SYSTEM AND METHOD FOR CHARGING ELECTRIC VEHICLES

A system for charging a plurality of electric vehicles includes a rail structure, a mobile base unit, at least one battery and a controller. The mobile base unit is supported by the rail structure and is configured to move along the rail structure between respective vehicle charging stations. The battery is configured to provide power to the mobile base unit to move along the rail structure. The controller is configured to obtain a charge request from one or more electric vehicles, determine a charging sequence of the electric vehicles based on vehicle parameters and charge parameters of the battery, and move the mobile base unit along the rail structure based on the charging sequence.

FIELD

The present disclosure relates to a system and method for charging electric vehicles.

BACKGROUND

Various types of automotive vehicles such as battery electric vehicles (BEVs), hybrid electric vehicles (HEVs), plug-in electric vehicles (PHEVs), or fuel cell vehicles, for example, include one or more electric motors that employs electrical energy stored in an energy storage apparatus, such as one or more vehicle batteries, to perform one or more propulsion-based operations. The energy storage apparatus requires periodic charging by connecting the energy storage apparatus to a power source

The teachings of the present disclosure address these and other issues with charging the energy storage apparatus of electric vehicles.

SUMMARY

In one form, the present disclosure provides a system for charging a plurality of electric vehicles. The system includes a rail structure, a first mobile base unit, and a central control system. The first mobile base unit is supported by the rail structure and is configured to move along the rail structure between respective vehicle charging stations. The central control system is configured to obtain a charge request from one or more electric vehicles, determine a charging sequence of the electric vehicles based on vehicle parameters and charge parameters of the first battery, and move the first mobile base unit along the rail structure based on the charging sequence.

In variations of the system of the above paragraph, which can be implemented individually or in any combination: the vehicle parameters comprise a current state of charge level and a predetermined state of charge level of each electric vehicle the electric vehicles; the charge parameters comprise a current power level and a predetermined power level of the first battery; the rail structure is an overhead rail structure; a plurality of first batteries configured to provide power to the first mobile base unit to move along the rail structure; a plurality of battery charging stations, one battery charging station disposed at one end of the rail structure and another battery charging station disposed at another end of the rail structure that is opposite the one end, each first battery of the first batteries is configured to be selectively mechanically and electrically coupled to a respective battery charging station of the battery charging stations to charge the first battery; the first mobile base unit comprises at least one battery, a movable base connected to the rail structure and powered by the battery to move along the rail structure between the charging stations, a robot arm having a first end and a second end, the robot arm secured to the movable base at the first end, and an end-effector secured to the robot arm at the second end; the movable base includes an end having a battery terminal configured to be selectively electrically and mechanically coupled to the battery; the at least one battery includes a first battery and a second battery; the movable base includes a first end having a first battery terminal configured to be selectively electrically and mechanically coupled to the first battery and a second end having a second battery terminal configured to be selectively electrically and mechanically coupled to the second battery, the first end of the movable base is opposite the second end of the movable base; the robot arm includes a plurality of segments connected to each other such that the robot arm has multiple degrees of freedom; the movable base is connected to the rail structure by wheels; a plurality of battery charging stations, one battery charging station of the plurality of battery charging stations disposed at one end of the rail structure and another battery charging station of the plurality of battery charging stations disposed at another end of the rail structure that is opposite the one end, the movable base is located between the one battery charging station and the other battery charging station; a second mobile base unit supported by the rail structure and configured to move along the rail structure; and a plurality of second batteries configured to provide power to the second mobile base unit to move along the rail structure.

In another form, the present disclosure provides a system for charging a plurality of electric vehicles. The system includes a rail structure, a plurality of electric charging apparatuses, a first mobile base unit, a plurality of first batteries, and a central control system. The plurality of electric charging apparatuses are disposed at respective vehicle charging stations. The first mobile base unit is supported by the rail structure and is configured to move along the rail structure between the respective vehicle charging stations. The first mobile base unit including a robot arm. The plurality of first batteries are configured to provide power to the first mobile base unit to move along the rail structure. The central control system is configured to obtain a charge request from one or more electric vehicles, determine a charging sequence of the one or more electric vehicles based on vehicle parameters and charge parameters of the first batteries, move the first mobile base unit along the rail structure based on the charging sequence, and control the robot arm to move a charger of a corresponding electric charging apparatus from the corresponding electric charging apparatus to a corresponding electric vehicle located within the respective vehicle charging station associated with the respective electric charging apparatus such that the charger is electrically coupled to the corresponding electric vehicle.

In variations of the system of the above paragraph, which can be implemented individually or in any combination: the vehicle parameters comprise a current state of charge level and a predetermined state of charge level of each electric vehicle the electric vehicles; the charge parameters comprise a current power level and a predetermined power level of the first battery; the rail structure is an overhead rail structure; a plurality of battery charging stations, one battery charging station disposed at one end of the rail structure and another battery charging station disposed at another end of the rail structure that is opposite the one end, each first battery of the first batteries is configured to be selectively mechanically and electrically coupled to a respective battery charging station of the battery charging stations to charge the battery; the first mobile base unit comprises a movable base, the robot arm, and an end-effector, the movable base is connected to the rail structure and powered by a respective first battery to move along the rail structure between the charging stations, the robot arm has a first end and a second end, the robot arm secured to the movable base at the first end, and the end-effector is secured to the robot arm at the second end; a second mobile base unit supported by the rail structure and configured to move along the rail structure; a plurality of second batteries configured to power the second mobile base unit to move along the rail structure; the plurality of vehicle charging stations include first vehicle charging stations and second vehicle charging stations; and the plurality of electric charging apparatuses include first electric charging apparatuses and second electric charging apparatuses, the first electric charging apparatuses disposed at respective first vehicle charging stations and the second electric charging apparatuses disposed at respective second vehicle charging stations, the first mobile base unit movable between the first vehicle charging stations and the second mobile base unit moveable between the second vehicle charging stations.

In another form, the present disclosure provides a method for charging a plurality of electric vehicles. The method includes obtaining a charge request from one or more electric vehicles, determining a charging sequence of the electric vehicles based on vehicle parameters and charge parameters of first batteries, moving a mobile base unit along a rail structure based on the charging sequence, and controlling a robot arm of the mobile base unit to move a charger of a corresponding electric charging apparatus from the corresponding electric charging apparatus to a corresponding electric vehicle of the electric vehicles located at a respective charging station such that the charger is electrically coupled to the corresponding electric vehicle.

DETAILED DESCRIPTION

Referring toFIGS.1A and1B, a manufacturing environment5-1is shown and generally includes a robotic charging system10-1and a plurality of vehicles20. In one form, the robotic charging system10-1includes a plurality of charging stations40, a plurality of robots50, a gantry system60, a localization system70, and a central control system80. It should be understood that any one of the modules of the vehicles20, the charging stations40, the robots50, the gantry system60, the localization system70, and the central control system80can be provided at the same location or distributed at different locations (e.g., via one or more edge computing devices) and communicably coupled accordingly. In one form, the vehicles20, the charging stations40, the robots50, the gantry system60, the localization system70, and the central control system80are communicably coupled using a wireless communication protocol (e.g., a Bluetooth®-type protocol, a cellular protocol, a wireless fidelity (Wi-Fi)-type protocol, a near-field communication (NFC) protocol, an ultra-wideband (UWB) protocol, among others).

In one form, the vehicles20are provided by electric vehicles. As used herein, “electric vehicle” refers to a vehicle that employs one or more electric motors for propulsion. Some examples of electric vehicles are battery electric vehicles (BEVs), hybrid electric vehicles (HEVs), plug-in electric vehicles (PHEVs), or fuel cell vehicles, for example. In one form, the vehicles20may be provided by autonomous or semi-autonomous vehicles that are configured to perform one or more known autonomous routines within the manufacturing environment5-1, such as an autonomous navigation routine, a driver assistance routine, an adaptive cruise control routine, an autonomous braking routine, and/or an object detection routine. It should be understood that the vehicles20may be provided by other types of vehicles and are not limited to the examples described herein.

In one form, the vehicles20may each include an electric motor24that employ electrical energy stored in an energy storage apparatus22, such as one or more vehicle batteries, to perform one or more propulsion-based operations. In one form, the vehicles20include a vehicle control system26that is configured to control and/or monitor a particular system or subsystem of the vehicles20. As an example, the vehicle control system26may include a propulsion control module for controlling the operation of the electric motor24, a powertrain control module for controlling operation of a powertrain system of the vehicle20, a transmission control module for controlling operation of a transmission system of the vehicle20, a brake control module for controlling operation of a braking system of the vehicle20, a body control module for controlling the operation of various electronic accessories in the body of the vehicle20, a climate control module for controlling operation of a heating and air conditioning system of the vehicle20, and a suspension control module for controlling operation of a suspension system of the vehicle20, among other vehicle modules. In one form, the electric motor24, the energy storage apparatus22, and the vehicle control system26are communicably coupled by a vehicle interface, such as a control system area network (CAN) bus, a local interconnect network (LIN) bus, and/or a clock extension peripheral interface (CXPI) bus.

In one form and referring toFIGS.1A-1C, the vehicles20may each include a vehicle charging system30(FIG.1A) that is configured to receive electrical energy from the charging stations40. The vehicle charging system30may include a charging port cover32(FIG.1B), a charging port34, and a power network36. In one form, the charging port cover32is movable between a closed position in which the charging port34and the power network36are inaccessible from a location external to the vehicle20(i.e., physically isolated from an ambient environment of the vehicle20) and an open position in which the charging port34and the power network36are accessible from a location external to the vehicle20. In the example illustrated, the charging cover32is a door or cap, for example.

In one form, the charging port34provides an electrical interface for physically and electrically/inductively coupling an electrical charger of the charging station40(described below in further detail) to the power network36. As an example, the charging port34is provided by a charging receptacle (e.g., an electrical outlet) that receives one or more conductive components of the electrical charger of the charging station40. As another example, the charging port34is provided by a charging pad (e.g., a wireless power transfer pad comprising one or more inductive coils) that is configured to inductively and physically couple to a charging pad of the electrical charger.

In one form, the power network36selectively adjusts one or more characteristics of the electric signal received from the charging stations40and provides the adjusted signal to the energy storage apparatus22. As an example, the power network34includes an alternating current-alternating current (AC-AC) converter circuit that is configured to adjust an amplitude and/or frequency component of an AC electric signal, such as a voltage source inverter, a current source inverter, a cycloconverter, a matrix converter, among other AC-AC converter circuits. As another example, the power network36includes an AC-direct current (AC-DC) converter circuit that is configured to convert the AC electric signal into a DC electric signal, such as a rectifier circuit and/or other AC-DC converter circuits. As an additional example, the power network36includes a DC-AC converter circuit that is configured to convert the DC electric signal into an AC electric signal, such as an inverter circuit and/or other DC-AC converter circuits. As yet another example, the power network36includes a DC-DC converter circuit that is configured to adjust an amplitude of the DC electric signal, such as a buck converter circuit, a boost converter circuit, a buck-boost converter circuit, among other DC-DC converter circuits.

In one form, the charging stations40are configured to provide electrical energy to the vehicles20during a charging operation and include an electric charger or charging apparatus42, a power converter network44, and a charging station control system46. In one form, the electric charger42is electrically coupled to a power grid via the power converter network44and may include a conductive cable (e.g., a Level 4 DC fast charger cable, a Level 3 DC charger cable, or a Level 2 AC charger cable) and a charging interface for physically and electrically/inductively coupling to the power network36via the charging port34, such as a plug or a wireless charging pad. In one form, the power converter network44is configured to adjust one or more characteristics of the electrical power output by the grid and provide the adjusted electrical power to the energy storage apparatus22via the charging port34and the power network36. As an example, the power network44may include similar circuits and converter networks as the power network36, and as such, the description thereof is omitted for brevity.

In one form, each robot50includes a robot arm or robotic arm52, an end of arm tool (EOAT) or end-effector54, robot sensors56, and a robot control system58configured to control the robotic arm52and the EOAT54to perform one or more automated tasks. Example automated tasks include, but are not limited to, retrieving the electric charger42from the charging station40and moving the electric charger42proximate to the vehicle20(e.g., the charging port34), removing the charging port cover32to insert the electric charger42into the charging port34, among other automated tasks.

In one form, the robotic arm52includes a plurality of segments52a(FIG.1C) connected to each other at joints, thereby allowing the robotic arm52to have multiple degrees of freedom. Stated differently, the robotic arm52is a multi-axis robotic arm having various portions that are rotatable about various axes (e.g., a six-axis robot having five degrees of freedom). In one form, the EOAT54is secured to an end of the robotic arm52and includes one or more components for performing the automated tasks described herein, such as an image/vision sensor, a hook, and a gripper. One example of such robotic arm52and/or the EOAT54are disclosed in U.S. Patent App. No. XX/000,000, and titled “ROBOTIC ARM ASSEMBLY FOR ELECTRIC VEHICLE CHARGER,” which is commonly owned with the present application and the contents of which are incorporated herein by reference in its entirety.

In one form, the robot sensors56generate data corresponding to various characteristics of the robot50. As an example, the robot sensors56may include a location sensor (e.g., an NFC sensor or UWB sensor) configured to generate location information of the robot50. As another example, the robot sensors56may include an accelerometer, a gyroscope, and/or a magnetometer configured to generate orientation information of the robot50. As yet another example, the robot sensors56may include a velocity sensor configured to generate velocity information of the robot50, a power sensor to generate power information (e.g., information regarding amount of current and/or voltage being applied by a power source to the robot50), a torque sensor configured to generate torque information of various joints of the robot50, and/or a touch sensor at a handle of the robot50configured to detect contact. The robot sensors56are configured to provide the corresponding data to the robot control system58for controlling the robotic arm52and/or EOAT54.

In one form, with reference toFIGS.1A and1C, the gantry system60includes a structural base assembly62(FIG.1C), a plurality of robot bases64(FIG.1A), a plurality of propulsion systems68(FIG.1A), and a gantry control system69(1A). The structural base assembly62is secured to a ground surface and is configured to physically support the robot base64. In one example, the structural base assembly62is permanently fixed to the ground surface. In another example, the structural base assembly62may include wheels that may be movable between a locked position to inhibit movement of the structural base assembly62in the manufacturing environment5-1and an unlocked position to permit movement of the structural base assembly62in the manufacturing environment5-1. In the example illustrated, the structural base assembly62includes support legs62a,62band a rail structure62c. The support legs62a,62bare spaced apart from each other and extend in a vertical direction. Stated differently, the support leg62ais disposed at a first end of the gantry system60and the support leg62bis disposed at a second end of the gantry system60that is opposite the first end.

The rail structure62cextends in a horizontal direction and is secured to upper ends of the support legs62a,62b. In this way, the rail structure62cis located above the charging stations40and the vehicles20located at the charging stations40. In some forms, the rail structure62cmay be secured to the support legs62a,62bat a location that is between the upper ends of the support legs62a,62band lower ends of the support legs62a,62b(i.e., the lower ends of the support legs62a,62bare secured to the ground surface). In this way, the rail structure62cmay be positioned below the charging stations40, for example. In the example illustrated, the rail structure62chas opposing sides that each define a track74(only one side72having track74is shown inFIG.1C). In one variation, the support legs62a,62bof the structural base assembly62may be omitted such that the structural base assembly62includes only the rail structure62c. In such variation, the rail structure62cis secured to a ceiling, wall, or other infrastructure member of the manufacturing environment5-1.

Each robot base64is connected to the rail structure62cand connected to an end of a respective robotic arm52, and is configured to move along the rail structure62cbetween the charging stations40. In this way, the robot50can initiate the charging operation at any one of the charging stations40. In the example illustrated, the robot base64is connected to the rail structure62csuch that the robot base64and the respective robotic arm52are suspended therefrom above the ground surface. In some forms, the robot base64is mounted on top of the rail structure62csuch that the respective robotic arm52is suspended from the rail structure62c. In the example illustrated, the robot base64is connected to the rail structure62cby wheels62received in respective tracks74. In this way, the wheels62roll along the track to move the robot base64and the respective robotic arm52between the charging stations40. In some forms, the robot base64may be connected to the rail structure62csuch that the robot base64is slidable along the rail structure62c.

The robot base64is powered by a battery78a,78bsuch as a rechargeable battery, for example. Each robot base64includes an electrical terminal80aat a first end of the robot base64and an electrical terminal80bat a second end of the robot base64that is opposite the first end. Each of the electrical terminals80a,80bprovides an electrical interface for physically and electrically/inductively coupling a respective battery78a,78bto the robot base64. That is, the battery78ais configured to be electrically coupled to the electrical terminal80ato power the robot base64and mechanically coupled to the robot base64so that the battery78ais supported by the robot base64. Similarly, the battery78bis configured to be electrically coupled to the electrical terminal80bto power the robot base64and mechanically coupled to the robot base64so that the battery78bis supported by the robot base64. A coupling structure (not shown) may be communicably coupled to the central control system80and may mechanically lock the battery78a,78bto the robot base64such that the battery78a,78bis inhibited from moving relative to the robot base64when electrically coupled the respective electrical terminals80a,80b. In some forms, locking assemblies (not shown) may be communicably coupled to the central control system80and may be associated along the rail structure62cat respective charging stations40. In this way, each locking assembly may lock the robot base64to the rail structure62cwhen the robot50initiates the charging operating at the respective charging station40. The batteries78a,78bmay be lithium-ion batteries, for example.

In the example illustrated, a battery charging station84ais disposed proximate the support leg62aof the gantry system60and is configured to recharge the battery78a. The battery charging station84ais powered by solar panels (not shown) associated with the manufacturing environment5-1, a swappable battery pack, and/or the power grid. The battery charging station84amay be secured to and supported by one or both of the support leg62aand the rail structure62c. The battery charging station84aincludes an electrical terminal86athat faces and is aligned with the electrical terminal80aof the robot base64. The electrical terminal86aprovides an electrical interface for physically and electrically/inductively coupling the battery78ato the battery charging station84a. That is, the battery78ais configured to be electrically coupled to the battery charging station84ato charge the battery78aand mechanically coupled to the battery charging station84aso that the battery78ais supported by the battery charging station84a. A coupling structure (not shown) may be communicably coupled to the central control system80and may mechanically lock the battery78ato the battery charging station84asuch that the battery78ais inhibited from moving relative to the battery charging station84awhen electrically coupled to the battery charging station84a.

A battery charging station84bis disposed proximate the support leg62bof the gantry system60and is configured to recharge the battery78b. The battery charging station84bis powered by solar panels (not shown) associated with the manufacturing environment5-1, a swappable battery pack, and/or the power grid. The battery charging station84bmay be secured to and supported by one or both of the support leg62band the rail structure62c. The battery charging station84bincludes an electrical terminal86bthat faces and is aligned with the electrical terminal80bof the robot base64. The electrical terminal86bprovides an electrical interface for physically and electrically/inductively coupling the battery78bto the battery charging station84b. That is, the battery78bis configured to be electrically coupled to the battery charging station84bto charge the battery78band mechanically coupled to the battery charging station84bso that the battery78bis supported by the battery charging station84b. A coupling structure (not shown) may be communicably coupled to the central control system80and may mechanically lock the battery78bto the robot base64such that the battery78bis inhibited from moving relative to the battery charging station84awhen electrically coupled to the battery charging station84a. Each robot base64is disposed between the battery charging station84aand the battery charging station84b.

One battery78a,78bis being charged while the other battery78a,78bis providing power to the robot base64(and the robot50). In this way, when the battery78a,78bproviding power to the robot base64is below a predetermined threshold needed to carry out a charge sequence as described in more detail below, the robot base64may swap out batteries such that the robot base64can continue the charge sequence. In one form, the robot base64may pick-up the charged battery78a,78bbefore dropping off the depleted battery78a,78b. In some forms, the robot base64may drop off the depleted battery78a,78bbefore picking up the charged battery78a,78b. In this form, an internal battery system of the robot base64may power the robot base64along the rail structure62cto pick-up the charged battery78a,78b.

In one form, the propulsion system68is associated with a respective robot base64and includes various known components for moving the robot base64and the attached robot50along the rail structure62c. As an example, the propulsion system68includes drive motors, cable carriers, electrically conductive wires, and other known components that are employed for moving the robot base64and the attached robot50along the rail structure62c.

In one form, the localization system70is configured to localize the robots50relative to the vehicles20and/or the vehicles20relative to the robots50. That is, the localization system70is configured to convert a robot-based position of the robot50to a vehicle-based position of the robot50, a vehicle-based position of the vehicle20to a robot-based position of the vehicle20, or a combination thereof. As an example, the localization system70may employ known imaging and fiducial marker systems that employ predefined robot/vehicle location coordinates and translation routines for localizing the robots50relative to the vehicles20and/or the vehicles20relative to the robots50. As another example, the localization system70may employ known object detection systems having predefined robot/vehicle location coordinates and translation routines for localizing the robots50relative to the vehicles20and/or the vehicles20relative to the robots50, such as a localization structure. Example details regarding localization structures that are employed for localizing the robots50relative to the vehicles20and/or the vehicles20relative to the robots50are disclosed in U.S. Patent App. No. XX/000,000, and titled “SYSTEM AND METHOD FOR CHARGING ELECTRIC VEHICLES,” which is commonly owned with the present application and the contents of which are incorporated herein by reference in its entirety.

In one form, the central control system80is configured to control the operation of the robotic charging system10-1. As an example, the central control system80obtains robot data associated with the robots50, vehicle data associated with the vehicles20, charging station data associated with the charging stations40, and battery data associated with the batteries78a,78b. Furthermore, the central control system80determines whether one of the vehicles20has an amount of electrical energy stored in the corresponding energy storage apparatus22that is less than a threshold amount and instructs a selected robot50to perform the charging operation. Furthermore, the central control system80may determine whether the battery78a,78bpowering a selected robot base64has enough power to move the robot base64along the rail structure62cin accordance with a desired charging sequence and may instruct the selected robot base64to swap out the battery78a,78bbefore moving the robot base64along the rail structure in the desired charging sequence. Additional details regarding controlling the operation of the robotic charging system10-1are provided below with reference toFIG.3.

In one form, the manufacturing environment5-1may include a facility or building that is temperature controlled. In another form, the manufacturing environment5-1may be outside where the electric vehicles20are exposed to ambient temperatures. In one example, as shown inFIG.2, the manufacturing environment may have a double row layout. In this way, charging stations140may have one or more conductive cables that can be moved to the vehicles20located in each row by the robots50such that the robots50can initiate the charging operation of the vehicles20.

Referring toFIG.3, an example control algorithm200for charging one or more vehicles20is illustrated. The processing may begin once a current state of charge (SOC) level of the energy storage apparatus22of one or more vehicles20falls below a predetermined threshold SOC level. In one example, the predetermined threshold SOC level may be 60% of a fully charged state. In another example, the predetermined threshold SOC level may be 70% of a fully charged state. At204, the control algorithm, using the central control system80, obtains a charge request from one or more vehicles20requiring charging. At208, the control algorithm, using the central control system80, selects an available charging station40from a list of available charging stations40for each vehicle20requiring charging. The vehicles20are then driven to the selected charging stations40to be charged. In some forms, the vehicles20may be autonomously driven over to the selected charging stations40.

At212, the control algorithm, using the central control system80, notifies the robot50that each vehicle20requiring charging has arrived at the charging stations40. Additionally or alternatively, the robot50may be notified by the respective vehicle20or an image/vision sensor associated with the robot50that each vehicle20requiring charging has arrived at the charging stations40. At216, the control algorithm, using the central control system80, determines a charging sequence of the vehicles20based on vehicle parameters and charge parameters of the batteries78a,78b. That is, the vehicle parameters may include a current SOC level for each vehicle20and a predetermined threshold SOC level of each vehicle20. The charge parameters may include a current power level of each battery78a,78band a predetermined power level of the batteries78a,78b.

At220, the control algorithm, using the central control system80, moves the robot base64along the rail structure62cbased on the charging sequence and controls the robot arm52to move a corresponding electric charger42from the charge station40to a corresponding vehicle20located at the respective vehicle charging station40such that the electric charger42is electrically coupled to the charge port34of the corresponding vehicle20.

Knowing the production volume of the vehicles being manufactured, the time it takes for the robot to plug in the electric charger to a vehicle desiring charging, the time it takes for the robot to remove the electric charger from the charged vehicle, the time it takes for the robot to traverse the gantry, and the total charge time for each vehicle, it can be determined the total time the vehicles will be staying in charge stations, the total number of charge stations desired for a given production volume, the total number of robots required for the charge stations, and the length of travel for each robot. In this way, the system of the present disclosure for charging electric vehicles reduces cost for vehicle charging as well as charge station utilization time.