AU2021107281A4 - Electric vehicle charging station assembly - Google Patents

Abstract

An electric vehicle (EV) charging station assembly kit (400) comprises a charging station enclosure (412, 430) adapted to be installed on a pole (11) supporting a live overhead cable (120) of an electrified tramway, and a charging cable (480) terminating in a charging plug (482) adapted for charging an electric vehicle, the charging station enclosure receiving a cable feed (130) from the live overhead cable (120) and the cable feed operatively connected to the charging cable (460) for charging an electric vehicle when the kit is assembled and installed. The assembly kit (400) can be assembled and installed in a single charger configuration or a double charger configuration. FIG 1 14 1/24 00 04

Description

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ELECTRIC VEHICLE CHARGING STATION ASSEMBLY TECHNICAL FIELD

[0001] The present invention relates to electric vehicle charging.

BACKGROUNDART

[0002] Electric vehicles (EVs) have to date achieved relatively low penetration in many markets.

[0003] One explanation for the low uptake in EVs is thought to be modest range (or at least the perception) combined with a paucity of charging stations when compared with the network of fuel stations for internal combustion vehicles.

[0004] Simply put, there is significant reluctance to embrace electric vehicles owing to apprehensions of inconvenience owing to limited charging options, and ultimately a fear of being stranded.

[0005] Australia as an example has a particular lack of EV charging stations at present. Where charging stations exist, they are often positioned in car parks and suffer a lack of prominent visibility compared to conventional fuel stations.

[0006] As a consequence of the significant works required to achieve installation of charging stations, the reach and coverage of charging stations has remained poor while electric vehicles remain in low circulation. And this very lack of coverage and visibility suppresses penetration of electric vehicles as already noted.

[0007] Furthermore, costs associated with installing EV charging stations will tend to be higher in built up metropolitan locations (owing to many factors) where electric vehicles and thus well located charging stations might otherwise be of most utility.

[0008] One objective of the present invention is to at least attempt to address one or more of these and other limitations associated with existing means of charging electric vehicles.

SUMMARY OF INVENTION

[0009] The inventive concept arises from a recognition that the coverage of electrified tramways (in cities having such tramways) tends to coincide with areas that can benefit from low-cost and widely distributed EV charging stations.

[0010] Electrified tramways are trams, light rail and the like that mostly follow vehicle roadways in metropolitan areas as are familiar to the public at large. Modern electrified tramways are characterised by direct current (DC) electricity supply at say 600-750V DC via an overhead cable suspended by spaced apart poles and having an earth return through the tramway rails. Melbourne, Australia is one example of a city having an extensive electrified tramway network.

[0011] The overhead cable is supported by regularly spaced poles, which are typically located at intervals of say 30m along a footpath adjacent a roadway edge along which the tramway is installed.

[0012] Current collection to the tram is through a roof-mounted trolley pole and wheel arrangement, arranged so that contact with the overhead cable is maintained by pressure from a spring-loaded trolley base.

[0013] Existing tramway infrastructure in terms of the poles and distributed DC power supply though overhead cables can be exploited to support installation and operation of electric vehicle charging stations.

[0014] More specifically, an electric vehicle charging station assembly, supplied in kit form ready for assembly and installation by mounting to the poles are supply of a live cable feed from the overhead cable of the electrified tramway.

[0015] Assembly and installation is preferably either in single-sided or double-sided configuration to serve electric vehicles parked along the roadway in proximity of the charging station.

[0016] The form factor of the charging station so assembled and installed-in either single or double charger configuration-is preferably and advantageously characterised as compact. The envelope is low profile or commensurate with respect to the width of the pole upon which it is mounted, which accounts for a minor dimension of the charging station. A major dimension of the charging station extends in longitudinal relationship with the (vertical) orientation of the pole.

[0017] The orientation of the charging station in a preferred embodiment as depicted is generally upright and parallel to a roadway beside which it is located to avoid pedestrian obstruction along the adjacent footpath.

[0018] As will be appreciated, a variety of other designs and form factors for the charging station can be devised within the scope of the invention disclosed herein as a matter of design preference, for any combination of aesthetic and engineering reasons.

[0019] As an example, an alternative embodiment may contemplate a larger enclosure used to accommodate additional componentry such as high-capacity battery storage. Such alternative embodiments may be supported by the ground adjacent the pole in addition to being connected or mounted to the pole to bear the additional weight.

[0020] A cable feed from the live overhead cable of the tramway is routed down along the pole and into an enclosure of the charging station assembly. Preferred embodiments depict this routing as external to the pole, though alternative configurations internal to the pole may be used.

[0021] The cable feed so routed connects to a charging cable, which emerges from charging station and terminates in a charging plug that is ordinarily retained in its socket recessed in the charging station.

[0022] A fascia of the charging station presents a selection of interface options which may be specified as a matter of preference. Example indicative user interface features are LED status indicator, camera, emergency stop, payment interface, for example, initiated via NFC sensor in the preferred embodiments described and depicted herein. A protective bezel forms a guard around the user interface features.

[0023] The envelope of the charging station preferably incorporates various shape features that act to act to mitigate wear and damage, as described further below in connection with the preferred embodiment.

[0024] According to the present invention there is provided an electric vehicle charging station assembly kit comprising a charging station enclosure adapted to be installed on a pole supporting a live overhead cable of an electrified tramway, and a charging cable terminating in a charging plug adapted for charging an electric vehicle, the charging station enclosure when assembled and installed receiving a cable feed from the live overhead cable and the cable feed operatively connected to the charging cable for charging an electric vehicle via the charging plug.

[0025] The term pole is used herein broadly as indicative of any form of support for an overhead cable of an electrified tramway. A circular pipe is depicted in connection with a preferred embodiment. This term is however not so limited, and may embrace many other forms, with small consequent variation of details of the preferred embodiment, as may be reality envisaged.

[0026] The advantages of the electric vehicle charging station assembly kit both according to the invention and in accordance with its preferred embodiments are manifest and manifold.

[0027] Using the assembly kit according to the present invention and its preferred embodiments, an electric vehicle charging network can be distributed across a metropolitan area having an electrified tramway with relative efficiency and economy compared to existing alternatives.

[0028] A large number of possible installation sites will be available along the breadth of the electrified tramway network, and located directly beside vehicle roadways.

[0029] Many other advantages exist, as will be evident to those skilled in the relevant art.

BRIEF DESCRIPTION OF DRAWINGS

[0030] FIG 1 is a diagram depicting an isometric environmental view of an electric vehicle charging station (single charger configuration) assembled and installed in situ in connection with an electrified tramway.

[0031] FIG 2 is a diagram similar to FIG 1 though depicted in side elevation as viewed from the roadway.

[0032] FIG 3 is a diagram similar to FIG 1 though depicted with an alternative double charger configuration.

[0033] FIG 4 is a diagram similar to FIG 3 though depicted in side elevation as viewed from the roadway.

[0034] FIG 5 is a detail of FIG 1 with focus on the assembled charging station.

[0035] FIG 6 is a diagram similar to FIG 5 though depicted with the alternative double charger configuration of FIG 3.

[0036] FIG 7 is a detail of FIG 5 depicting the charging station (single charger configuration) in a close up view.

[0037] FIG 8 is a detail similar to FIG 7 though depicted with the charging plug withdrawn from its socket in the charging station.

[0038] FIG 9 is a detail of FIG 6 depicting the charging station (double charger configuration) in a close up view.

[0039] FIG 10 is a diagram similar to FIG 9 though depicted with the near charging plug withdrawn from its socket in the charging station.

[0040] FIG 11 is a diagram similar to FIG 5 through depicted in front elevation (or front or rear elevation for a charging station in double charger configuration).

[0041] FIG 12 is a diagram similar to FIG 11 though depicted in side elevation from the roadway.

[0042] FIG 13 is a diagram similar to FIG 12 though depicted in side elevation towards the roadway.

[0043] FIG 14A and FIG 14B are diagrams in plan view from above and below respectively of the charging station in single charge configuration.

[0044] FIG 15 is a diagram similar to FIG 6 though in side elevation from the roadway.

[0045] FIG 16 is a diagram similar to FIG 6 though in side elevation twoards the roadway.

[0046] FIG 17A and FIG 17B are diagrams in plan view from above and below respectively of the charging assembly in double charger configuration.

[0047] FIG 18A and FIG 18B are diagrams in exploded and assembled isometric environmental views of a mounting bracket assembly fastened to the pole.

[0048] FIG 19A and FIG 19B are similar diagrams to FIG 18B, though depicted with cable feeds and their connectors in exploded and assembled views respectively.

[0049] FIG 20A and FIG 20B are similar diagrams to FIG 19B though depicted with the progressive assembly of a charging housing and connection to the connector respectively.

[0050] FIG 21A and FIG 21B are diagrams depicting partly exploded isometric environmental views from alternative perspectives for a charging station in double charger configuration.

[0051] FIG 22A and FIG 22B are diagrams similar to FIG 21A and FIG 21B though with a blanking part rather than an additional charger housing for a charging station in single charger configuration.

[0052] FIG 23A and FIG 23B are diagrams in partial environmental isometric views from above depicting exploded and assembled views of tamper-proof screws fixing a charger housing to a mounting bracket.

[0053] FIG 24A and FIG 24B are diagrams similar to FIG 23A and FIG 23B from below-also depicting tamper-proof screws in explode and assembled views.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0054] FIG 1 and FIG 2 depict environmental views of a preferred embodiment of an electric vehicle charging station assembly kit when assembled and installed on site as a charging station 400. A single charger configuration is depicted. A double charger configuration which is an alternative to the single charger configuration is depicted per corresponding views of FIG 3 and FIG 4.

[0055] The charging station 400, as assembled and installed either in single charger configuration or double charger configuration, and its kit form either unassembled or assembled in part is as a matter of convenience referred to herein synonymously unless context indicates otherwise.

[0056] As is evident, the charging station 400 as later described is installed (retro fitted) to a tramway pole 110 which collectively with other such poles 110 support overhead cables 120 of an electrified tramway network. The poles 110 are located on a footpath 130 beside a roadway 140 which accommodates the tramway as depicted.

[0057] The supporting electrical mains grid supply for the electrified tramway comprises 6.6kV, 11kV and 22kV feeding lines that route to substations and rectifiers that operate to output a nominal 600V DC for overhead cables 120. These substations and rectifiers may in some instances benefit from a storage battery and battery management to support smooth operation of the charging stations 400 installed in connection with the electrified tramway network, according to the coverage and extent of use of the charging stations 400.

[0058] Overhead cables 120 operate at (say) a nominal 600V, and ordinarily supply trams (not shown) operating along the tramway network as is familiar. The electrical power supplied as DC voltage already powering the tramway network can be diverted in part (and supplemented as necessary) to also supply an electric vehicle charging network as described herein.

[0059] FIG 5 and FIG 6 depict the charging station 400 in its alternative configurations (single, double) in closer detail.

[0060] FIG 7-FIG 10 depict the charging station 400 in still closer detail to the point finer details are evident.

[0061] The main housing 412 and blanking part 430 co-operate to encircle the pole 110 as depicted.

[0062] Cable feed 210 runs down the pole 110 and is affixed to the pole 110 by regularly spaced mounting brackets 230, which may be specified as routing clamps or similar hardware, and associated fasteners. The cable feed 210 is enclosed within electrical conduit, or interlocking lengths of conduit sealed as required.

[0063] Charging cable 480 protrudes from the housing 412 at its lower end and terminates in a plug 482, which further acts as a handle. Plug 482 is ordinarily retained within its matching socket 484 located at and recessed into fascia 414, and is removed for use when charging an electric vehicle (not shown). The plug 482 and matching socket 484 can be of any required design or standard as may be specified for interoperability with charging sockets of electric vehicles.

[0064] A charging station enclosure 412, 430 is formed by a charger housing 412 featuring at its front end a fascia 414 and supplemented at its rear (in its single configuration) by a blanking part 430. The enclosure 412, 430 defines the form factor and envelope of the charging station 400, which excludes the cable 480 which descends from and returns to the enclosure 412, 430.

[0065] Components of the enclosure 412, 430 are preferably unitary in construction, and fabricated from any material suitable to meet usual requirements for public use street furniture. An example may be engineering grade polyurethane.

[0066] Housing 412 is depicted as having a camera bezel 416 on its roadward facing side, which may be used in conjunction with a camera and associated supporting hardware to monitor the immediate environment, and in particular any electric vehicles as use the charging station 400.

[0067] Fascia 414 is depicted as carrying various user interface features, which are optional in nature and selected as a matter of preference. The fascia 414 and housing 412 as a whole (and blanking part 430) is of ruggedised design and construction, to suit outdoor elements and robust use as a public amenity. As depicted, the features located on fascia 414 are surrounded by a protective bezel 415 forming a guard. The fascia 414, and bezel or guard 415 are preferably integral with the housing 412 as a whole, which is of unitary construction.

[0068] A lower portion of the fascia 414 also carries socket 484 as abovementioned. This portion of the fascia 414 is in profile chamfered, with effect that this portion of the fascia 414 is angled back towards the pole 110. This arrangement-in combination with protective guard 415-offers some protection for the plug 482 when ordinarily retained within matching socket 484.

[0069] A central portion of the fascia 414 is thus recessed relative to its periphery, to guard against incidental damage.

[0070] LED status indicator 418 is depicted as a ring which gives a visible indicator of the operating (or non-operating status) of the charging station 400. As an example, the indicator may illuminate green when charging.

[0071] Below indicator 418 is a small camera bezel 420, and below that an emergency stop button 424. A payment pad 426 is below the button 424, and may incorporate (for example) an NFC (near-field communication) reader to initiate payment transaction and other supporting communication via, say an NFC-equipped smartphone owned by a driver wishing to charge their vehicle.

[0072] The arrangement, selection and function of interface features on fascia 414 (or elsewhere) is a matter of preference and implementation detail, and may be varied to suit prevailing requirements of any specific electric vehicle charging network, and as a consequence is not specified further.

[0073] FIG 11-FIG 14 depict in elevation and plan view details of the charging station 400 in single charger configuration, while FIG 15-FIG 17 depicts the same for the charging station in double charger configuration.

[0074] As is evident in these diagrams (amongst other details) is that the envelope of the charging station 400 is not much wider that the pole 110 to which the charging station 400 is mounted. The envelope of the charging station is commensurate with the width (diameter in this case) of the pole 110. The major dimension of the charging station 400 is in longitudinal relationship to the length of the pole 110.

[0075] This means that pedestrian traffic and other use of the footpath 130 is not inconvenienced by installation of the charging stations 400 about the poles 110. Also, the charging stations 400 are visible without being visually obtrusive.

[0076] Sides of the charging station 400 facing the roadway or footpath offer sufficient space to carry identifying indicia as required, as well as for example, instructions regarding use and payment and the like as is customary with some public infrastructure.

[0077] FIG 18A and FIG 18B are diagrams depicting exploded and assembled views of mounting brackets 440 installed on a pole 110. As is to be described and depicted, the mounting brackets 440 are used to mount other components of the charging station 400.

[0078] The mounting brackets 440 are longitudinal in aspect, with a height commensurate with the height of the charging station 400 and a width commensurate with the width of the pole 110.

[0079] The mounting brackets 440 are used in pairs to encircle pole 110 with assistance of fasteners, namely bolts 450 and matching nuts 452. The bolts 450 and nuts 452 align and secure the brackets 440 to each other and to the pole 110. Mounting brackets 440 are identical in construction for convenience and economy.

[0080] The mounting brackets 440 are generally longitudinal as described above, and formed by pressing and punching a metal sheet to a generally C-shaped channel to achieve the form presented. Narrow longitudinal flanges at either side edge have bolt holes formed and located for passage of bolts 450.

[0081] Opposed ends of the mounting brackets 440 feature L-shaped extensions 448 carrying a pair of bolt holes for mounting and securing a charger housing 412 or blanking part 430 as described below in further detail.

[0082] Mounting brackets 440 feature as depicted a 3x2 array of keyhole voids 444, sometimes termed keyholes 444, which further assist in locating and securing the housing 412 and blanking part 430, as described below in further detail.

[0083] As will be appreciated, a wide variety of alternative mounting arrangements can be used as an alternative to mounting brackets 440 to fasten or clamp to pole 110 and secure other components of the charging station 400.

[0084] FIG 19A and FIG 19B depict successive steps of assembly of a charging station 400 following mounting of mounting brackets 440 per FIG 18A and FIG 18B.

[0085] Cable feed 210 terminates at a cable feed connector 214 which can be located and optionally secured using routing clamp or similar to the upper L-shaped extension 448 of the mounting bracket 440. The connector 214 is fastened to the mounting bracket 440 using fasteners, such as screws, as depicted.

[0086] FIG 20A and FIG 20B depict the charging station 400 in further successive states of assembly. FIG 21A and FIG 21B, and FIG 22A and FIG 22B depict other perspectives, which competing assembly either another housing 412 (double charger configuration) or a blacking part 430 (singe charger configuration).

[0087] FIG 21A and FIG 21B follow from FIG 20A and FIG 20B and depict the charging station 400 in a final remaining step of assembly to a double charger configuration, from different angles as is evident.

[0088] An additional charger housing 412 is assembled to be mounting bracket 440 in the same manner as its identical charging station 412 which is already assembled. This is as an alternative to the blanking part 430 used in the single charger configuration.

[0089] The charger housings 412 are configured so that they are attached to the mounting bracket by tamper-proof fasteners 432 and mate flush with each other (for a seamless appearance, and integrity of the enclosure). The cable connector 214 and charger connector 484 must be connected prior to this final step of assembling the charging station 400. The charger housing 412 features mounting lugs 434 in an array on a recessed internal surface of the housing 412.

[0090] The mounting lugs 434 are spaced apart in a pattern that matches the spaced apart pattern of the keyhole voids 444 punched in a mounting plate 442 of the mounting bracket 440. As is familiar the keyholes 444 and plate 442 form keyhole plates that co-operate with mounting lugs 434 to position and retain the charging housing to the mounting bracket 440. The lugs 434 are sized to pass in part through the plate 442 at an upper circumference of the voids 444.

[0091] FIG 22A and FIG 22B depicts an alternative to FIG 21A and FIG 21B, as the charging station 400 is depicted in a final step of assembly to a single charger configuration. Rather than a double charge configuration featuring two identical charger housings 412, these illustrations depict a charger housing 412 and a blanking part 430. The same mechanism of keyhole plate mounting and retention using tamper-proof means is used as is also evident from the drawings.

[0092] FIG 23A and FIG 23B depict details of a final steps in assembly of the charging station 400 though exploded and assembled views of the tamper-proof fasteners 432 secured to mounting bracket 440, at its upper end via upper L-shaped extensions 448.

[0093] FIG 24A and FIG 24B depict the same as FIG 23A and FIG 23B though from below as tamper-proof fasteners 432 secure to mounting bracket 440 at its lower end via lower L-shaped extensions 448.

[0094] The foregoing description concerns a preferred embodiment only. As will be appreciated many modifications or alternatives may be made without departing from the present invention.

Claims (5)

CLAIMS The claims defining the invention are as follows:

1. An electric vehicle charging station assembly kit comprising a charging station enclosure adapted to be installed on a pole supporting a live overhead cable of an electrified tramway, and a charging cable terminating in a charging plug adapted for charging an electric vehicle, the charging station enclosure when assembled and installed receiving a cable feed from the live overhead cable and the cable feed operatively connected to the charging cable for charging an electric vehicle via the charging plug.

2. An electric vehicle charging station assembly kit of claim 1, wherein the assembly kit is adapted to be assembled and installed in a single charger configuration or a double charger configuration by assembling the charging enclosure for the double charger configuration using two identical charger housings, or assembling the charging enclosure for the single charger configuration using a single charger housing and a blanking part as an alternative for another charger housing in the double charger configuration.

3. An electric vehicle charging station assembly kit of claim 2, wherein the charger housing comprises a fascia having a protective bezel disposed around its perimeter, and user interface features for operation of the kit when assembled and installed disposed within the protective bezel.

4. An electric vehicle charging station assembly kit of any one of claims 1 to 3, further comprising at least one mounting bracket that mounts to the pole and to which the charging station enclosure is mounted during assembly and installation.

5. An electric vehicle charging station assembly kit of any one of claims 1 to 3, further comprising a cable connector attached at an end of the charging cable opposite the charging plug and adapted to connect within the enclosure with a complementary cable feed connector attached to the live cable feed from the overhead cable of the electrified tramway when the kit is assembled and installed.

212 1/24

110 210

400

FIG 1 1

130

221010 2/24

111010 440000

FIG 2

11100 3/24

400

FIG 3

130

110 4/24

400

FIG 4

110

210

400 5/24

FIG 5

110

210

400 6/24

FIG 6

432 400 432 415 418

420

424 430 414 412 7/24

416

426

482

FIG 7

110

430 412 8/24

484

482 FIG 8

412 412 9/24

FIG 9

400

412 412 10/24

FIG 10

415

414 11/24

FIG 11

400

415

414 430 416 12/24

412

FIG 12

430 414 412 13/24

110 FIG 13

432 430 414 400 400 110

412 412 14/24

230

110 430

432 FIG 14A 482 FIG 14B

400

412 412 15/24

FIG 15

412 412 16/24

FIG 16 110

400

400

412

412

110 110 17/24

412

412

FIG 17A FIG 17B

110

440 440 440 440 448

444 18/24

452

442 446 450

FIG 18A FIG 18B

210 210

212 212

214

214 19/24

440

440

110 110

FIG 19A FIG 19B

432 432

214

214 412 412 484 20/24

432 432 110

110

FIG 20A FIG 20B

432 432

484 412 412 412 434 444 412 21/24

432 432 110 110

FIG 21A FIG 21B

432 432 430

444

400 412

434 22/24

110 110

FIG 22A FIG 22B

110 110 432 432

440 440 23/24

412 412

FIG 23B FIG 23A

412 412 24/24

432 432

110 110

FIG 24A FIG 24B