position 109 can be uniquely set for each site by counting the number of pulses at 507D and bringing the connector to the appropriate height and activating the dip switch 604 which sets the number of pulses that determines the cable/connector distance and thus determines when the assist (ADA) position 109 is obtained. The pulses are used for subsequent cycles to replicate position 109. Other switches in the bank 602 may be attached if different extension heights for the connection are desired. [0060] The cable/connector extension is initiated by switch 502 (which may be wall mounted) that provides a start input 507A over 208-240 VAC contactor 506. The cable is driven to the assist position 109 upon starting the motor until the number of pulses has been properly reached. The cable is then placed in a locked position at the assist position 109. When the button 108 is pushed on the connector 100, the cable 102 may be further extended by the operator and connected with the EV. When the connector 100 is released from the connection with the EV and the button 108 is released, the cable/connector is then retracted to the home position, as best illustrated in Fig. 1. The home position communicates to input 507F of the control module.

[0061] It should be appreciated that the cable 102 is retracted into the coiling reservoir 400 without requiring a slip ring and the coils are smoothly progressively created during the retraction process without jamming or entangling. Clips may extend at the housing interior to facilitate the coiling and uncoiling of the cable.

[0062] With additional reference to Fig. 4, a strain relief 405 is provided at the housing enclosure which allows for the cable to be slightly rotated while the cable 102 is being coiled or retracted, as indicated by the arrows 407 in Fig. 4. The cable lines are rotatably fixed to the nut which connects to a bracket. The bracket is slightly moveable in a slot of the lower portion of the end plate (or other enclosure structure) to allow a limited rotation of the cable 102. The strain relief 405 thus minimizes the wear on the cable 102 during the extension and retraction process.

[0063] With reference to Figs. 6-9, an overhead pole mounted EVSE is generally designated by the numeral 1000. EVSE assembly housing 1100 is mounted to a pole 1104 at an elevated location on the pole. Pole 1104 may be round or square and may be manufactured from numerous materials. For some applications, pole 1104 may essentially be a post such as, for example, for a street light or other utility.

[0064] The housing 1100, which may assume numerous configurations, but in the drawings, is illustrated in a polygonal configuration with planar panels. A mounting plate 1105 is affixed to the back of the housing. The mounting plate engages against the pole 1104. In one embodiment, vertically spaced straps 1118 are wrapped around the mounting plate and the pole to secure the housing to the pole. The mounting plate 1105 preferably extends below the bottom of the housing 1100. The top of the housing has a polygonal cover 1120 which shields an antenna for wireless communication and provides access to the housing interior.

[0065] Pole mounted EVSE 1000 principally differs from overhead EVSE 10 in the orientation of the storage tub or receptacle 1400 for the coiling and storage of cable 102. The receptacle has a truncated conical shape with an enlarged end panel 1410 at a lower horizontal orientation and a vertically higher parallel second end 1420 with a central opening 1430 for receiving the cable 102. It will be appreciated that the cable 102 is driven down into the reservoir 1400 by the cable driver mechanism 1109 which essentially functions in a manner similarly described for the motor, the drive pulley and the controller for EVSE 10. The central axis of the reservoir 1400 is preferably substantially vertical. The cable is thus coiled to form a stack of coils having a progressively smaller diameter from the bottom coil 102A to the upper coil 102n.

[0066] The lower portion of the housing has an opening at which a power cable guide and home sensor 1110 is mounted. A rubber gasket is provided so that the cable 102 may efficiently engage the cable as it passes through the opening to provide a cleaning function. The sensor senses the home position of the connector at the illustrated storage position of Figs. 6 and 9.

[0067] The housing 1100 also mounts a communication module 1115. The cover 1120 can be easily removed to provide access to the communication module 1115 and other components at the housing interior.

[0068] A display router module 112 and a ground fault control module GFCI 1113, which interrupts current in case of a ground fault, are also located in or at the housing. A service line connect/disconnect module 1112 at the lower portion of the housing facilitates the electrical connection and disconnection. [0069] With reference to Figs. 6 and 6A, plate 1108 affixed with identification to scan for instructions and payment may be mounted to the pole 1104.

[0070] As best illustrated in Fig. 7, the user 1107 uses a cell phone 106 to transmit a message to the communication module 1115 to cause the drive mechanism to lower the connector 100 to the ADA height 117, as best illustrated in Fig. 7. After the ADA height is achieved, the user grasps the connector 101 , pushes button 108 and extends the cable so that the connector can be inserted into the input port 1510 of the electric vehicle 1500, as best illustrated in Fig. 8.

[0071] Payment is preferably made via the cell phone 1107. After the charging is complete, the connector is released from the connection at the port 1510, and button 108 is activated to return the cable 102 to the home position 116 illustrated in Figs. 6 and 9.

[0072] With reference to Figs. 10-28, two general versions of a track mounted overhead EVSE which incorporate many of the structures and functions of EVSE 10 are illustrated. A stationary overhead EVSE is generally designated by the numeral 2000 (Figs. 21 , 23). A moveable overhead shuttle or trolley EVSE is generally designated by the numeral 3000 (Figs. 24, 27-28).

[0073] For overhead EVSE 2000, the track comprises a pair of parallel rails 2010 which are preferably suspended by support rods 2012. The rails 2010 form a pair of laterally spaced shallow channels 2014 (Fig. 11 ).

[0074] A mounting plate 2020 is mounted to the rails by channel nuts 2030 (Fig. 12) which are spaced along the rails. Each of the nuts 2030 includes a central threaded bore 2032 which receives a mounting bolt 2034 inserted through the underside of the mounting plate 2020. The nuts 2032 have a pair of opposed laterally spaced V-shaped recesses 2036 which engage (seat on) upper edges of the shallow channels. As illustrated in Figs. 16, 19, four bolts 2034 extend through the openings of the mounting plate 2020 and threadably engage channel nuts to affix the mounting plate 2020 to the rails 2010 at a stationary position. Washers may be employed. [0075] The mounting plate 2020 has downward, forward and rearward panels 2022, 2024 which respectfully mount a grommet 2026 for the power cable conduit 2028 and a grommet at the rear if required for multiple installations. The mounting plate additionally has opposed downward abbreviated side panels 2021 , 2023. The mounting plate also supports a power disconnect unit 2040. Four threaded bosses 2042 adjacent corners of the mounting plate extend from the underside of the plate 2020 and receive threaded screws 2044 (Fig. 19).

[0076] An overhead EVSE sub-assembly 2100 (Figs. 17-20) which may be similar in form and function to that of overhead EVSE 10, except for modifications described herein, is mounted to the underside of the mounting plate 2020. EVSE sub-assembly 2100 includes an upper support base 2200 which defines at four corner-like locations thereof keyholes 2210 (Fig. 18). The keyholes 2210 are spaced to align with the bosses 2042 and received screws 2044. The base may be easily installed on the base by aligning the screws with the enlarged keyhole portions, forcing the base 2200 against the bosses 2042 asserted and slightly displacing the base along the rails so that the screws 2044 are located in the reduced keyhole portion and tightened in place to secure the EVSE assembly 2100 to the mounting plate 2020.

[0077] The EVSE sub-assembly 2100 preferably includes the motive drive assembly 300, truncated conical coil reservoir 400, the EVSE control module 500, the data router module 600, and the extendable and retractable cable 102 with the connector 100 and the connector button 108, as previously described.

[0078] With reference to Figs. 20 and 21 , a cover 2300 has a polygonal shape which is dimensioned and configured to fit over the sub-assembly 2100, including the EVSE motor assembly 300 the truncated conical coil receptacle 400, the EVSE module 500 and the data router module 600. The central axis of receptacle 400 is preferably canted at a small acute angle to the vertical plane through the receptacle. The panels 2021 , 2022, 2023 and 2024 closely interiorly receive the cover 2300. The cover 2300 has an opening 2310 so that the cable 100 extends through the opening at the bottom of the cover. The cover is secured by screws 2320 which are secured to flanges 2150, 2610 of the sub- assembly. Access opening 2312 provides a window for the status LEDs of the data router module 600. A status light 2120 projects through an opening 2314 of the cutter to indicate that usage is authorized, for example, an illuminated green light indicates that payment is authorized.

[0079] With additional reference to Fig. 16, the stationary track mounted EVSE 2000 may be positioned to service two service bays or parking spaces. One or more optional EV sensor units 2900 may extend from opposed sides of the housing. The sensor unit would include a conduit and a proximity sensor at the terminus. It should be appreciated that multiple stationary mounted overhead EVSE units may be mounted along the track. The end grommets provide an opening for connecting the units in series.

[0080] With reference to Figs. 17, 20 and 20A, the track mounted EVSE 2000 (as well as EVSE 3000) have a power disconnect unit 2040 which facilitates the connection of the EVSE to the lines enclosed in the power conduit 2028 which essentially correspond to the previously discussed lines 503, 504 and ground 505. The ground is ultimately connected to ground bar 2505 (Fig. 20A). The various lines and their corresponding connections have been annotated as black, red and green to further illustrate how the connections may be easily implemented. Thus, an assembled EVSE may be relatively easily connected and/or disconnected from the power as required for installation, maintenance or replacement. A rotatable on/off switch 2017 is employed to selectively supply or terminate power at the unit 2040.

[0081] With reference to Figs. 13-15 and 25, the trolley or shuttle mounted overhead EVSE 3000 is configured very similarly to that of overhead EVSE 2000, except that four trolley units 3100 with tandem rollers 3120 are employed. The rails 3010 form a deeper central channel than rails 2010 with laterally spaced channels 3014 having upper edges 3016. The rails 3010 each receive the rollers 3120 of two trolley units 3100 which traverse or roll across the upper channel edges 3016.

[0082] Each trolley unit 3100 comprises a U-shaped yoke 3130 which mounts an axle 3140 that mounts opposed rollers 3120 for rotation. An opening 3132 at the yoke bridge bottom receives a screw or a bolt 3150 which extends through the opening and an opening of the mounting plate 2020 and is secured by a nut 3152 (Fig. 14). Otherwise, the assembly and remaining components and sub-assemblies are preferably substantially similar to that for the stationary track mounted overhead are EVSE 2000. The trolley mounted EVSE 3000 may be advanced along the track by grasping the lowered cable 102 and pulling the cable and connected EVSE housing.

[0083] It will be appreciated that the fixed mounted and trolley mounted overhead EVSE units can be easily mounted and dismounted to the mounting plate 2020 and the electrical cables and leads can also be easily connected and disconnected for installation, repair and maintenance. Both the stationary track mounting overhead EVSE 2000 and the track mounted trolley overhead EVSE 3000 preferably incorporate the features previously described for both the overhead EVSE 10 as well as the pole mounted EVSE 1000.

[0084] While preferred embodiments of the foregoing have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.

Claims

1. An overhead EVSE system comprising:

an EVSE module connectable to an external power source;

a power cable communicating with said EVSE module and terminating in a connector;

a storage receptacle having an inside surface defining a truncated cone having an enlarged diameter at a first end and a reduced diameter at a second end which defines an opening through which said cable bi-directionally passes; a drive pulley which selectively drives said cable in an extending and a retracting direction;

a controller which automatically controls the drive pulley;

so that said cable is extendable from a connector home position to a connector assist position and is drivably extendable from said assist position to an extended connector position and is retractable to a retracted position wherein said cable is coiled against said receptacle inside surface in coils having a progressively diminished coil diameter.

2. The EVSE system of claim 1 wherein said inside surface is coated with a non-stick material.

3. The EVSE system of claim 1 further comprising a strain relief assembly interposed between said EVSE module and said cable coils.

4. The EVSE system of claim 3 wherein said strain relief assembly comprises a member which is rotatable relative to a fixed position to allow limited rotation of said cable.

5. The EVSE system of claim 1 further comprising a height adjustment system which sets said assist position.

6. The EVSE system of claim 5 wherein said height adjustment system further comprises a cam having at least one lobe mounted to a shaft which rotates said drive pulley and a pulse generator which generates pulses in response to at least one lobe of said cam and a counter which counts said pulses.

7. The EVSE system of claim 6 wherein said height adjustment system further comprises a dip switch for setting the number of pulses which define said assist position.

8. The EVSE system of claim 1 further comprising a button on said connector wherein upon pressing said button, said cable is extendable.

9. The EVSE system of claim 1 further comprising a button on said connector wherein upon disconnecting said connector from an EV charging system and releasing said button, said cable is retractable to the home position.

10. An overhead EVSE system comprising:

a pole;

a housing mounted to said pole at an elevated location and having a lower opening; and

an EVSE module disposed in said housing connectable to an external power source;

a storage receptacle disposed in said housing and having an interior surface defining a truncated cone having an enlarged diameter at a first end and a reduced diameter at a second end which defines an opening through which said cable bi-directionally passes;

a driver operationally controlled by a controller which selectively drives said cable in an extending and a retracting direction; so that said cable is extendable to an extended connector position and is retractable through said receptacle opening to a retracted position wherein said cable is coiled against said receptacle inside surface in coils having a progressively diminished coil diameter.

11. The overhead EVSE system of claim 10 wherein said truncated core has a central axis and said central axis is substantially vertical.

12. The overhead EVSE system of claim 10 wherein said reduced end portion is disposed vertically above said enlarged diameter at said first end.

13. The overhead EVSE system of claim 10 further comprising a GFC control module.

14. The overhead EVSE system of claim 10 further comprising a power cable guide and home sensor disposed at said lower opening.

15. The overhead EVSE system of claim 10 further comprising a service line disconnect assembly.

16. The overhead EVSE system of claim 10 further comprising a display/data router module mounted to said housing.

17. The overhead EVSE system of claim 10 further comprising a communication module.

18. The overhead EVSE system of claim 17 wherein said communication module wirelessly communicates with a remote device for actuating said EVSE module.

19. The overhead EVSE system of claim 10 further comprising a pair of straps for removably mounting said housing to said pole.

20. An overhead EVSE system comprising:

a housing mounted to or suspended from an elevated structure, said housing having a cable opening;

a storage receptacle disposed in said housing and having an interior surface defining a truncated cone having an enlarged diameter at a first end and a reduced diameter at a second end which defines a receptacle opening through which said cable bi-directionally passes;

a driver which selectively drives said cable in an extending and a retracting direction;

a controller which controls the driver;

so that said cable is extendable from a connector home position to a connector assist position and is drivably extendable from said assist position to an extended connector position and is retractable through said cable opening to a retracted position wherein said cable is coiled against said receptacle inside surface in coils having a progressively staggered diameter.

21. The overhead EVSE system of claim 20 wherein an electrical disconnect module is disposed in said housing and selectively disconnects electrical power between said EVSE module and said external power source.

22. The overhead EVSE system of claim 20 further comprising a vehicle detector assembly mounted for connection to said housing.

23. The overhead EVSE system of claim 20 further comprising a communication module mounted to said housing.

24. The overhead EVSE system of claim 20 further comprising a data router module disposed adjacent a lower portion of said housing.

25. The overhead EVSE system of claim 20 further comprising a GFCI control module mounted to said housing.

26. The overhead EVSE system of claim 20 further comprising a power cable guide and home sensor disposed at the lower opening.

27. The overhead EVSE system of claim 20 wherein said receptacle defines a central axis and said central axis is disposed at an acute angle to a vertical plane through said housing.

28. The overhead EVSE system of claim 20 further comprising a suspended track, and wherein said housing is mounted to said track.

29. The overhead EVSE system of claim 28 wherein said housing is mounted to said track by four trolley assemblies each comprising a pair of rollers, and said housing is displaceable along the track.

30. An overhead EVSE system comprising:

an overhead track;

an EVSE assembly mounted to said track and disposed below said track, said assembly comprising:

an EVSE module connectable to an external power source;

a power cable communicating with said EVSE module and terminating in a connector; a storage receptacle having an interior surface having an enlarged diameter at a first end and a reduced diameter at a second end which defines an opening through which said cable bi-directionally passes;

a driver assembly which selectively drives said cable in an extending and a retracting direction;

a controller which controls the driver assembly;

so that said cable is extendable from a connector home position to an extended connector position and is retractable to a retracted position wherein said cable is coiled against said receptacle inside surface in coils having a progressively diminished diameter.

31. The overhead EVSE system of claim 30 wherein said storage receptacle is disposed in a canted relationship to said track.

32. The overhead system of claim 30 wherein said track comprises a pair of parallel rails and said EVSE assembly is mounted to said rails at a fixed position.

33. The overhead EVSE system of claim 32 wherein said overhead track comprises a pair of parallel rails each having opposed channels and wherein said EVSE assembly comprises a mounting plate which is fixedly secured to said rails by a plurality of fasteners, each being threaded to a nut bridging opposed channels of a rail.

34. The overhead EVSE system of claim 30 wherein said overhead track comprises a pair of parallel rails, each said rail forming a pair of parallel longitudinally extending edges, and said EVSE assembly comprises a mounting plate which is secured via a plurality of trolley assemblies, each having a least one roller which rolls along a said edge.

35. The overhead EVSE system of claim 34 wherein each said trolley assembly comprises a yoke which mounts a pair of rollers wherein said yoke is secured to said mounting plate.

36. The overhead EVSE system of claim 30 further comprising a sensor unit assembly which extends from said EVSE assembly and mounts a sensor for sensing the presence of an EV below said overhead EVSE system.

37. The overhead EVSE system of claim 30 wherein said EVSE module comprises a quick disconnect/connect assembly which connects the external power source to said EVSE module.

38. The overhead EVSE unit system of claim 30 wherein said EVSE assembly comprises a housing slidably displaceable along the track.

39. The overhead EVSE unit system of claim 38 wherein said housing defines a slot to provide visible access to a plurality of LEDs of a data/router module disposed in said housing.

40. The overhead EVSE unit system of claim 38 wherein a light is mounted to said housing and is illuminable to indicate that the overhead EVSE system is available for usage.