IL289315A - Charging electric vehicles in a robotic parking garage - Google Patents

Description

1378-20 CHARGING ELECTRIC VEHICLES IN A ROBOTIC PARKING GARAGE FIELD OF THE INVENTION The present invention is related to the field of automatic (or "robotic") parking garages.

BACKGROUND US Patent Application Publication 2011/0140658 describes systems and methods providing electric vehicle charging in a high-density parking system. A carriage receptacle is physically attached to a carriage of a high-density parking system. The carriage receptacle electrically connects to an electric vehicle supported by the carriage. A bay receptacle is physically attached to a bay of the high-density parking system. The bay receptacle electrically connects the carriage receptacle to a power source to provide electrical charging to the electric vehicle when the carriage is moved into the bay. An electrical vehicle charging request is received from a user at a controller of the high-density parking system. In response to the electrical vehicle charging request, the controller selects the carriage and the bay to provide electrical charging to the electric vehicle when the carriage is moved into the bay.

US Patent 9,365,128 describes systems and methods for connecting an electric or hybrid electric vehicle to a charging station. Automated charging and docking processes may be provided. In some embodiments, a vehicle arrival and position may be detected. The vehicle may be charged with a charging arm and some automated vehicle positioning may occur. The vehicle may be charged and released. Fault detection may occur.

US Patent 9,944,192 describes techniques for electric vehicle systems, and in particular to an electric vehicle charging system and method of use. In one embodiment, a system for charging an electric vehicle is provided, the system comprising: an electrical storage unit disposed on the electric 1378-20 vehicle; a charging panel in electrical communication with the electrical storage unit; a robotic unit comprising an external power source, a charging plate and a robotic arm, the charging plate interconnected to the robotic arm and configured to provide a charge to the charging panel; and a vehicle controller configured to communicate with the robotic unit and position the charging plate with respect to the charging panel; wherein the charging panel receives the charge from the external power source and charges the electrical storage unit.

SUMMARY OF THE INVENTION There is provided, in accordance with some embodiments of the present invention, a system including a standard vehicle-charging socket and a connecting cable. The system further includes a charging station connected to the vehicle-charging socket via the connecting cable and configured to charge an electric vehicle carried by a vehicle pallet while a first plug of a standard vehicle-charging cable is plugged into the electric vehicle and a second plug of the vehicle-charging cable is plugged into the vehicle-charging socket. The system further includes a holding element configured to facilitate the plugging of the second plug into the vehicle-charging socket by moving while holding the vehicle-charging socket such that, as the vehicle pallet, which carries the vehicle-charging cable, approaches the holding element, the vehicle-charging socket is aligned with the second plug.

In some embodiments, the vehicle pallet approaches the holding element along a first horizontal axis, and the holding element is configured to move along a second horizontal axis perpendicular to the first horizontal axis.

In some embodiments, the system further includes: a base; one or more first brackets coupled to the base at a first side of the base, and one or more second brackets coupled to the 1378-20 base at a second side of the base that is opposite the first side; and one or more first rods protruding from the holding element and slidingly passing through the first brackets, respectively, and one or more second rods protruding from the holding element and slidingly passing through the second brackets, respectively, and the holding element is configured to move by virtue of the first rods sliding through the first brackets and the second rods sliding through the second brackets.

In some embodiments, the system further includes one or more first springs coiled around the first rods, respectively, between the holding element and the first brackets, and one or more second springs coiled around the second rods, respectively, between the holding element and the second brackets, such that the first springs and the second springs stabilize the holding element prior to the movement of the holding element.

In some embodiments, the vehicle pallet is shaped to define a track, and the system further includes a protrusion coupled to the first rods and including a tapered end configured to enter the track, thereby causing the holding element to move.

In some embodiments, the system further includes a roller coupled to the holding element and configured to roll along a vertical surface behind the holding element as the holding element moves.

In some embodiments, the holding element includes a panel shaped to define an opening and configured to hold the vehicle-charging socket within the opening.

In some embodiments, the system further includes: the vehicle pallet; and a plug support coupled to the vehicle pallet and configured to couple to the second plug.

In some embodiments, 1378-20 the plug support is shaped to define one or more apertures, and the holding element further includes one or more pins protruding from the panel and including respective tapered ends configured to pass through the apertures, respectively, thereby causing the holding element to move.

In some embodiments, the panel is shaped to define one or more apertures, and the system further includes one or more pins protruding from the plug support and including respective tapered ends configured to pass through the apertures, respectively, thereby causing the holding element to move.

In some embodiments, the system further includes a stand coupled to the vehicle pallet and configured to hold the first plug when the first plug is not plugged into the electric vehicle.

In some embodiments, the stand includes, or is coupled to, the plug support.

In some embodiments, the plug support is coupled to the vehicle pallet at a corner of a top surface of the vehicle pallet.

There is further provided, in accordance with some embodiments of the present invention, a method including identifying a charging station for charging an electric vehicle while a first plug of a standard vehicle-charging cable is plugged into the electric vehicle and a second plug of the vehicle-charging cable is plugged into a standard vehicle-charging socket connected to the charging station and held by a holding element. The method further includes plugging the second plug into the vehicle-charging socket by moving a vehicle pallet, which carries the electric vehicle and the vehicle-charging cable, toward the holding element, thereby causing the 1378-20 holding element to move such that the vehicle-charging socket is aligned with the second plug.

There is further provided, in accordance with some embodiments of the present invention, an apparatus including a vehicle pallet configured to carry an electric vehicle and a standard vehicle-charging cable including a first plug plugged into the electric vehicle and a second plug configured to plug into a standard vehicle-charging socket. The apparatus further includes a holding element coupled to the vehicle pallet and configured to move while holding the second plug such that, as the vehicle pallet approaches the vehicle-charging socket, the second plug is aligned with the vehicle-charging socket.

There is further provided, in accordance with some embodiments of the present invention, a method, including identifying a charging station for charging an electric vehicle while a first plug of a standard vehicle-charging cable is plugged into the electric vehicle and a second plug of the vehicle-charging cable is plugged into a standard vehicle-charging socket connected to the charging station. The method further includes plugging the second plug into the vehicle- charging socket by moving a vehicle pallet, which carries the electric vehicle and the vehicle-charging cable, toward the vehicle-charging socket, thereby causing a holding element, which is coupled to the vehicle pallet and holds the second plug, to move such that the second plug is aligned with the vehicle-charging socket.

There is further provided, in accordance with some embodiments of the present invention, an apparatus including a base, one or more first brackets coupled to the base at a first side of the base, and one or more second brackets coupled to the base at a second side of the base that is opposite the first side. The apparatus further includes a holding element configured to hold a standard vehicle-charging connector. The 1378-20 apparatus further includes one or more first rods protruding from the holding element and slidingly passing through the first brackets, respectively, and one or more second rods protruding from the holding element and slidingly passing through the second brackets, respectively. The apparatus further includes one or more first springs coiled around the first rods, respectively, between the holding element and the first brackets, and one or more second springs coiled around the second rods, respectively, between the holding element and the second brackets. The apparatus further includes a protrusion coupled to the first rods and including a tapered end.

There is further provided, in accordance with some embodiments of the present invention, a system including a vehicle pallet, configured to carry an electric vehicle, a charging station coupled to the vehicle pallet and configured to charge the electric vehicle via a standard vehicle-charging cable, an electrical interface coupled to the vehicle pallet, and an energy-storage unit. The energy-storage unit is configured to convert the input electrical current to stored energy while receiving input electrical current via the electrical interface. The energy-storage unit is further configured to convert the stored energy to output electrical current and to deliver the output electrical current to the charging station, while not receiving the input electrical current.

In some embodiments, the electrical interface is coupled to an underside of the vehicle pallet.

In some embodiments, the electrical interface is a first electrical interface, and the system further includes: a drive system, including at least one frame and configured to move the vehicle pallet; and a second electrical interface coupled to the frame, connected to a supply of the input electrical current, and configured to interface with the first electrical interface 1378-20 while the vehicle pallet rests above the frame such that the energy-storage unit receives the input electrical current via the first electrical interface.

In some embodiments, the vehicle pallet includes a stand, and the charging station is mounted to the stand.

In some embodiments, the energy-storage unit is mounted to the stand.

In some embodiments, the energy-storage unit includes: a battery, configured to store the stored energy; an inverter, configured to convert the stored energy to the output electrical current; a switch including an output terminal connected to the charging station, a first input terminal connected to the electrical interface, and a second input terminal connected to the inverter; and a logic circuit, configured to: connect the output terminal to the first input terminal in response to the energy-storage unit receiving the input electrical current, and connect the output terminal to the second input terminal in response to the energy-storage unit ceasing to receive the input electrical current.

In some embodiments, the logic circuit is configured to connect the output terminal to the first input terminal in response to the energy-storage unit receiving the input electrical current for a predetermined threshold amount of time.

In some embodiments, the logic circuit is configured to connect the output terminal to the first input terminal in response to an instruction from a controller to connect the output terminal to the first input terminal.

In some embodiments, the system further includes a controller configured to pass the input electrical current to the electrical interface in response to calculating that the 1378-20 vehicle pallet will remain in place for at least a predetermined threshold amount of time.

There is further provided, in accordance with some embodiments of the present invention, a method including, while receiving input electrical current via an electrical interface coupled to a vehicle pallet carrying an electric vehicle, converting the input electrical current to stored energy. The method further includes, while not receiving the input electrical current, converting the stored energy to output electrical current and delivering the output electrical current to a charging station coupled to the vehicle pallet such that the charging station charges the electric vehicle via a standard vehicle-charging cable.

The present invention will be more fully understood from the following detailed description of embodiments thereof, taken together with the drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1A is a schematic illustration of an automated parking and vehicle-charging system, in accordance with some embodiments of the present invention; Fig. 1B is a schematic expanded overhead view of a portion of Fig. 1A, in accordance with some embodiments of the present invention; Fig. 2 is a schematic side view of a vehicle pallet and an alignment mechanism, in accordance with some embodiments of the present invention; Fig. 3A is a schematic illustration of an alignment mechanism, in accordance with some embodiments of the present invention; Fig. 3B is a schematic illustration of an underside of a vehicle pallet and an alignment mechanism, in accordance with some embodiments of the present invention; 1378-20 Fig. 3C is a schematic illustration of a corner of a vehicle pallet, in accordance with some embodiments of the present invention; and Fig. 4 is a schematic illustration of a charging station and an energy-storage unit coupled to a vehicle pallet, in accordance with some embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OVERVIEW Some solutions for charging an electric vehicle in a pallet-based parking garage require non-standard charging equipment. However, the use of such equipment may compromise the charging process, void the warranty on the vehicle, or even damage the vehicle.

To address this challenge, embodiments of the present invention provide solutions for charging an electric vehicle in a pallet-based parking garage using standard vehicle-charging equipment, including a standard charging station and a standard vehicle-charging cable.

In some embodiments, the charging station is mounted to a wall of the garage, and a standard vehicle-charging socket is connected to the charging station via a connecting cable. The vehicle-charging socket is disposed on a moveable platform, which is coupled to a protrusion.

Upon entry into the garage, the electric vehicle is loaded onto a vehicle pallet carrying a standard vehicle-charging cable. A first plug at one end of the cable is plugged into the vehicle, while a second plug at the other end of the cable remains coupled to the pallet, typically near the edge of the pallet. The pallet is then moved toward the platform. As the pallet approaches the platform, the protrusion is forced into a track in the underside of the pallet, such that the socket becomes aligned with the second plug. As the pallet completes 1378-20 its movement, the second plug mates with the socket, and the electric vehicle is then charged.

In other embodiments, the charging station is coupled to the pallet. In addition, an energy-storage unit, which is connected to a first electrical interface at the underside of the pallet, is coupled to the pallet. At least one drive system on the floor of the garage, which is designated for the parking of electric vehicles, comprises a second electrical interface connected to a supply of electricity.

Upon entry into the garage, the electric vehicle is loaded onto the vehicle pallet. The first plug at the first end of the standard vehicle-charging cable is plugged into the vehicle, while the second plug at the second end of the cable remains plugged into the charging station. Upon the plugging of the first plug into the vehicle, the charging station begins to charge the vehicle using energy stored in the energy-storage unit. (Thus, advantageously, the charging cycle of the vehicle begins immediately, even before the pallet reaches the designated drive system.) Subsequently, the pallet is moved toward the drive system while the charging station continues to charge the vehicle. Upon the pallet reaching its resting position over the drive system, the first electrical interface interfaces with the second electrical interface, such that electrical energy is supplied to the energy-storage unit by the supply of electricity. In response thereto, the energy-storage unit ceases to draw the stored energy, and instead passes the supplied energy to the charging station. Any supplied energy not used by the charging station may be used to replenish the store of energy in the energy-storage unit.

In the context of the present application, including the claims, a "standard" item of vehicle-charging equipment (such as a socket, plug, or cable) is an item complying with any vehicle-charging standard such as Society of Automotive Engineers (SAE) 1378-20 J1772, CHAdeMO, Combined Charging System (CCS) Type 1 or Type 2, or Tesla Supercharger.

SYSTEM DESCRIPTION Reference is initially made to Fig. 1A, which is a schematic illustration of an automated parking and vehicle- charging system 20, in accordance with some embodiments of the present invention.

System 20 comprises a network of drive systems 22, which lie on a floor 36 of a parking garage 21. System 20 further comprises a plurality of vehicle pallets 24 configured to carry respective vehicles 26, which may include one or more electric vehicles 26e. System 20 further comprises a central controller 35, which is configured to control the transfer of vehicles to and from garage 21 by moving vehicle pallets 24 through the network of drive systems 22. In general, drive systems 22 may be arranged in any suitable arrangement, so as to best utilize the available space in garage 21 and to facilitate the charging of electric vehicles 26e as described herein.

Typically, each drive system 22 comprises a plurality of wheels 25 mounted to floor 36, along with one or more drive- system motors 29. Drive-system motors 29 are configured to move any vehicle pallet 24, which may be occupied by a vehicle or unoccupied, to or from the drive system by turning wheels while the wheels contact the underside of the pallet, thus applying a tractive force to the underside of the pallet. (The transfer of a vehicle pallet between two drive systems typically requires that the wheels of both drive systems be turned.) In general, each drive system may comprise any suitable number of wheels, such as two or four wheels. (In the latter case, the four wheels are typically arranged in a rectangular arrangement, as shown in Fig. 1A.) Typically, the underside of each vehicle pallet comprises a set of tracks, and the pallet sits on the drive system such that the wheels are disposed within the 1378-20 tracks.

In some embodiments, drive system 22 further comprises one or more rollers 27, which, similarly to wheels 25, contact the underside of the vehicle pallets. Rollers 27 provide further support to, and facilitate the movement of, the vehicle pallets.

In some embodiments, at least some of the drive systems are configured to move pallets 24 along multiple different axes of movement, e.g., as described in International Patent Publication WO/2020/105039 to Naveh et al., whose disclosure is incorporated herein by reference. For example, a drive system may move pallets 24 along both an x-axis and a y-axis, which is perpendicular to the x-axis. To facilitate this multiaxial movement, the drive system may comprise any suitable mechanism for rotating wheels 25 so as to vary the axis with which the wheels are aligned. One such mechanism, which utilizes rotatable platforms and actuator units, is shown in Fig. 1 and is described in detail in International Patent Publication WO/2020/105039 to Naveh et al.

In some embodiments, at least some drive systems comprise a frame 23, which is mounted to floor 36, and wheels 25 (and, optionally, rollers 27) are mounted to the floor by virtue of being mounted to frame 23. In such embodiments, frame 23 may be generally rectangular, comprising two longer edges 38 and two shorter edges 40.

Alternatively or additionally, at least some drive systems may comprise one or more brackets mounted to the floor, and wheels 25 may be mounted to the floor by virtue of being mounted to the brackets. Alternatively or additionally, drive system may comprise any other structural components.

Typically, each drive system is connected, via electrical wiring 34, to a respective control unit 32, which controls the supply of electricity to the drive system. Typically, control unit 32 comprises a controller, along with other relevant 1378-20 electrical components such as one or more relays and/or circuit breakers.

Typically, system 20 further comprises a central control unit 33, which comprises a central controller 35. Central controller 35 is configured to control the movement of pallets 24 by issuing instructions to control units 32. For example, to move a pallet from a first drive system to a second, adjacent drive system, central controller 35 may instruct the control unit of the first drive system to turn the wheels of the first drive system toward the second drive system. The central controller may further instruct the control unit of the second drive system to turn the wheels of the second drive system in the same direction, until the pallet is positioned entirely over the second drive system.

In some embodiments, central control unit 33 further comprises a wireless communication interface 37, such as a wireless network interface controller (WNIC). In such embodiments, control units 32 may further comprise respective wireless communication interfaces, and central controller 35 may communicate with control units 32 via wireless communication interface 37. Alternatively, as shown in Fig. 1A, the central controller may communicate with each control unit 32 over a wired connection; nonetheless, wireless communication interface may be used for other wireless communication, as described below with reference to Fig. 4.

In some embodiments, parking garage 21 includes multiple levels, and an elevator 28 moves pallets 24 between the levels. In such embodiments, elevator 28 may comprise another drive system mounted to the platform of the elevator and configured to move vehicle pallets to and from the elevator. The control unit for this drive system may be located, for example, beneath the elevator platform.

To further optimize the use of the available space in the garage, the sizes of the drive systems may be varied. For 1378-20 example, as shown in Fig. 1A, system 20 may comprise multiple full-size drive systems 22f along with at least one half-size drive system 22h. The frame of half-size drive system 22h may have a length that is half that of full-size drive system 22f, or, as shown in Fig. 1A, a width that is half that of full-size drive system 22f. Typically, half-size drive system 22h comprises half the number of wheels 25 as does full-size drive system 22f.

System 20 further comprises at least one charging station configured to charge electric vehicles 26e. Charging station 30 is connected to a standard vehicle-charging socket 60 (shown in Fig. 1B, for example).

In some embodiments, as shown in Fig. 1A, charging station is mounted to the structure of garage 21 near a drive system designated for the parking of an electric vehicle. For example, the charging station may be mounted to floor 36 or to a wall 42 of the garage. Such embodiments are described below in the section entitled "Alignment mechanism for charging." Typically, in such embodiments, the charging station is connected to the main single-phase or three-phase supply of electricity that powers garage 21. For example, a power distribution unit (PDU) 106, which may be connected to central controller 35, may distribute the supplied power between the charging station and drive systems 22 (via control units 32). Alternatively, the charging station may be connected directly to the supply.

In other embodiments, as described below in the section entitled "Pallet-mounted charging station," the charging station is mounted to a pallet 24.

In general, central controller 35 may be embodied as a single processor, or as a cooperatively networked or clustered set of processors. In some embodiments, the functionality of central controller 35, as described herein, is implemented 1378-20 solely in hardware, e.g., using one or more fixed-function or general-purpose integrated circuits. In other embodiments, the functionality of central controller 35 is implemented at least partly in software. For example, central controller 35 may be embodied as a programmed processor comprising a central processing unit (CPU). Program code, including software programs, and/or data may be loaded for execution and processing by the CPU. The program code and/or data may be downloaded to the central controller in electronic form, over a network, for example. Alternatively or additionally, the program code and/or data may be provided and/or stored on non-transitory tangible media, such as magnetic, optical, or electronic memory. Such program code and/or data, when provided to the central controller, produce a machine or special-purpose computer, configured to perform the tasks described herein.

ALIGNMENT MECHANISM FOR CHARGING For embodiments in which charging station 30 is mounted to the structure of garage 21, charging station 30 is typically connected to the vehicle-charging socket via a connecting cable 44. Typically, the vehicle-charging socket is held by a holding element 46 belonging to an alignment mechanism 45, which is described in detail below with reference to Figs. 3A-C.

Upon the entry of an electric vehicle 26e into the garage, the electric vehicle is loaded onto a vehicle pallet 24 carrying a standard vehicle-charging cable 48. Subsequently, a first plug 50 at a first end of cable 48 is plugged (e.g., by the user of the electric vehicle) into the vehicle.

For example, a stand 52, which is coupled to the vehicle pallet, may hold first plug 50, as shown in Fig. 2. Following the loading of the electric vehicle onto the pallet, the first plug may be removed from stand 52 and plugged into the electric vehicle.

Subsequently, central controller 35 ascertains that 1378-20 electric vehicle 26e is an electric vehicle. For example, upon the electric vehicle entering the garage, an identification (e.g., a radio-frequency identification) tag or card belonging to the user of the electric vehicle may be read by a reader connected wiredly or wirelessly (via wireless communication interface 37) to the central controller. In response to ascertaining that electric vehicle 26e is an electric vehicle, the central controller identifies a charging station 30 for charging the vehicle. Subsequently, the central controller moves the pallet toward, and then onto, the drive system adjacent to the charging station, which is designated for the parking of electric vehicles. (In some cases, each electric vehicle registered with the garage has a different respective designated parking spot.) Holding element 46, which holds the vehicle-charging socket connected to charging station 30, is positioned at the edge of the drive system. As the pallet approaches the holding element, the holding element facilitates the plugging of a second plug (shown in Fig. 1B) at a second end of cable 48 into the vehicle-charging socket by moving such that the vehicle-charging socket is aligned with second plug 56. Thus, as the pallet completes its movement, the second plug plugs into the vehicle-charging socket, such that the electric vehicle may be charged by charging station 30 while the vehicle is parked.

For example, the vehicle pallet may approach the holding element along a first horizontal axis, and the holding element may facilitate the plugging of the second plug into the vehicle-charging socket by moving along a second horizontal axis perpendicular to the first horizontal axis. For example, per the embodiment shown in Fig. 1A, the vehicle pallet approaches the holding element along the x-axis, and the holding element moves along the y-axis.

For further details regarding the alignment of the vehicle-charging socket, reference is now made to Fig. 1B, which is a 1378-20 schematic expanded overhead view of a portion 54 of Fig. 1A, in accordance with some embodiments of the present invention. Reference is further made to Fig. 2, which is a schematic side view of pallet 24 and alignment mechanism 45 with second plug plugged into socket 60, in accordance with some embodiments of the present invention.

Second plug 56 of cable 48 is typically coupled to a plug support 58, which is coupled to vehicle pallet 24. For example, plug support 58 may comprise a panel shaped to define an opening (Fig. 3C), and second plug 56 may be held within opening 96. Plug support 58 facilitates the plugging of second plug 56 into vehicle-charging socket 60 by inhibiting movement of second plug relative to the vehicle pallet. Moreover, as further described below with reference to Figs. 3A-C, plug support may facilitate the alignment of the vehicle-charging socket with the second plug.

In some embodiments, as shown in Figs. 1A-B and Fig. 2, second plug 56 faces the front or rear of the pallet, i.e., the second plug is aligned with longer edges 38 (Fig. 1A). In such embodiments, the pallet moves toward the holding element (and hence, toward vehicle-charging socket 60) in a direction parallel to longer edges 38. In other embodiments, second plug faces the side of the pallet, i.e., the second plug is aligned with shorter edges 40 (Fig. 1A). In such embodiments, the pallet moves toward the holding element in a direction parallel to shorter edges 40.

Typically, plug support 58 is coupled to the vehicle pallet at a corner of the top surface of the vehicle pallet. For example, system 20 (Fig. 1A) may comprise two types of vehicle pallets for electric vehicles: one in which plug support 58 is at the front-left corner of the pallet (as shown in Figs. 1A-B and Fig. 2), for charging vehicles having a charging socket on the left side of the vehicle, and another in which plug support is at the front-right corner of the pallet, for charging 1378-20 vehicles having a charging socket on the right side of the vehicle.

In some embodiments, stand 52 comprises, or is coupled to, plug support 58. For example, stand 52 may comprise a plurality of walls 62 surrounding an internal space 64, and plug support 58 may be coupled to one of walls 62. Part of second plug 56, and/or part of cable 48, may be situated within internal space 64.

Reference is now made to Fig. 3A, which is a schematic illustration of alignment mechanism 45, in accordance with some embodiments of the present invention. Reference is further made to Fig. 3B, which is a schematic illustration of an underside of vehicle pallet 24 and alignment mechanism 45, in accordance with some embodiments of the present invention. Reference is also made to Fig. 3C, which is a schematic illustration of a corner of vehicle pallet 24, in accordance with some embodiments of the present invention.

Alignment mechanism 45 comprises a base 66, which may be anchored to the floor or wall of garage 21 (Fig. 1A), e.g., via a supporting bracket 76. Typically, alignment mechanism 45 further comprises one or more (e.g., two) first brackets 68a coupled to base 66 at a first side of the base, and one or more (e.g., two) second brackets 68b coupled to the base at a second side of the base. The first and second sides of the base are opposite one another, e.g., along the y-axis.

Typically, alignment mechanism 45 further comprises one or more first rods 70a protruding from holding element 46 and slidingly passing through first brackets 68a, respectively, along with one or more second rods 70b protruding from the holding element and slidingly passing through second brackets 68b, respectively. Holding element 46 is configured to move (e.g., along the y-axis) by virtue of first rods 70a sliding through first brackets 68a and second rods 70b sliding through second brackets 68b. 1378-20 Typically, alignment mechanism 45 further comprises one or more first springs 72a coiled around first rods 70a, respectively, between the holding element and the first brackets, and one or more second springs 72b coiled around second rods 70b, respectively, between the holding element and the second brackets. (One end of each spring is coupled to a bracket, and the other end is coupled to the holding element.) First springs 72a and second springs 72b stabilize the holding element by applying opposing compressive forces to the holding element, prior to the movement of the holding element due to the approaching vehicle pallet. Typically, the springs are configured such that the resting position of the holding element is approximately midway between first brackets 68a and second brackets 68b.

As the holding element moves, each spring expands or contracts. For example, as the holding element moves toward first brackets 68a, first springs 72a contract while second springs 72b expand.

Typically, holding element 46 comprises a panel 88 shaped to define an opening 90 and configured to hold socket 60 within opening 90.

In some embodiments, the holding element comprises a platform 84, which is coupled to first rods 70a and second rods 70b. In some such embodiments, the holding element further comprises a top plate 80 and coupling elements 82, which couple top plate 80 to platform 84. Top plate 80 is coupled to, or is deformed so as to define, panel 88. In some embodiments, to facilitate vertical alignment of socket 60 with second plug 56, coupling elements 82 are made from an elastic material.

Typically, vehicle pallet 24 is shaped to define a track 79. For example, as shown in Figs. 3B-C, the underside of the vehicle pallet may be shaped to define track 79. Alternatively, the top surface of the vehicle pallet, which is shown in Fig. 1B, may be shaped to define the track. 1378-20 In such embodiments, alignment mechanism 45 further comprises a protrusion 74 coupled to first rods 70a and comprising a tapered end 74e. As the vehicle pallet approaches the alignment mechanism, tapered end 74e enters track 79, such that holding element 46 moves (e.g., along the y-axis) by virtue of the horizontal force applied to the protrusion by the track. The holding element continues to move until at least part of the full-width portion 74w of the protrusion, which is behind tapered end 74e, enters track 79. Typically, the width of track is only slightly greater (e.g., less than 4 mm greater) than the width of full-width portion 74w.

In some cases, the movement of the holding element due to the entry of protrusion 74 into track 79 may not sufficiently align socket 60 with second plug 56. Hence, typically, alignment mechanism 45 is further configured to facilitate a fine alignment of socket 60 with second plug 56.

For example, as shown in Fig. 3A, the holding element may further comprise one or more pins 92 protruding from panel and comprising respective tapered ends 92e. For example, a respective pin 92 may protrude from panel 88 at each side of socket 60. Also, as shown in Fig. 3C, plug support 58 may be shaped to define one or more apertures 94, such as a respective aperture 94 on each side of second plug 56. Following the coarse alignment of the socket resulting from the entry of protrusion into track 79, tapered ends 92e pass through apertures 94, respectively. As tapered ends 92e pass through the apertures, plug support 58 applies a force to the pins. This force causes the holding element to move, thereby further aligning the socket with the second plug.

For example, a horizontal force applied to the pins may move the holding element along the same horizontal axis, though not necessarily in the same direction, as the holding element moved before the pins entered the apertures. Alternatively or additionally, a horizontal and/or vertical force applied to the 1378-20 pins may slightly contort the holding element, e.g., by shifting panel 88 and/or top plate 80 relative to the rest of the holding element.

Alternatively, panel 88 may be shaped to define apertures 94, and pins 92 may protrude from plug support 58. In such embodiments, the force applied to panel 88 by pins 92 may finely align the socket with the second plug, as described above.

In some embodiments, alignment mechanism 45 further comprises a roller 78 coupled to holding element 46 (e.g., to top plate 80) and configured to roll along a vertical surface behind the holding element as the holding element moves. For example, roller 78 may roll along a wall of the garage or along a back panel 86 of base 66. As the second plug approaches the socket, roller 78 may apply a compressive force to the holding element, thus facilitating the connection of the second plug with the socket.

In alternate embodiments, holding element 46 is coupled to vehicle pallet 24, second plug 56 is held by the holding element, and socket 60 is held by a stationary holding element coupled to a wall of the garage. As the pallet approaches the socket (e.g., along the x-axis), holding element 46 moves (e.g., along the y-axis), such that the second plug is aligned with the socket. This movement may be effected, for example, by the entry of protrusion 74, which is coupled to first rods 70a, into a slot in the stationary holding element. Pins 92 and apertures 94 may facilitate a fine alignment of the second plug, as described above.

PALLET-MOUNTED CHARGING STATION Reference is now made to Fig. 4, which is a schematic illustration of a charging station 30 and an energy-storage unit 98 coupled to a vehicle pallet 24, in accordance with some embodiments of the present invention.

In some embodiments, charging station 30, which is 1378-20 configured to charge an electric vehicle 26e via cable 48, is coupled to pallet 24. For example, pallet 24 may comprise stand 52, and charging station 30 may be mounted to the stand. (Typically, in such embodiments, socket 60 is built-in to charging station 30, such that connecting cable 44 (Fig. 1A) is not required.) In such embodiments, an electrical interface 100 is coupled to pallet 24, typically to the underside thereof. Energy-storage unit 98 is configured to receive input electrical current from a supply of electricity via electrical interface 100. Energy- storage unit 98 is further configured to power charging station 30, as further described below.

Typically, energy-storage unit 98 is coupled to pallet 24; for example, the energy-storage unit may be mounted to stand 52. In such embodiments, energy-storage unit 98 is typically connected to electrical interface 100 and to charging station via cables 102.

Typically, another electrical interface 104, which is connected to the supply of electricity, is coupled to a frame belonging to a drive system 22. For example, electrical interface 104 may be connected to the main single-phase or three-phase supply of garage 21 (Fig. 1) via PDU 106. Electrical interface 104 is configured to interface with electrical interface 100 while pallet 24 rests above frame 23, such that energy-storage unit 98 receives the input electrical current via electrical interface 100. (It is noted that any number of drive systems in the garage may be designated for the charging of electric vehicles 26e, and may thus comprise respective electrical interfaces 104.) For example, electrical interface 100 and electrical interface 104 may comprise complementary electrical brush contactors. As another example, one of the electrical interfaces may comprise a plug, and the other electrical interface may comprise a socket. (In such embodiments, at least one of the 1378-20 electrical interfaces may be coupled to a mechanical arm configured to move the electrical interface toward the other electrical interface such that the plug plugs into the socket.) As yet another example, electrical interface 104 may comprise a transmitter and electrical interface 100 may comprise a receiver, such that the input electrical current is transferred via inductive coupling.

Alternatively, electrical interface 100 may connect to the supply of electricity (e.g., via PDU 106) directly, such that electrical interface 104 is not required.

While energy-storage unit 98 is receiving the input electrical current via electrical interface 100 (e.g., while pallet 24 rests on frame 23 such that electrical interface 1interfaces with electrical interface 104), the energy-storage unit converts the input electrical current to stored energy. Conversely, while not receiving the input electrical current, the energy-storage unit converts the stored energy to output electrical current and delivers the output electrical current to charging station 30.

For example, in some embodiments, energy-storage unit 98 comprises a battery 112, an inverter 114, a logic circuit 116, and a switch 118. Switch 118 comprises an output terminal 1connected to charging station 30, a first input terminal 122a connected to electrical interface 100, and a second input terminal 122b connected to inverter 114. In response to the energy-storage unit receiving the input electrical current, logic circuit 116 connects output terminal 120 to first input terminal 122a. Thus, any of the input electrical current required by charging station 30 flows to the charging station, while the remainder of the input electrical current is converted to energy stored in battery 112, as further described below. In response to the energy-storage unit ceasing to receive the input electrical current, the logic circuit connects output terminal 120 to second input terminal 122b. Thus, inverter 114 converts 1378-20 the stored energy to output electrical current, which flows to charging station 30.

Typically, logic circuit 116 is connected to electrical interface 100, such that the logic circuit may identify the flow of input electrical current to energy-storage unit 98 by identifying a flow of input electrical current to the logic circuit.

Typically, it is preferable that output terminal 120 be connected to first input terminal 122a only if the pallet is to remain in place for at least a predetermined threshold amount of time. (This threshold may be reached, for example, if the pallet is at the drive system at which the pallet will remain parked or is delayed in reaching this drive system.) Thus, in some embodiments, the logic circuit is configured to connect output terminal 120 to first input terminal 122a in response to receipt of the input electrical current by the energy-storage unit for the threshold amount of time.

Alternatively or additionally, central controller 35 (Fig. 1A), via PDU 106, may pass the input electric current to electrical interface 100 in response to calculating that the pallet will remain in place for at least the threshold amount of time. Alternatively or additionally, logic circuit 116 may be configured to connect output terminal 120 to first input terminal 122a in response to receipt of the input electrical current by the energy-storage unit and an instruction from the central controller to connect the output terminal to the first input terminal. In some such embodiments, logic circuit 1comprises a wireless communication interface 124, such as a WNIC, and the logic circuit communicates wirelessly with the central controller via wireless communication interface 124 and wireless communication interface 37 (Fig. 1A). In other such embodiments, the logic circuit communicates with the central controller over a wired connection.

Typically, energy-storage unit 98 further comprises a 1378-20 battery charger 110, which is configured to charge battery 112, and a power divider 108, which is configured to distribute the input electrical current between battery charger 110 and the charging station. Thus, for example, while vehicle 26e is charging, 50%-80% of the supplied electrical power may flow to the charging station, while the remainder may flow to the battery charger. While vehicle 26e is fully charged or pallet is unoccupied, close to 100% of the supplied power may flow to the battery charger.

Typically, as indicated in Fig. 4, the input and output electrical currents are alternating currents (AC). While the input current is being received, battery charger 110 converts this input to a direct current (DC) that charges battery 112. Subsequently to a cessation of the input, another DC current, which carries the stored energy from the battery to inverter 114, is converted by the inverter to the output current.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of embodiments of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof that are not in the prior art, which would occur to persons skilled in the art upon reading the foregoing description. Documents incorporated by reference in the present patent application are to be considered an integral part of the application except that to the extent any terms are defined in these incorporated documents in a manner that conflicts with the definitions made explicitly or implicitly in the present specification, only the definitions in the present specification should be considered.

Claims (46)

1378-20 CLAIMS

1. A system, comprising: a standard vehicle-charging socket; a connecting cable; a charging station connected to the vehicle-charging socket via the connecting cable and configured to charge an electric vehicle carried by a vehicle pallet while a first plug of a standard vehicle-charging cable is plugged into the electric vehicle and a second plug of the vehicle-charging cable is plugged into the vehicle-charging socket; and a holding element configured to facilitate the plugging of the second plug into the vehicle-charging socket by moving while holding the vehicle-charging socket such that, as the vehicle pallet, which carries the vehicle-charging cable, approaches the holding element, the vehicle-charging socket is aligned with the second plug.

2. The system according to claim 1, wherein the vehicle pallet approaches the holding element along a first horizontal axis, and wherein the holding element is configured to move along a second horizontal axis perpendicular to the first horizontal axis.

3. The system according to claim 1, further comprising: a base; one or more first brackets coupled to the base at a first side of the base, and one or more second brackets coupled to the base at a second side of the base that is opposite the first side; and one or more first rods protruding from the holding element and slidingly passing through the first brackets, respectively, and one or more second rods protruding from the holding element and slidingly passing through the second brackets, respectively, wherein the holding element is configured to move by virtue of the first rods sliding through the first brackets and the second rods sliding through the second brackets. 1378-20

4. The system according to claim 3, further comprising one or more first springs coiled around the first rods, respectively, between the holding element and the first brackets, and one or more second springs coiled around the second rods, respectively, between the holding element and the second brackets, such that the first springs and the second springs stabilize the holding element prior to the movement of the holding element.

5. The system according to claim 3, wherein the vehicle pallet is shaped to define a track, and wherein the system further comprises a protrusion coupled to the first rods and comprising a tapered end configured to enter the track, thereby causing the holding element to move.

6. The system according to claim 1, further comprising a roller coupled to the holding element and configured to roll along a vertical surface behind the holding element as the holding element moves.

7. The system according to any one of claims 1-6, wherein the holding element comprises a panel shaped to define an opening and configured to hold the vehicle-charging socket within the opening.

8. The system according to claim 7, further comprising: the vehicle pallet; and a plug support coupled to the vehicle pallet and configured to couple to the second plug.

9. The system according to claim 8, wherein the plug support is shaped to define one or more apertures, and wherein the holding element further comprises one or more pins protruding from the panel and comprising respective tapered ends configured to pass through the apertures, respectively, thereby causing the holding element to move.

10. The system according to claim 8, wherein the panel is shaped to define one or more 1378-20 apertures, and wherein the system further comprises one or more pins protruding from the plug support and comprising respective tapered ends configured to pass through the apertures, respectively, thereby causing the holding element to move.

11. The system according to claim 8, further comprising a stand coupled to the vehicle pallet and configured to hold the first plug when the first plug is not plugged into the electric vehicle.

12. The system according to claim 11, wherein the stand comprises, or is coupled to, the plug support.

13. The system according to claim 11, wherein the plug support is coupled to the vehicle pallet at a corner of a top surface of the vehicle pallet.

14. A method, comprising: identifying a charging station for charging an electric vehicle while a first plug of a standard vehicle-charging cable is plugged into the electric vehicle and a second plug of the vehicle-charging cable is plugged into a standard vehicle-charging socket connected to the charging station and held by a holding element; and plugging the second plug into the vehicle-charging socket by moving a vehicle pallet, which carries the electric vehicle and the vehicle-charging cable, toward the holding element, thereby causing the holding element to move such that the vehicle-charging socket is aligned with the second plug.

15. The method according to claim 14, wherein moving the vehicle pallet comprises moving the vehicle pallet along a first horizontal axis, and wherein causing the holding element to move comprises causing the holding element to move along a second horizontal axis perpendicular to the first horizontal axis.

16. The method according to claim 14, wherein one or more first brackets are coupled to a base at 1378-20 a first side of the base, and one or more second brackets are coupled to the base at a second side of the base that is opposite the first side, wherein one or more first rods protrude from the holding element and slidingly passing through the first brackets, respectively, and one or more second rods protrude from the holding element and slidingly pass through the second brackets, respectively, and wherein causing the holding element to move comprises causing the holding element to move by virtue of the first rods sliding through the first brackets and the second rods sliding through the second brackets.

17. The method according to claim 16, wherein one or more first springs are coiled around the first rods, respectively, between the holding element and the first brackets, and one or more second springs are coiled around the second rods, respectively, between the holding element and the second brackets, such that the first springs and the second springs stabilize the holding element prior to the movement of the holding element.

18. The method according to claim 16, wherein the vehicle pallet is shaped to define a track, wherein a protrusion is coupled to the first rods and includes a tapered end, and wherein causing the holding element to move comprises causing the holding element to move by causing the tapered end to enter the track.

19. The method according to claim 14, wherein a roller coupled to the holding element rolls along a vertical surface behind the holding element as the holding element moves.

20. The method according to any one of claims 14-19, wherein the holding element includes a panel shaped to define an opening, and wherein the panel holds the vehicle-charging socket within the opening. 1378-20

21. The method according to claim 20, wherein a plug support is coupled to the vehicle pallet and to the second plug.

22. The method according to claim 21, wherein the plug support is shaped to define one or more apertures, wherein the holding element further includes one or more pins protruding from the panel and including respective tapered ends, and wherein causing the holding element to move comprises causing the holding element to move by causing the tapered ends to pass through the apertures.

23. The method according to claim 21, wherein the panel is shaped to define one or more apertures, wherein one or more pins protrude from the plug support and include respective tapered ends, and wherein causing the holding element to move comprises causing the holding element to move by causing the tapered ends to pass through the apertures.

24. The method according to claim 21, wherein a stand is coupled to the vehicle pallet and is configured to hold the first plug when the first plug is not plugged into the electric vehicle.

25. The method according to claim 24, wherein the stand includes, or is coupled to, the plug support.

26. The method according to claim 24, wherein the plug support is coupled to the vehicle pallet at a corner of a top surface of the vehicle pallet.

27. Apparatus, comprising: a vehicle pallet configured to carry an electric vehicle and a standard vehicle-charging cable including a first plug plugged into the electric vehicle and a second plug configured to plug into a standard vehicle-charging socket; and 1378-20 a holding element coupled to the vehicle pallet and configured to move while holding the second plug such that, as the vehicle pallet approaches the vehicle-charging socket, the second plug is aligned with the vehicle-charging socket.

28. A method, comprising: identifying a charging station for charging an electric vehicle while a first plug of a standard vehicle-charging cable is plugged into the electric vehicle and a second plug of the vehicle-charging cable is plugged into a standard vehicle-charging socket connected to the charging station; and plugging the second plug into the vehicle-charging socket by moving a vehicle pallet, which carries the electric vehicle and the vehicle-charging cable, toward the vehicle-charging socket, thereby causing a holding element, which is coupled to the vehicle pallet and holds the second plug, to move such that the second plug is aligned with the vehicle-charging socket.

29. Apparatus, comprising: a base; one or more first brackets coupled to the base at a first side of the base, and one or more second brackets coupled to the base at a second side of the base that is opposite the first side; a holding element configured to hold a standard vehicle-charging connector; one or more first rods protruding from the holding element and slidingly passing through the first brackets, respectively, and one or more second rods protruding from the holding element and slidingly passing through the second brackets, respectively; one or more first springs coiled around the first rods, respectively, between the holding element and the first brackets, and one or more second springs coiled around the second rods, respectively, between the holding element and the second brackets; and a protrusion coupled to the first rods and comprising a 1378-20 tapered end.

30. A system, comprising: a vehicle pallet, configured to carry an electric vehicle; a charging station coupled to the vehicle pallet and configured to charge the electric vehicle via a standard vehicle-charging cable; an electrical interface coupled to the vehicle pallet; and an energy-storage unit configured to: while receiving input electrical current via the electrical interface, convert the input electrical current to stored energy, and while not receiving the input electrical current, convert the stored energy to output electrical current and deliver the output electrical current to the charging station.

31. The system according to claim 30, wherein the electrical interface is coupled to an underside of the vehicle pallet.

32. The system according to claim 31, wherein the electrical interface is a first electrical interface, and wherein the system further comprises: a drive system, comprising at least one frame and configured to move the vehicle pallet; and a second electrical interface coupled to the frame, connected to a supply of the input electrical current, and configured to interface with the first electrical interface while the vehicle pallet rests above the frame such that the energy-storage unit receives the input electrical current via the first electrical interface.

33. The system according to claim 30, wherein the vehicle pallet comprises a stand, and wherein the charging station is mounted to the stand.

34. The system according to claim 33, wherein the energy-storage unit is mounted to the stand. 1378-20

35. The system according to any one of claims 30-34, wherein the energy-storage unit comprises: a battery, configured to store the stored energy; an inverter, configured to convert the stored energy to the output electrical current; a switch comprising an output terminal connected to the charging station, a first input terminal connected to the electrical interface, and a second input terminal connected to the inverter; and a logic circuit, configured to: connect the output terminal to the first input terminal in response to the energy-storage unit receiving the input electrical current, and connect the output terminal to the second input terminal in response to the energy-storage unit ceasing to receive the input electrical current.

36. The system according to claim 35, wherein the logic circuit is configured to connect the output terminal to the first input terminal in response to the energy-storage unit receiving the input electrical current for a predetermined threshold amount of time.

37. The system according to claim 35, wherein the logic circuit is configured to connect the output terminal to the first input terminal in response to an instruction from a controller to connect the output terminal to the first input terminal.

38. The system according to any one of claims 30-34, further comprising a controller configured to pass the input electrical current to the electrical interface in response to calculating that the vehicle pallet will remain in place for at least a predetermined threshold amount of time.

39. A method, comprising: while receiving input electrical current via an electrical interface coupled to a vehicle pallet carrying an electric 1378-20 vehicle, converting the input electrical current to stored energy; and while not receiving the input electrical current, converting the stored energy to output electrical current and delivering the output electrical current to a charging station coupled to the vehicle pallet such that the charging station charges the electric vehicle via a standard vehicle-charging cable.

40. The method according to claim 39, wherein the electrical interface is coupled to an underside of the vehicle pallet.

41. The method according to claim 40, wherein the electrical interface is a first electrical interface, wherein a drive system includes at least one frame and is configured to move the vehicle pallet, and wherein a second electrical interface is coupled to the frame, connected to a supply of the input electrical current, and configured to interface with the first electrical interface while the vehicle pallet rests above the frame such that the input electrical current is received via the first electrical interface.

42. The method according to claim 39, wherein the vehicle pallet includes a stand, and wherein the charging station is mounted to the stand.

43. The method according to any one of claims 39-42, wherein converting the stored energy to the output electrical current comprises converting the stored energy to the output electrical current using an inverter, wherein a switch includes an output terminal connected to the charging station, a first input terminal connected to the electrical interface, and a second input terminal connected to the inverter, and wherein the method further comprises: connecting the output terminal to the first input 1378-20 terminal in response to receiving the input electrical current; and connecting the output terminal to the second input terminal in response to ceasing to receive the input electrical current.

44. The method according to claim 43, wherein connecting the output terminal to the first input terminal comprises connecting the output terminal to the first input terminal in response to receiving the input electrical current for a predetermined threshold amount of time.

45. The method according to claim 43, wherein connecting the output terminal to the first input terminal comprises connecting the output terminal to the first input terminal in response to an instruction from a controller to connect the output terminal to the first input terminal.

46. The method according to any one of claims 39-42, further comprising passing the input electrical current to the electrical interface in response to calculating that the vehicle pallet will remain in place for at least a predetermined threshold amount of time. 20