Description:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of Invention:

PROXIMITY DETECTION FOR MAGNETIC LOCKING IN ELECTRIC CHARGING SYSTEMS DURING DEEP-DISCHARGE STATE OF BATTERY

Applicant:
River Mobility Private Limited
A company based in India,
Having its address as:
No. 25/3, KIADB EPIP Zone, Seetharampalya, Hoodi Road, Mahadevapura, Whitefield, Bengaluru, Karnataka, India- 560048

The following specification particularly describes the invention and the manner in which it is to be performed:

PRIORITY INFORMATION
The present application is a patent of addition dependent on the application no. 202343023509 filed on 29/03/2023 which is a patent of addition of Indian parent application no: 202341015332 filed on 07/03/2023.

TECHNICAL FIELD
This invention relates to a system for performing proximity detection for performing magnetic locking and more particularly related to a magnetic locking establishing system and a method employed in electric charging systems.

BACKGROUND OF INVENTION
Electric charging systems are in high demand as there is a radical shift from fossil fuel generated power towards electric power, which is environmentally sustainable, for various applications. Electric vehicles (EV) are the future of sustainable mobility and an effective mode of transport in urban and rural areas. Vehicles utilizing fossil fuels significantly cause carbon emissions and associated environmental problems, including climatic change. These conventional modes of mobility lead to air pollution and consequently to many health problems. Fossil fuels being non-renewable, their utilization by vehicles is another area of environmental concern. To address the more important issue of climate change, vehicles running on fossil fuel need to be replaced with electric vehicles in the long run. Green mobility with reduced emissions from the transport sector is expected to aid in achieving the sustainable development goals.
Various innovations are happening throughout the world in the arena of electric vehicles. A charging system is designed to charge an electric vehicle or a plug-in hybrid electric vehicle. In the conventional electric charging systems, the connection between the charging gun and the vehicle charging inlet is established through a mechanical or physical locking such as a solenoid lock provided in the vehicle inlet. The charging pins of the charging gun or the vehicle inlet socket may get damaged physically, if the locking means is disconnected mistakenly before the charge storing device gets fully charged. This may lead to a reduction in the overall life of the charging system and an increase in its maintenance cost.
Further, as the conventional charging systems employ mechanical or physical locking with moving parts for connecting the charging gun and vehicle inlet, the alignment between the changing gun and the vehicle inlet may not always be proper. The lack of proper alignment increases the chances of wear and tear in the charging system, thereby reducing the overall life of the charging system.
Accidental disconnection of the charging gun may happen during a fast-charging process. In the conventional charging systems, accidental disconnections may cause arcing and consequently lead to a dangerous scenario, especially in Direct Current (DC) charging stations.
Therefore, there is a need for a unique solution that addresses the problem of accidental disconnection and the associated physical damage to the charging gun and/or the vehicle inlet socket and the potential danger due to arching (especially during DC charging) present in the existing electric charging systems.
Further, some conventional charging systems utilizing guiding mechanisms for connecting the charging gun and the vehicle inlet during charging utilize a large amount of electrical power, especially from a battery connected to the vehicle inlet. Such a large amount of electrical power is utilized in conventional charging systems because the guiding mechanisms are constantly powered and working even during lack of a need for charging. In some situations, the battery connected to the vehicle inlet may get drained out i.e. may enter into a deep-discharge state. In such situations, the vehicle inlet may not be able to enable its guiding mechanism for connecting with the charging gun. Further, the charging gun may not have the information about the presence of the battery in the deep-discharge state. As a result, achieving connection between the charging gun and the vehicle inlet may not be possible.
Therefore, there remains a need to provide a charging system that saves power, especially when the charging isn’t required. Further, there remains a need to provide a charging system that can work even when the battery powering the vehicle inlet is present in a deep-discharge state.
The above-mentioned shortcomings, disadvantages and problems are addressed herein, which will be understood by reading and studying the following specification.

OBJECT OF INVENTION
The principal object of the embodiments herein is to provide a magnetic locking system and method employed in electric charging systems.
Another objective of the present invention is to provide an electric charging system in which an accidental disconnection of the charging gun may not cause any physical damage to the charging gun and/or the vehicle inlet socket.
Yet another objective of the present invention is to provide an electric charging system in which an accidental disconnection of the charging gun may not pose any danger such as arcing.
Yet another objective of the present invention is to provide an electric charging system without any moving parts so that the wear and tear of the charging system can be reduced thereby ensuring higher overall life of the charging system.
Still another objective of the present invention is to energize a second electromagnetic coil provided in a second unit/vehicle inlet after detecting presence of a first unit/charging gun in vicinity of a second unit/charging gun, for magnetic locking.
Yet another objective of the present invention is to save power utilized for achieving magnetic locking of the first unit/charging gun with the second unit/vehicle inlet.
Yet another objective of the present invention is to save power of a battery connected with the second unit/vehicle inlet, during the magnetic locking.
Still another objective of the present invention is to enable the magnetic locking when the battery powering the vehicle inlet is present in a deep-discharge state.

SUMMARY
The embodiments herein provide a system for magnetic locking during electric charging of one or more electric charge storing units. The system comprises a first unit and a second unit. The first unit may be connected to a power source. The first unit includes at least one of a metallic element, a magnet and an electromagnetic coil. The second unit may be operatively connected to the first unit to allow a flow of electric charge to one or more electric charge storing units. The second unit includes an electromagnetic coil. The second unit may be adapted to magnetically attach to the first unit with a predefined force during the electric charging of the one or more electric charge storing units. Further, the system includes one or more current modulating units connected with at least one of the first unit and the second unit to control a current flow through the electromagnetic coil. The first unit may be magnetically attached to the second unit with a predefined force of attraction. The predefined force of attraction is higher than a force required to keep the first unit and the second units operatively connected while the charging is in progress and lower than a force at which the first unit and/or the second unit gets damaged. The electromagnetic coil is laid around the circumference of at least one of the first unit and the second unit. The first unit and the second unit include one or more terminals. The one or more electric charging stages comprises one of a fast-charging mode and a slow-charging mode. A control unit is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil upon receipt of an input from a user, thereby enabling the user to detach the first unit from the second unit while the fast-charging mode is in progress. A control unit is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the first unit from the second unit.
In another embodiment, a magnetic locking during electric charging of one or more electric charge storing units is disclosed. The system includes a first unit and a second unit. The first unit is connected to a power source. The first unit includes an electromagnetic coil and a second unit operatively connected to the first unit for allowing a flow of electric charge to one or more electric charge storing units. The second unit includes at least one of a metallic element, a magnet and an electromagnetic coil. The second unit is adapted to magnetically attach to the first unit with a predefined force during the electric charging of the one or more electric charge storing units. Further, the system includes one or more current modulating units connected with at least one of the first unit and the second unit for controlling a flow of current through the electromagnetic coil. The first unit is magnetically attached to the second unit with a predefined force of attraction, where the predefined force of attraction is higher than a force required to keep the first unit and the second unit operatively connected while the charging is in progress, and lower than a force at which the first unit and/or the second unit gets damaged. The electromagnetic coil is laid around the circumference of at least one of the first unit and the second unit. The first unit and the second unit comprise one or more terminals. Further, one or more electric charging stages comprises one of a fast-charging mode and a slow-charging mode. A control unit is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil upon receipt of an input from a user, thereby enabling the user to detach the first unit from the second unit while the fast-charging mode is in progress. Further, a control unit is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the first unit from the second unit.
In yet another embodiment, a system for providing a magnetic locking during electric charging of one or more batteries of a vehicle is disclosed. The system includes a charging gun and a vehicle inlet. The charging gun may be connected to an external power source. The charging gun includes at least one of a metallic element, a magnet and an electromagnetic coil. The vehicle inlet is operatively connected to the charging gun for allowing a flow of electric charge to one or more electric charge storing units of the vehicle. The vehicle inlet includes an electromagnetic coil. The vehicle inlet is adapted to magnetically attach to the charging gun with a predefined force during the electric charging of the one or more electric charge storing units.
Further, a vehicle control unit (VCU) is adapted to shift a power supply source of the electromagnetic coil of the vehicle inlet from the electric charge storing units of the vehicle to the external power supply during the electric charging of electric charge storing units. Additionally, a vehicle control unit (VCU) is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units is fully charged, thereby enabling a user to detach the charging gun from the vehicle inlet. Additionally, a vehicle control unit (VCU) is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil upon receipt of an input from the user by way of turning ON the vehicle, thereby enabling the user to detach the charging gun from the vehicle inlet while the fast-charging mode is in progress.
In another embodiment, a system for providing a magnetic locking during electric charging of one or more electric charge storing units of a vehicle is provided. The system includes a charging gun and a vehicle inlet. The charging gun is connected to an external power source. The charging gun includes an electromagnetic coil. The vehicle inlet may be operatively connected to the charging gun for allowing a flow of electric charge to one or more electric charge storing units of the vehicle. The vehicle inlet comprises at least one of a metallic element, a magnet and an electromagnetic coil. Further, the vehicle inlet is adapted to magnetically attach to the charging gun with a predefined force during the electric charging of one or more electric charge storing units of the vehicle.
Additionally, a vehicle control unit (VCU) is adapted to shift a power supply source of the electromagnetic coil of the vehicle inlet from the electric charge storing units of the vehicle to the external power supply during the electric charging of electric charge storing units. Further, a vehicle control unit (VCU) is adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil upon receipt of an input from a user by way of turning on the vehicle, thereby enabling the user to detach the charging gun from the vehicle inlet while the fast-charging mode is in progress. Additionally, the system includes a vehicle control unit (VCU) adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units is fully charged, thereby enabling the user to detach the charging gun from the vehicle inlet.
In yet another embodiment, a method for establishing a magnetic locking between a charging gun and a vehicle inlet during electric charging of a vehicle is provided. The method includes generating electromagnetic fields around an electromagnetic coil, aligning the charging gun with the vehicle inlet and magnetically locking the charging gun with the vehicle inlet with a predefined force wherein the predefined force is established by the generated electromagnetic fields.
The method includes providing an automatic guiding of a charging gun with a vehicle inlet by the electromagnetic fields if the charging gun comprises at least one of an electromagnetic coil. The vehicle inlet includes at least one of a metallic element and a magnet.
The method further includes providing an automatic guiding of a charging gun with a vehicle inlet by the electromagnetic fields, if the electric charge storing units of the vehicle holds an electric charge. The charging gun comprises at least one of a metallic element, a magnet and an electromagnetic coil and the vehicle inlet comprises an electromagnetic coil.
The method further includes stopping the electromagnetic fields if a user turns ON the vehicle during a fast-charging mode. The method includes sensing the ON state of the vehicle by the vehicle control unit (VCU), sending a signal to an external power source to discontinue the charging of the electric charge storing units of the vehicle by the vehicle control unit (VCU), sending a control signal to stop the current flow to the electromagnetic coil by the vehicle control unit (VCU), de energizing the electromagnetic coil and disconnecting the charging gun from the vehicle inlet. The method further includes controlling flow of current through the electromagnetic coil by the one or more current modulating units. The one or more current modulating units are connected to at least one of the charging gun and the vehicle inlet.
The method further includes providing a source of power supply to the electromagnetic coil of the vehicle inlet, from the external power supply during the vehicle charging, thereby enabling fast charging of the electric charge storing units of the vehicle.
In yet another embodiment, a charging gun for electric charging one or more electric charge storing units includes one or more terminals and at least one of a metallic element, a magnet and an electromagnetic coil. The charging gun is adapted to magnetically attach to a vehicle inlet with a predefined force during the electric charging of the one or more electric charge storing units.
The charging gun further includes one or more current modulating units for controlling flow of current through the electromagnetic coil. The electromagnetic coil is laid around the circumference of the charging gun. The charging gun is magnetically attached to the vehicle inlet with a predefined force of attraction. The predefined force of attraction is higher than a force required to keep the charging gun and the vehicle inlet operatively connected while the electric charging of the one or more electric charge storing units is in progress, and lower than a force at which the charging gun and/or vehicle inlet gets damaged.
In yet another embodiment, a vehicle inlet for electric charging one or more electric charge storing units includes one or more terminals and at least one of a metallic element, a magnet and an electromagnetic coil. The vehicle inlet is adapted to magnetically attach to a charging gun with a predefined force during the electric charging of the one or more electric charge storing units. The vehicle inlet further includes one or more current modulating units for controlling flow of current through the electromagnetic coil. The electromagnetic coil is laid around the circumference of the vehicle inlet.
The vehicle inlet is adapted to magnetically attach to the charging gun with a predefined force of attraction. The predefined force of attraction is higher than a force required to keep the charging gun and the vehicle inlet operatively connected while the charging of the one or more electric charge storing units is in progress, and lower than a force at which the vehicle inlet and/or the charging gun gets damaged.
The vehicle inlet is provided with a control unit adapted for sending a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil upon receipt of an input from a user, thereby enabling the user to detach the charging gun from the vehicle inlet while the fast-charging mode is in progress.
Further, the vehicle inlet is provided with a control unit adapted to send a control signal to one or more current modulating units for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units is fully charged, thereby enabling the user to detach the charging gun from the vehicle inlet.
Embodiments herein also provide a magnetic locking system for electric charging. The magnetic locking system comprises the first unit connected to a power source. The first unit comprises at least one of a metallic element, a magnet, and a first electromagnetic coil. The magnetic locking system further comprises a second unit connected to one or more electric charge storing units. The second unit comprises one or more proximity detection elements and a second electromagnetic coil. The second electromagnetic coil is energized from the one or more electric charge storing units upon determining presence of the first unit in vicinity of the second unit by the one or more proximity detection elements. The magnetic locking system further comprises a switching unit to switch a source for energizing the second electromagnetic coil when the first unit is mated with the second unit.
In one aspect, the first unit is magnetically locked with the second unit after the first unit is mated with the second unit.
In one aspect, the one or more proximity detection elements include a transmitter for transmitting a signal to the first unit and a receiver for receiving a reflection of the signal for detecting the first unit.
In one aspect, the first unit comprises a transmitter for transmitting a signal to the second unit and the one or more proximity detection elements present in the second unit include a receiver for receiving the signal for detecting the first unit.
In one aspect, the one or more proximity detection elements are Infrared based, radio-frequency based or ultrasonic based.
In one aspect, the one or more of the first electromagnetic coil and the second electromagnetic coil generates an electromagnetic force to assist in guiding the first unit towards the second unit for the magnetic locking of the first unit and the second unit when presence of the first unit in vicinity of the second unit is determined.
In one aspect, the switching unit switches the source for energizing the second electromagnetic coil from the one or more electric charge storing units to the power source.
In one aspect, the switching unit comprises a power multiplexer.
In one aspect, the magnetic locking of the second unit with the first unit causes charging of the one or more electric charge storing units by the power source.
In one aspect, the first electromagnetic coil is laid around a circumference of the first unit and the second electromagnetic coil is laid around a circumference of the second unit.
In one aspect, one or more current modulators are connected with at least one of the first unit and the second unit for controlling current flow through one or more of the first electromagnetic coil and the second electromagnetic coil.
In one aspect, the one or more electric charge storing units are charged in one of a fast-charging mode and a slow-charging mode.
In one aspect, a control unit is adapted to send a control signal to one or more current modulators for stopping current flow through one or more of the first electromagnetic coil and the second electromagnetic coil upon receiving an input from a user, thereby enabling the user to detach the first unit from the second unit while the charging of the one or more electric charge storing units is in progress in the fast-charging mode.
In one aspect, a control unit is adapted to send a control signal to one or more current modulators for stopping current flow through one or more of the first electromagnetic coil and the second electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the first unit from the second unit.
In one aspect, the first unit is a charging gun and the second unit is a vehicle inlet present on an Electric Vehicle (EV).
In one embodiment, a method of magnetic locking is described. The method comprises determining, by one or more proximity detection elements present in a second unit, presence of a first unit connected with a power source in vicinity of the second unit. The method further comprises energizing, by one or more electric charge storing units connected with the second unit, a second electromagnetic coil present in the second unit upon determining the presence of the first unit in vicinity of the second unit. The method further comprises switching, by a switching unit, a source for energizing the second electromagnetic coil when mating of the first unit with the second unit is detected.
In one aspect, the first unit is magnetically locked with the second unit after the first unit is mated with the second unit.
In one aspect, the one or more proximity detection elements include a transmitter for transmitting a signal to the first unit and a receiver for receiving a reflection of the signal for detecting the first unit.
In one aspect, the first unit comprises a transmitter for transmitting a signal to the second unit and the one or more proximity detection elements present in the second unit include a receiver for receiving the signal for detecting the first unit.
In one aspect, the one or more proximity detection elements are Infrared based, radio-frequency based or ultrasonic based.
In one aspect, one or more of the first electromagnetic coil present in the first unit and the second electromagnetic coil present in the second unit generates an electromagnetic force to assist in guiding the first unit towards the second unit for the magnetic locking of the first unit and the second unit when presence of the first unit in vicinity of the second unit is determined.
In one aspect, the switching unit switches the source for energizing the second electromagnetic coil from the one or more electric charge storing units to the power source.
In one aspect, the magnetic locking of the second unit with the first unit causes charging of the one or more electric charge storing units by the power source.
In one aspect, the second electromagnetic coil is de-energized for detaching the first unit from the second unit when the one or more electric charge storing units are completely charged.
In one aspect, current flow through the one or more of the first electromagnetic coil and the second electromagnetic coil is controlled by the one or more current modulators connected with at least one of the first unit and the second unit.
In one aspect, the first unit is a charging gun and the second unit is a vehicle inlet present on an Electric Vehicle (EV).
In one aspect, the second electromagnetic coil is de-energized for detaching the charging gun from the vehicle inlet when a user turns ON the EV.
In one embodiment, a vehicle inlet for charging an Electric Vehicle (EV) is described. The vehicle inlet comprises one or more terminals connected with one or more electric charge storing units present in the EV. The vehicle inlet further comprises a second electromagnetic coil, and one or more proximity detection elements for determining presence of a charging gun in vicinity of the vehicle inlet. The second electromagnetic coil is energized by the one or more electric charge storing units upon determining presence of the charging gun in vicinity of the vehicle inlet. A switching unit switches a source for energizing the second electromagnetic coil when the mating of the charging gun with the vehicle inlet is detected.
In one aspect, the charging gun is magnetically locked with the vehicle inlet after the charging unit is mated with the vehicle inlet.
In one aspect, the second electromagnetic coil generates an electromagnetic force to assist in guiding the charging gun towards the vehicle inlet for the magnetic locking of the charging gun and the vehicle inlet when presence of the charging gun in vicinity of the vehicle inlet is determined.
In one aspect, the second electromagnetic coil is laid around the circumference of the vehicle inlet.
In one aspect, a current modulator controls current flow through the second electromagnetic coil.
In one aspect, a control unit is adapted to send a control signal to the current modulator for stopping the current flow through the second electromagnetic coil upon receiving an input from the user, thereby enabling the user to detach the charging gun from the vehicle inlet while the charging of the one or more electric charge storing units is in progress in a fast-charging mode.
In one aspect, a control unit is adapted to send a control signal to the current modulator for stopping the current flow through the second electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the charging gun from the vehicle inlet.
In one embodiment, a magnetic locking system may comprise a first unit connected to a power source. The first unit comprises a first transceiver and a first electromagnetic coil. The magnetic locking system may further comprise a second unit connected to one or more electric charge storing units. The second unit comprises a second transceiver and a second electromagnetic coil. The magnetic locking system may further comprise an auxiliary power source and a power detector. The power detector may detect a voltage level of the one or more electric charge storing units. When the voltage level is below a threshold value, the auxiliary power source powers the second transceiver to detect presence of the first transceiver in vicinity, and the second transceiver communicates the voltage level to the first transceiver to enable magnetic locking of the first unit with the second unit.
In one aspect, the first transceiver and the second transceiver are Infrared based, ultrasonic based or Radio Frequency based.
In one aspect, the first unit generates an electromagnetic force to assist in guiding the first unit towards the second unit for the magnetic locking of the first unit and the second unit.
In one aspect, the voltage level below a threshold value indicates a deep-discharge state of the one or more electric charge storing units.
In one aspect, the magnetic locking of the second unit with the first unit causes charging of the one or more electric charge storing units by the power source.
In one aspect, the second electromagnetic coil is energized by the power source after the first unit is connected with the second unit.
In one aspect, the first electromagnetic coil is laid around a circumference of the first unit and the second electromagnetic coil is laid around a circumference of the second unit.
In one aspect, one or more current modulators are connected with at least one of the first unit and the second unit for controlling current flow through one or more of the first electromagnetic coil and the second electromagnetic coil.
In one aspect, the one or more electric charge storing units are charged in one of a fast-charging mode and a slow-charging mode.
In one aspect, a control unit is adapted to send a control signal to the one or more current modulators for stopping current flow through one or more of the first electromagnetic coil and the second electromagnetic coil upon receiving an input from a user, thereby enabling the user to detach the first unit from the second unit while the charging of the one or more electric charge storing units is in progress in the fast-charging mode.
In one aspect, the control unit is adapted to send a control signal to the one or more current modulators for stopping current flow through one or more of the first electromagnetic coil and the second electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the first unit from the second unit.
In one aspect, the first unit is a charging gun and the second unit is a vehicle inlet present on an Electric Vehicle (EV).
In one embodiment, a method of magnetic locking comprises determining, by a power detector, a voltage level of one or more electric charge storing units connected to a second unit. The method further comprises determining, by a second transceiver present in the second unit, presence of a first transceiver of a first unit in vicinity. The method further comprises communicating, by the second transceiver, the voltage level of the one or more electric charge storing units (i.e. battery) to the first transceiver present on the first unit. The method further comprises energizing, by a power source connected with the first unit, a first electromagnetic coil of the first unit to enable magnetic locking of the first unit with the second unit.
In one aspect, the power source connected to the first unit generates an electromagnetic force to assist in guiding the first unit towards the second unit for the magnetic locking of the first unit and the second unit.
In one aspect, the voltage level below a threshold value indicates a deep-discharge state of the one or more electric charge storing units.
In one aspect, the magnetic locking of the second unit with the first unit causes charging of the one or more electric charge storing units of the second unit by the power source.
In one aspect, one or more current modulators connected with at least one of the first unit and the second unit may control current flow through one or more of the first electromagnetic coil and the second electromagnetic coil.
In one aspect, the second electromagnetic coil may be de-energized for detaching the first unit from the second unit when the one or more electric charge storing units are completely charged.
In one aspect, the first unit is a charging gun and the second unit is a vehicle inlet present on an Electric Vehicle (EV).
In one aspect, the second electromagnetic coil is de-energized for detaching the charging gun from the vehicle inlet when the user turns ON the EV.
In one embodiment, a charging gun for an Electric Vehicle (EV) comprises one or more terminals, a first transceiver, and a first electromagnetic coil. The first electromagnetic coil is energized to produce a magnetic field sufficient for magnetic locking of the charging gun with a vehicle inlet for charging one or more electric charge storing units present in the EV by a power source powering the charging gun. The first electromagnetic coil is energized to produce sufficient magnetic force based on receipt of, by the first transceiver from the second transceiver present in the vehicle inlet, a voltage level of the one or more electric charge storing units connected to the vehicle inlet.
In one aspect, the first transceiver and the second transceiver are Infrared based, ultrasonic based or Radio Frequency based.
In one aspect, the first electromagnetic coil is laid around the circumference of the charging gun.
In one aspect, a current modulator controls current flow through the first electromagnetic coil.
In one aspect, a control unit is adapted to send a control signal to the current modulator for stopping the current flow through the first electromagnetic coil upon receiving an input from a user, thereby enabling the user to safely detach the charging gun from the vehicle inlet while the charging of the one or more electric charge storing units is in progress in the fast-charging mode.
In one aspect, the control unit is adapted to send a control signal to the current modulator for stopping the current flow through the first electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the charging gun from the vehicle inlet.
In one embodiment, a vehicle inlet for electric charging of an EV comprises one or more terminals connected with one or more electric charge storing units present in the EV, a second electromagnetic coil, a second transceiver, an auxiliary power source, and a power detector. The power detector detects a voltage level of the one or more electric charge storing units. When the voltage level is below a threshold value, the auxiliary power source powers the second transceiver to detect presence of a first transceiver of a charging gun in vicinity, and the second transceiver transmits, to the first transceiver, the voltage level to enable magnetic locking of the charging gun with the vehicle inlet.
In one aspect, the first transceiver and the second transceiver are Infrared based, ultrasonic based or Radio Frequency based.
In one aspect, the magnetic locking of the charging gun with the vehicle inlet causes charging of the one or more electric charge storing units by a power source powering the charging gun.
In one aspect, the second electromagnetic coil is laid around the circumference of the vehicle inlet.
In one aspect, a current modulator controls current flow through the second electromagnetic coil.
In one aspect, a vehicle control unit is adapted to send a control signal to the current modulator for stopping the current flow through the second electromagnetic coil upon receiving an input from a user, thereby enabling the user to detach the charging gun from the vehicle inlet while the charging of the one or more electric charge storing units is in progress in the fast-charging mode.
In one aspect, the control unit is adapted to send a control signal to the current modulator for stopping the current flow through the second electromagnetic coil when the one or more electric charge storing units are fully charged, thereby enabling the user to detach the charging gun from the vehicle inlet.
These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The example embodiments herein will be better understood from the following description with reference to the drawings, in which:
Figure 1 illustrates a system for providing a magnetic locking during electric charging of one or more electric charge storing units, in accordance with an embodiment of the present invention.
Figure 2a illustrates an exemplary model of a charging gun for charging an electric vehicle, in accordance with an embodiment of the present invention.
Figure 2b illustrates a schematic diagram of an electric vehicle inlet for charging an electric vehicle, in accordance with an embodiment of the present invention.
Figure 2c illustrates a schematic diagram of a charging gun for charging an electric vehicle, in accordance with an embodiment of the present invention.
Figure 3 illustrates an energy refilling system for charging an electric vehicle, in accordance with an embodiment of the present invention.
Figure 4 illustrates a flow chart showing a method of charging an electric vehicle, in accordance with an embodiment of the present invention.
Figure 5 illustrates a flow chart showing a method for providing a magnetic locking between a charging gun and a vehicle inlet during electric charging of a vehicle, in accordance with an embodiment of the present invention.
Figure 6 illustrates a flow chart showing stopping of the electromagnetic fields in case a user turns ON the vehicle during a fast-charging mode of the electric vehicle, in accordance with an embodiment of the present invention.
Figure 7 illustrates an energy refilling system for charging an electric vehicle in which the vehicle inlet includes an electromagnetic coil and the charging gun includes a metallic element or a magnet, in accordance with an embodiment of the present invention.
Figure 8 illustrates an energy refilling system for charging an electric vehicle in which the charging gun and the vehicle inlet include electromagnetic coils, in accordance with an embodiment of the present invention.
Figure 9 illustrates an energy refilling system for charging an electric vehicle in which the vehicle inlet includes a metallic element or a magnet and the charging gun includes an electromagnetic coil, in accordance with an embodiment of the present invention.
Figure 10 illustrates an energy refilling system for charging a high-power system in which the connector 1 includes an electromagnetic coil and the connector 2 includes a metallic element or a magnet, in accordance with an embodiment of the present invention.
Figure 11 illustrates an energy refilling system for charging a high-power system in which the connector 1 and the connector 2 include electromagnetic coils, in accordance with an embodiment of the present invention.
Figure 12 illustrates an energy refilling system for charging a high-power system in which the connector 1 includes a metallic element or a magnet and the connector 2 includes an electromagnetic coil, in accordance with an embodiment of the present invention.
Figure 13a illustrates a magnetic locking system for power transfer between two units, in accordance with an embodiment of the present invention.
Figure 13b illustrates a magnetic locking system for power transfer between two units, in accordance with another embodiment of the present invention.
Figures 14a and 14b cumulatively illustrate a flow chart showing a method of charging by utilizing a magnetic locking system, in accordance with an embodiment of the present invention.
Figure 15 illustrates a magnetic locking system for power transfer between two units during deep-discharge of a battery, in accordance with another embodiment of the present invention.
Figures 16a, 16b, and 16c cumulatively illustrate a flow chart showing a method of charging by utilizing a magnetic locking system during deep-discharge of a battery, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as not to unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “retaining”, “connecting”, “charging”, “latching”, “transmitting”, "enabling”, "establishing", “attaching” and other forms thereof, are intended to be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. The terms “comprises,” “comprising,” “has,” “having,” “includes” and/or “including” as used herein, specify the presence of stated features, elements, and/or components and the like, but do not preclude the presence or addition of one or more other features, elements, components and/or combinations thereof. The term “an embodiment” is to be read as “at least one embodiment.” The term “another embodiment” is to be read as “at least one other embodiment.” Although any system and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary system and methods are now described.
The disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms. Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments described but is to be accorded the widest scope consistent with the principles and features described herein.
There is a need for an electric charging system that addresses the problem of accidental disconnection and the associated physical damage to the charging gun and/or the vehicle inlet socket and arcing related danger due to accidental disconnection during fast charging especially in DC charging stations.
Figure 1 illustrates a system for providing a magnetic locking during electric charging of one or more electric charge storing units 108 in accordance with an embodiment of the present invention. The system includes a first unit 104 and a second unit 106. The first unit 104 may be connected to a power source 102. The first unit 104 may include at least one of a metallic element, a magnet and an electromagnetic coil. The second unit 106 may be operatively connected to the first unit 104 for allowing flow of electric charge to one or more electric charge storing units 108. The second unit 106 includes an electromagnetic coil.
In an alternative embodiment, the first unit 104 may include an electromagnetic coil and a second unit 106 operatively connected to the first unit 104 for allowing a flow of electric charge to one or more electric charge storing units 108. The second unit 106 may include at least one of a metallic element, a magnet and an electromagnetic coil.
The second unit 106 may be adapted to magnetically attach to the first unit 104 with a predefined force during the electric charging of the one or more electric charge storing units 108. Further, the system includes one or more current modulating units 112 connected with at least one of the first unit 104 and the second unit 106 for controlling a flow of current through the electromagnetic coil. The first unit 104 may be magnetically attached to the second unit 106 with a predefined force of attraction. The predefined force of attraction is higher than a force required to keep the first unit 104 and the second unit 106 operatively connected while the charging is in progress and lower than a force at which the first unit 104 and/or the second unit 106 gets damaged. The electromagnetic coil is laid around the circumference of at least one of the first unit 104 and the second unit 106. The first unit 104 and the second unit 106 include one or more terminals. The one or more electric charging stages include one of a fast-charging mode and a slow-charging mode.
A control unit 110 is adapted to send a control signal to one or more current modulating units 112 for stopping the current flow through the electromagnetic coil upon receipt of an input from a user, thereby enabling the user to detach the first unit 104 from the second unit 106 while the fast-charging mode is in progress. A control unit 110 is adapted to send a control signal to one or more current modulating units 112 for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units 108 is fully charged, thereby enabling the user to detach the first unit 104 from the second unit 106.
The term “electric charge storing units” refers to “batteries” or “power system” for storing electric charge in electric vehicles or high-power systems and can be used interchangeably.
It may be noted that the terms such as terminals, pins, connectors, and receptacles may be referred to as synonyms to each other and are represented as well understood concepts or the conventional terminologies used in the present art of the invention. It may further be noted that the interchangeable use of the terms does not limit the scope of the present invention in any way. In one embodiment, the term “terminals” refers to pins that are used to establish a plurality of connections with either the charging gun or the electric vehicle inlet when the pins act as a male connector. In another embodiment, the term “terminals” refers to connector pins that are the receiving terminals of either the charging gun or electric vehicle inlet that act as a female connector. In yet another embodiment, the terms ‘set of communication terminals’, ‘set of charging terminals’, and ‘set of proximity terminals’ refers to one or more corresponding terminals.
Figure 2a illustrates an exemplary model of a charging gun 200 for charging an electric vehicle, in accordance with an embodiment of the present invention.
The term “charging gun” refers to a “connector” for charging an electric vehicle or a high-power system using an external power supply/charger and can be used interchangeably. Specifically, the charging gun includes a plug at one end that connects the external power supply or a charger.
The charging gun includes a plurality of terminals at the other end to connect with the electric vehicle inlet terminals for transferring power safely to a battery of the electric vehicle. The charging gun may be implemented either as a female or as male connector.
The term ‘electric vehicle inlet/ vehicle inlet’ refers to a ‘power inlet’ or ‘socket’ provided in the electric vehicle for receiving power from the electric power supply via the charging gun or a connector. The electric vehicle inlet may be implemented either as a male connector or as a female connector for receiving the power.
As illustrated in Figure 2a, the charging gun 200 includes a housing 202. Further, the housing 202 includes a plurality of terminals 204, 206a, 206b, 208, 210 to establish a plurality of connections with an electric vehicle inlet. The plurality of terminals 204, 206a, 206b, 208, 210 of the charging gun 200 may be provided either as male connectors or as female connectors.
As illustrated in Figure 2b, the electric vehicle inlet may be provided as a female connector and the charging gun 200 may be provided as a male connector. Alternatively, in another embodiment, the electric vehicle inlet may be provided as a male connector and the charging gun 200 may be provided as a female connector. Therefore, when the plurality of terminals 204, 206a, 206b, 208, 210 of the charging gun 200 are male connectors, a plurality of terminals of a casing of the electric vehicle inlet may be provided as female connectors. In some embodiments, the electric vehicle inlet may be provided as a male connector having a plurality of terminals 204, 206a, 206b, 208, 210 whereas the charging gun 200 may be provided as a female connector having a plurality of terminals 204, 206a, 206b, 208, 210.
The plurality of terminals 206a, 206b, 204, 208, 210 for charging the electric vehicle are accommodated in the housing 202. Further, a set of temperature sensors 220 are provided in the housing 202 to monitor the temperature of the plurality of terminals 204, 206a, 206b, 208, 210. In case, the temperature of the housing 202 exceeds a threshold, the set of temperature sensors 220 notify a Vehicle Control Unit (VCU) to stop the charging of the battery. The set of temperature sensors 220 may include but not limited to thermocouples, resistance temperature detectors (RTDs), Negative Temperature Coefficient (NTC) thermistors, infrared sensor and semiconductor sensors. The temperature sensor 220 may be positioned inside the charging gun 200.
The vehicle inlet in the present embodiment includes at least one of a metallic element, a magnet and an electromagnetic coil. Further, the vehicle inlet may be adapted to magnetically attach to a charging gun 200 with a predefined force during the electric charging of the one or more batteries. The vehicle inlet further includes one or more current modulating units 112 for controlling flow of current through the electromagnetic coil. The electromagnetic coil may be laid around the circumference of the vehicle inlet.
Further, the vehicle inlet may be adapted to magnetically attach to the charging gun 200 with a predefined force of attraction. The predefined force of attraction is higher than a force required to keep the charging gun 200 and the vehicle inlet operatively connected while the charging of the one or more batteries is in progress, and lower than a force at which the vehicle inlet and/or the charging gun 200 gets damaged.
Further, a control unit 110 may be provided to send a control signal to one or more current modulating units 112 for stopping the current flow through the electromagnetic coil upon receipt of an input from a user, thereby enabling the user to detach the charging gun 200 from the vehicle inlet while the fast-charging mode is in progress.
Additionally, a control unit 110 is adapted to send a control signal to one or more current modulating units 112 for stopping the current flow through the electromagnetic coil when the one or more electric charge storing units is fully charged, thereby enabling the user to detach the charging gun 200 from the vehicle inlet.
Figure 2c illustrates a schematic diagram of a charging gun 200 for charging an electric vehicle. In accordance with the embodiment, the inside of the housing 202 is provided with the plurality of terminals 204, 206a, 206b, 208, 210 for power transfer from an electric power supply or a charging station to the electric vehicle through an electric vehicle inlet. The electric vehicle inlet is attached to the electric vehicle, whereas the charging gun 200 is portable. The charging gun 200 may be placed within a storage unit of the electric vehicle.
In another embodiment, the charging gun 200 can be attached to the charging station for charging the battery. The electric vehicle inlet is a port or a socket through which electric charge is transferred to the electric vehicle from the charging station.
The plurality of terminals 204, 206a, 206b, 208, 210 comprises an earth terminal 204, a set of communication terminals 208, a set of power terminals 206a, 206b and a set of proximity terminals 210. Initially, the earth terminal 204 may be connected to the electric vehicle inlet. The electric vehicle inlet first establishes contact with the earth terminal 204 to prevent any potential hazards such as electrical hazards due to surge or residual current. The residual current or leakage current detected in the AC supply lines may be diverted to the ground for safe discharge.
The term “Vehicle Control unit (VCU)” refers to a master controller configured for monitoring and regulating the charging operations of the electric vehicle via the electric vehicle inlet. The electric vehicle of the present invention may include but is not limited to hybrid vehicles, plug-in hybrid vehicles, battery driven or electric motor-assisted vehicles and the like.
The term “vehicle control unit” is used in the context of electric vehicle charging and “control unit” is used in the context of charging of high-power systems and can be used interchangeably. It may further be noted that the interchangeable use of the terms does not limit the scope of the present invention in any way.
The term ‘operation’ or ‘charging operation’ or ‘charging process’ refers to the activation of charging of the battery of an electric vehicle. That is, one end of the charging gun is connected to the electric vehicle via the electric vehicle inlet and another end of the charging gun is connected to a charging station or an external power supply. Subsequently, the charging station or the external power supply is triggered to transfer AC or DC power to the electric vehicle.
The term ‘external power supply’ or ‘power supply’ or ‘power source’ refers to a charging station or charger that can supply either Direct Current (DC) supply or Alternating Current (AC) supply and can be used interchangeably.
Figure 3 illustrates an energy refilling system 300 for charging an electric vehicle 304 according to an embodiment. The energy refilling system 300 for charging an electric vehicle 304 includes a charging gun 200 and a vehicle inlet 306. The charging gun 200 may be connected to an external power supply 302.The charging gun 200 includes at least one of a metallic element, a magnet and an electromagnetic coil. The vehicle inlet 306 may be operatively connected to the charging gun 200 for allowing a flow of electric charge to one or more batteries 308 of the vehicle. Further, the vehicle inlet 306 includes an electromagnetic coil. The vehicle inlet 306 may be adapted to magnetically attach to the charging gun 200 with a predefined force during the electric charging of the one or more batteries 308.
In an alternative embodiment, the charging gun 200 includes an electromagnetic coil and the vehicle inlet 306 comprises at least one of a metallic element, a magnet and an electromagnetic coil.
Further, a vehicle control unit (VCU) 310 is adapted to shift a power supply source of the electromagnetic coil of the vehicle inlet 306 from the batteries 308 of the vehicle to the external power supply 302 during the electric charging of batteries 308. Additionally, a vehicle control unit (VCU) 310 is adapted to send a control signal to one or more current modulating units 112 for stopping the current flow through the electromagnetic coil when the one or more batteries 308 is fully charged, thereby enabling a user to detach the charging gun 200 from the vehicle inlet 306.
Additionally, a vehicle control unit (VCU) 310 is adapted to send a control signal to one or more current modulating units 112 for stopping the current flow through the electromagnetic coil upon receipt of an input from the user by way of turning ON the vehicle, thereby enabling the user to detach the charging gun 200 from the vehicle inlet 306 while the fast-charging mode is in progress.
Figure 4 illustrates a flowchart showing a method of charging of the electric vehicle in accordance with an embodiment of the present invention. Step 402 depicts the connection of charging gun 200 to the vehicle inlet 306. When the charging gun 200 is not connected to the vehicle inlet 306 in step 402, the method proceeds to step 404 via “No”. In step 404, the electromagnet control circuit draws battery power to excite the electromagnetic coil. Further, the method loops back to step 402. In case, the charging gun 200 is connected to the vehicle inlet 306 in step 402, the method proceeds to step 406 via “Yes”. In step 406, the electromagnet control circuit draws AC power through the charging gun 200 to excite the electromagnetic coil.
At step 408, the VCU determines the current flow through the electromagnetic coil based on the vehicle state (ON/OFF) and the charging stage (fast/slow charging). In step 410, the VCU controls the current flow through the electromagnetic coil based on the determined current flow using the electromagnet control circuit. In step 412, the current flow through the electromagnetic coil generates a predefined magnetic force required for the determined vehicle state.
After the step 412, in case an error is detected during the charging of the electric vehicle such as over temperature, over voltage or accidental disconnection of the gun etc., the method proceeds to step 414, in which the VCU stops current through the electromagnetic coil.

After the step 412, in case, the charging of the electric vehicle is completed, the method proceeds to step 416, in which the VCU stops current through the electromagnetic coil so that the charging gun 200 can be removed from the vehicle inlet 306 easily.
After the step 412, in case of any user intervention during the fast or slow charging of the electric vehicle, the method proceeds to step 418. In step 418, the charging gun 200 may be locked to the vehicle inlet 306 with a greater force during fast charging. Further, the VCU stops current through the electromagnetic coil if the user turns the vehicle ‘ON’ or gives any input to stop the charging. Further, in step 418, the charging gun 200 may be locked with a lesser force during slow charging thus giving the user indication in the course of disconnection. The VCU detects disconnection of the charging gun 200 by the user and stops current through the electromagnetic coil so that the charging gun 200 can be removed from the vehicle inlet 306 easily.
Figure 5 illustrates a flowchart showing a method for providing a magnetic locking between a charging gun 200 and a vehicle inlet 306 during electric charging of a vehicle in accordance with an embodiment. The method that is illustrated in Figure 5, as a collection of operations in a logical flow graph representing a sequence of operations that can be implemented in hardware, software, firmware or a combination thereof.
At step 502, an electromagnetic field is generated around the electromagnetic coil. At step 504, the charging gun 200 is aligned with the vehicle inlet 306. The method further includes providing automatic guiding of a charging gun 200 with a vehicle inlet 306 by the electromagnetic fields. The charging gun 200 includes at least one of an electromagnetic coil and the vehicle inlet 306 comprises at least one of a metallic element and a magnet. In an alternative embodiment, automatic guiding of a charging gun 200 with a vehicle inlet 306 by the electromagnetic fields may be achieved, if the charging gun 200 comprises at least one of a metallic element, a magnet or an electromagnetic coil and the vehicle inlet 306 comprises an electromagnetic coil.
Further, at step 506, the charging gun 200 is magnetically locked with the vehicle inlet 306 with a predefined force. The predefined force is established by the generated electromagnetic fields. The method further includes providing automatic guiding of a charging gun 200 with a vehicle inlet 306 by the electromagnetic fields, when the vehicle batteries 308 retain electric charge.
Figure 6 illustrates a flowchart showing stopping of the electromagnetic fields if a user turns ‘ON’ the vehicle during a fast-charging mode. The method that is illustrated in Figure 6, as a collection of operations in a logical flow graph representing a sequence of operations that can be implemented in hardware, software, firmware, or a combination thereof.
At step 602, the vehicle control unit (VCU) 310, senses the ‘ON’ state of the vehicle. At step 604, the VCU sends a signal to an external power source 302 to discontinue the charging of the batteries 308 of the vehicle after detecting the ‘ON’ state of the vehicle.
Further, at step 606, the vehicle control unit (VCU) 310 sends a control signal to stop the current flow to the electromagnetic coil. At step 608, the electromagnetic coil will be deenergized. Further, at step 610, the charging gun 200 may be disconnected from the vehicle inlet 306.
In yet another implementation of energy refilling system for charging the electric vehicle as illustrated in Figure 7, the vehicle inlet 306 includes an electromagnetic coil 702 and the charging gun 200 includes a metallic element or a magnet 704. When the C+ terminals of the charging gun 200 and the vehicle inlet 306 are connected, the vehicle inlet 306 shifts its source of power and starts receiving power from the charging gun 200. A power MUX circuit present inside the Electromagnet Control Circuit continuously monitors Input 1 (i.e., C+ terminal) as shown in Fig. 7. Further, the power MUX circuit preferentially facilitates in exciting the vehicle inlet coil 702 using the power from the external power supply in a case when the charging gun 200 is mated with the terminals of the vehicle inlet 306. However, in a scenario when power from the Input 1 is absent or, in other words, when the charging gun 200 is not mated with the vehicle inlet 306, the power MUX usually excites the vehicle inlet coil 702 using the power from the battery that is from Input 2 as shown in Fig. 7. The vehicle inlet coil 702 continuously remain excited using the power from the battery unless the charging gun 200 is mated with the vehicle inlet 306.
In yet another implementation, a magnet may be provided on the charging gun side and a metallic core may be provided on the vehicle inlet 306. In case the vehicle battery 308 is completely discharged, the only force of attraction that exists is the one between a magnet on the charging gun side and the metallic core of the vehicle inlet 306. This force of attraction may not be sufficient to facilitate the automatic guiding process. In the present embodiment, guiding may not happen since the vehicle inlet 306 coil will not be excited due to the completely discharged state of the vehicle battery 308.
In yet another implementation of the energy refilling system for charging an electric vehicle as illustrated in Figure 8, both the vehicle inlet 306 and the charging gun 200 include electromagnetic coils 702. In this implementation, the VCU sends the current modulating instruction via Controller Area Network (CAN) to the charging station. The charging station in turn controls the current through the electromagnetic coil 702 of the charging gun 200 via the current modulating unit.
Further, prior to the connection of vehicle inlet 306 and charging gun 200 and establishment of the CAN communication, the charging station will establish a continuous magnetic field through the charging gun 200 coil using current from the charging station. This magnetic field is sufficient for facilitating guiding of the charging gun 200 towards the vehicle inlet 306 during the connection process. On the vehicle inlet side, the vehicle battery 308 is charged and excites the electromagnetic coil 702 provided in the vehicle inlet 306, for producing an electromagnetic field.
Further, in case the vehicle battery 308 is completely discharged, the only force of attraction is the one in between the electromagnetic coil 702 on the charging gun side and the metallic core of the vehicle inlet 306, which may not be sufficient to facilitate in the automatic guiding process as a passive magnet or a metal is not present on the vehicle inlet side.
In yet another implementation of energy refilling system for charging the electric vehicle as illustrated in Figure 9, the vehicle inlet 306 includes a metallic element or a magnet 704 and the charging gun 200 includes an electromagnetic coil 702. In the present embodiment, power saving of the vehicle battery 308 is not a concern since there is no electromagnetic coil 702 to be powered on the vehicle inlet side. The metallic element or magnet included on the vehicle inlet side is not consuming any power from the battery 308. Consequently, a power MUX circuit is not required on the vehicle inlet side.
In the present implementation, a continuous magnetic field is established in the electromagnetic coil 702 of the charging gun 200 using current from the charging station, even before the vehicle inlet 306 and the charging gun 200 are connected to each other. This magnetic field is sufficient for automatic guiding of the charging gun 200 towards the vehicle inlet 306. In the present implementation, automatic guiding is always possible as there is no electromagnetic coil 702 on the vehicle inlet side, thereby obtaining the magnetic force by the vehicle inlet 306 independent of the battery charge.
Further, once the charging gun 200 is connected to the vehicle inlet 306, the VCU sends current modulating instruction via CAN to the external charging station. Subsequently, the charging station controls the current through the electromagnetic coil 702 via the current modulating unit.
In yet another implementation of the energy refilling system for charging the high-power system as illustrated in Figure 10, the connector 1 (1002) includes an electromagnetic coil 702 and the connector 2 (1004) includes a metallic element or a magnet 704. When the C+ terminals of the connector 2 (1004) and the connector 1 (1002) are connected, the connector 1 (1002) shifts its source of power and starts receiving power from the connector 2 (1004). A power MUX circuit present inside the Electromagnet Control Circuit continuously monitors Input 1 (i.e., C+ terminal) as shown in Fig. 10 Further, the power MUX circuit preferentially facilitates in exciting the vehicle inlet coil 702 using the power from the external power supply in a case when the connector 2 (1004) is mated with the terminals of the connector 1 (1002). However, in a scenario when power from the Input 1 is absent or, in other words, when the connector 2 (1004) is not mated with the connector 1 (1002), the power MUX usually excites the vehicle inlet coil 702 using the power from the battery that is from Input 2 as shown in Fig. 10. The vehicle inlet coil 702 continuously remains excited using the power from the battery unless the connector 2 (1004) is mated with the connector 1 (1002).
In yet another implementation, a magnet may be provided on the connector 2 side and a metallic core may be provided on the connector 1 side. In case the power system is completely discharged, the only force of attraction that exists is the one between a magnet on the connector 2 side and the metallic core of the connector 1 (1002). However, this force of attraction may not be sufficient in facilitating the automatic guiding process. In the present embodiment, the guiding may not happen as the connector 1 (1002) coil will not be excited due to the completely discharged state of the power system.
In another implementation of an energy refilling system for charging the high-power system as illustrated in Figure 11, both the connector 1 (1002) and the connector 2 (1004) include electromagnetic coil 702. In this implementation, the control unit 110 sends the current modulating instruction via CAN to the external power system. The external power system in turn controls the current through the electromagnetic coil 702 of the connector 2 (1004) via the current modulating unit.
Further, prior to the connection of connector 1 (1002) and connector 2 (1004) and establishment of the CAN communication, the external power system will establish a continuous magnetic field through the connector 2 (1004) coil using current from the external power system. This magnetic field is sufficient for facilitating the guiding of the connector 2 (1004) towards the connector 1 (1002) during the connection process. On the connector 1 side, the power system is charged and excites the connector 1 (1002) electromagnetic coil 702 for producing an electromagnetic field.
Further, in case the power system is completely discharged, the only force of attraction is the one in between the electromagnetic coil 702 on the connector 2 side and the metallic core of the connector 1 (1002), which may not be sufficient to help in the automatic guiding process as a passive magnet or a metal is not present on the connector 1 side.
In yet another implementation of energy refilling system for charging the high-power system as illustrated in Figure 12, the connector 1 (1002) includes a metallic element or a magnet 704 and the connector 2 (1004) includes an electromagnetic coil 702. In the present embodiment, power saving of the power system is not a concern since there is no electromagnetic coil 702 to be powered on the connector 1 side. The metallic element or magnet included on the connector 1 side may not be consuming any power from the power system. Consequently, a power MUX circuit is not required on the connector 1 side.
In the present implementation, a continuous magnetic field is established in the electromagnetic coil 702 of the connector 2 (1004) using current from the external power system, even before the connector 1 (1002) and the connector 2 (1004) are connected to each other. This magnetic field is sufficient for automatic guiding of the connector 2 (1004) towards the connector 1 (1002). In the present implementation, automatic guiding is always possible as there is no electromagnetic coil 702 on the connector 1 side, which makes the magnetic force by the connector 1 (1002) independent of power system charge.
Further, once the connector 2 (1004) is connected to the connector 1 (1002), the control unit 110 sends current modulating instruction via CAN to the external power system. Subsequently, the external power system controls the current through the electromagnetic coil 702 via the current modulating unit.
Figures 13a and 13b illustrate magnetic locking systems 1300a, 1300b for power transfer between two units, in accordance with different embodiments of the present invention. The magnetic locking systems 1300a, 1300b may include a first unit 1302 and a second unit 1304. The first unit 1302 may be connected to a power source 1306, such as a charging station 1306 and may be used for charging or supplying power to the second unit 1304. The second unit 1304 may comprise one or more electric charge storing units 1308, such as a battery 1308 for storing the power received from the first unit 1302. It must be noted that the battery 1308 may be an integral part of the second unit 1304 or may be electrically connected with the second unit 1304. The magnetic locking systems 1300a, 1300b may find use in a variety of areas, such as Electric Vehicles (EVs), high voltage high current connectors used in solar panel applications, and other applications where connectors are required to be connected securely using magnetism for charging of electric charge storing units or batteries 1308 without involvement of physically moving parts. For ease of explanation, the magnetic locking systems 1300a, 1300b have been illustrated and explained by considering their implementation in an EV.
When the magnetic locking systems 1300a, 1300b are implemented in the EV, the first unit 1302 may be a charging gun 1302 and the second unit 1304 may be a vehicle inlet 1304 i.e., a power socket with which the charging gun 1302 would attach magnetically. The charging gun 1302 may be connected with the power source 1306 through a power cable 1310. Further, a metallic element or a magnet 1312 may be laid around a circumference of the charging gun 1302 for magnetic locking with the second unit 1304, as illustrated in Figure 13a. The magnet 1312 may be a permanent magnet for example, a neodymium magnet or any other types of suitable permanent magnet. Alternatively or additionally, a first electromagnetic coil 1314 may be laid around the circumference of the charging gun 1302 for magnetic locking with the second unit 1304, as illustrated in Figure 13b. The first electromagnetic coil 1314 may be a solenoid electromagnet. The charging gun 1302 may further include a plurality of terminals as described above with reference to Figures 2a and 2c.
A second electromagnetic coil 1316 may be laid around a circumference of the vehicle inlet 1304 for magnetic coupling with the charging gun 1302. The second electromagnetic coil 1316 may be a solenoid electromagnet. During usage of the metallic element on the charging gun 1302, an amount of current required to be passed through the second electromagnetic coil 1316 to attract the metallic element would be high as compared to an amount of current required to be passed through the second electromagnetic coil 1316 when the magnet 1312 or the first electromagnetic coil 1314 is used on the charging gun 1302. The vehicle inlet 1304 may further include a plurality of terminals as described above with reference to Figure 2b. The vehicle inlet 1304 may further comprise one or more proximity detection elements for determining presence of the charging gun 1302 in vicinity of the vehicle inlet 1304. The one or more proximity detection elements may be powered using the battery 1308. In one implementation, the one or more proximity detection elements provided on the vehicle inlet 1304 may include a transmitter (not illustrated) and a receiver 1318. The transmitter may transmit a signal to the charging gun 1302 and the receiver 1318 may receive a reflection of the signal to determine the presence of the charging gun 1302 in vicinity. In another implementation, the one or more proximity detection elements provided on the vehicle inlet 1304 may include the receiver 1318 only. A transmitter 1320 corresponding to the receiver 1318 may be provided on the charging gun 1302. The receiver 1318 provided on the vehicle inlet 1304 may receive the signal transmitted by the transmitter 1320 provided on the charging gun 1302 to determine presence of the charging gun 1302 in vicinity. In different implementations, the proximity detection elements, the transmitter 1320 and/or the receiver 1318 may be Infrared based, radio-frequency based, ultrasonic based, capacitance based, or inductance based.
The presence of the charging gun 1302 may be determined by the vehicle inlet 1304 when the charging gun 1302 and the vehicle inlet 1304 are mated together by a user/operator. Upon determining presence of the charging gun 1302, the second electromagnetic coil 1316 of the vehicle inlet 1304 may be energized from the battery 1308. Energization of the second electromagnetic coil 1316 would generate an electromagnetic force for attracting the metallic element or the magnet 1312 provided on the charging gun 1302. The electromagnetic force would guide the charging gun 1302 towards the vehicle inlet 1304, for achieving the magnetic locking between the charging gun 1302 and the vehicle inlet 1304. Further, for generating the electromagnetic force, the second electromagnetic coil 1316 would draw power from the battery 1308 i.e., Input 2 illustrated in Figures 13a and 13b. When the first electromagnetic coil 1314 is present on the charging gun 1302, the first electromagnetic coil 1314 would also generate an electromagnetic force for achieving the magnetic locking between the charging gun 1302 and the vehicle inlet 1304. Further, for generating the electromagnetic force, the first electromagnetic coil 1314 would draw power from the charging station 1306.
When the first electromagnetic coil 1314 and the second electromagnetic coil 1316 are being energized, the charging gun 1302 and the vehicle inlet 1304 are mated together by an operator/user. After the mating of the charging gun 1302 and the vehicle inlet 1304 is completed, availability of Input 1 at C+ terminal of the charging gun 1302 may be determined by a switching unit 1322 present in the magnetic locking systems 1300a, 1300b. Upon identification of availability of the Input 1, the switching unit 1322 may switch power from the battery 1308 to an external power source i.e., the charging station 1306 for energizing the second electromagnetic coil 1316 for magnetic locking. Successively, a control unit, such as a Vehicle Control Unit (VCU) 1330 present in the magnetic locking systems 1300a, 1300b may communicate with the charging station 1306 to determine if the charging station 1306 supports a fast-charging mode or a slow charging mode. Upon determining the charging mode supported by the charging station 1306, the VCU 1330 may send a control signal to control the amount of current flowing through the second electromagnetic coil 1316 to generate a predefined magnetic force required for the magnetic locking.
The switching unit 1322 may include a power multiplexer 1324 and a current modulator 1326. The current modulator 1326 may be a part of the EV or the vehicle inlet 1304. The current modulator 1326 may control an amount of current flowing through the second electromagnetic coil 1316 for managing the amount of electromagnetic force generated by the second electromagnetic coil 1316. Similarly, a current modulator 1328 may be provided in the charging station 1306 also known as an Electric vehicle supply Equipment (EVSE), as illustrated in Figure 13b. In other implementations, the current modulator 1328 may be a part of a housing of the charging gun 1302 or the power cable 1310. The current modulator 1328 may control an amount of current flowing through the first electromagnetic coil 1314 for controlling the amount of electromagnetic force generated by the first electromagnetic coil 1314. The current modulator 1326 and the current modulator 1328 may include various active/passive constant current sources, such as SEPIC converter, Buck converter, transistor based constant current circuits like current mirror circuits, or any other type of suitable current modulator circuits.
Once the magnetic locking of the charging gun 1302 with the vehicle inlet 1304 is established, the battery 1308 may start charging with power derived from the charging station 1306. The battery 1308 may be charged in a fast-charging mode or a slow-charging mode based on the charging mode supported by the charging station 1306.
The VCU 1330 may be also adapted to send a control signal to the current modulator 1326 for stopping current flow through the second electromagnetic coil 1316 upon receiving an input from a user when charging of the battery 1308 is in progress in the fast-charging mode. The input received from the user may correspond to the EV being turned ON. Alternatively, the VCU 1330 may also communicate details of the ON state of the EV to a control unit (not illustrated) provided in the charging station 1306. The VCU 1330 may communicate the details of the ON state of the EV through CAN pins present on the charging gun 1302. Upon receiving the details of the ON state of the EV, the control unit provided in the charging station 1306 may stop current flow through the first electromagnetic coil 1314. Stopping the current flow through the first electromagnetic coil 1314 and/or the second electromagnetic coil 1316 would result in absence of the electromagnetic force and would thus enable the user to detach the charging gun 1302 from the vehicle inlet 1304. In a similar manner, the VCU 1330 may enable the user to detach the charging gun 1302 from the vehicle inlet 1304 when the battery 1308 is fully charged. The switching unit 1322 and the VCU 1330 may be a part of the vehicle inlet 1304 or may be separate elements electrically connected with the vehicle inlet 1304.

Figures 14a and 14b cumulatively illustrate a flow chart showing a method of charging by utilizing a magnetic locking system, in accordance with an embodiment of the present invention. At step 1402, a proximity detection element i.e., a receiver or a pair of transmitter and receiver provided on a vehicle inlet determines presence of a charging gun in proximity of the vehicle inlet. When presence of the charging gun is determined, a VCU sends a control signal to a current modulator for energizing a second electromagnetic coil provided on the vehicle inlet, at step 1404. To energize the second electromagnetic coil, a power multiplexer utilizes an Input 2 i.e., power from the vehicle’s battery, at step 1406. Energization of the second electromagnetic coil generates an electromagnetic force to assist in guiding the charging gun towards the vehicle inlet for magnetic locking of the charging gun and the vehicle inlet.
Thereafter, connection of the charging gun with the vehicle inlet is determined, at step 1408. When connection of the charging gun with the vehicle inlet is not determined, presence of the charging gun in proximity of the vehicle inlet is determined, at step 1402. Alternatively, when connection of the charging gun with the vehicle inlet is determined, the power multiplexer switches from the Input 2 to an Input 1 i.e., power obtained from the charging gun for energizing the second electromagnetic coil for magnetic locking, at step 1410. Further, the vehicle’s battery is charged using the power obtained from the charging gun.
Successively, the VCU determines an amount of current required to be passed through the second electromagnetic coil based on vehicle state i.e., ON/OFF state and/or a charging mode i.e., fast-charging mode or slow-charging mode, at step 1412. Based on the vehicle state and/or the charging mode determined at step 1412, the VCU sends a control signal to the current modulator for controlling the amount of current required to be passed through the second electromagnetic coil, at step 1414. Using the current provided by the current modulator, the second electromagnetic coil generates a magnetic field required for magnetic locking of the charging gun and the vehicle inlet, at step 1416.
When charging of the vehicle’s battery is in progress and an error occurs, the VCU stops flow of current through the second electromagnetic coil, at step 1418. The error may be anyone from the following, such as over-voltage, over-temperature, and unintentional disconnection of the charging gun. When charging of the vehicle’s battery gets completed, the VCU stops flow of current through the second electromagnetic coil, at step 1420. When charging of the vehicle’s battery is in progress in a slow-charging mode or a fast-charging mode, and an error or a user intervention is detected, the VCU stops flow of current through the second electromagnetic coil, at step 1422. It must be noted that the VCU stops flow of current through the second electromagnetic coil by operating the current modulator. Stopping the flow of current through the second electromagnetic coil would result in absence of the electromagnetic force present earlier. Further, the VCU may also communicate details of the error or the user intervention to a charging station through CAN pins present on the vehicle inlet and the charging gun. Upon receipt of the details of the error or the user intervention by the charging station, a control unit present in the charging station stops flow of current through a first electromagnetic coil present in the charging gun. Stopping the flow of current through the first electromagnetic coil would result in absence of the electromagnetic force present earlier. By stopping the flow of current through the first electromagnetic coil and/or the second electromagnetic coil, a user may be enabled to safely detach the charging gun from the vehicle inlet.
Figure 15 illustrates a magnetic locking system 1500 for power transfer between two units during deep-discharge state of a battery, in accordance with different embodiments of the present invention. The magnetic locking system 1500 may include a first unit 1502 and a second unit 1504. The first unit 1502 may be connected to a power source 1506, such as a charging station 1506 and may be used for charging or supplying power to the second unit 1504. The second unit 1504 may comprise one or more electric charge storing units 1508, such as a battery 1508 for storing the power received from the first unit 1502. It must be noted that the battery 1508 may be an integral part of the second unit 1504 or may be electrically connected with the second unit 1504. The magnetic locking system 1500 may find use in a variety of areas, such as Electric Vehicles (EVs), high voltage high current connectors used in solar panel applications, and other applications where connectors are required to be connected securely using magnetism for charging of electric charge storing units without involvement of physically moving parts. For ease of explanation, the magnetic locking system 1500 has been illustrated and explained by considering its implementation in an EV.
When the magnetic locking system 1500 is implemented in the EV, the first unit 1302 may be a charging gun 1502 and the second unit 1504 may be a vehicle inlet 1504 i.e., a power socket with which the charging gun 1502 would attach magnetically. The charging gun 1502 may be connected with the power source 1506 through a power cable 1510. Further, a first electromagnetic coil 1512 may be laid around the circumference of the charging gun 1502 for magnetic locking with the vehicle inlet 1504. The first electromagnetic coil 1512 may be a solenoid electromagnet. The charging gun 1502 may further include a plurality of terminals as described above with reference to Figures 2a and 2c.
A second electromagnetic coil 1514 may be laid around a circumference of the vehicle inlet 1504 for magnetic coupling with the charging gun 1502. The second electromagnetic coil 1514 may be a solenoid electromagnet. The vehicle inlet 1504 may further include a plurality of terminals as described above with reference to Figure 2b.
In one implementation, the charging gun 1502 may comprise a first transceiver 1516, and the vehicle inlet 1504 may comprise a second transceiver 1518. The first transceiver 1516 may be powered by the charging station 1506 and the second transceiver 1518 may be powered by the battery 1508. The first transceiver 1516 may transmit a signal to the second transceiver 1518 to indicate its presence. Upon receiving the signal, the vehicle inlet 1504 may determine presence of the charging gun 1502 in vicinity. In different implementations, the first transceiver 1516 and the second transceiver 1518 may be Infrared based, radio-frequency based or ultrasonic based. The vehicle inlet 1504 may further include a power detector 1520 for detecting a voltage level of the battery 1508. The second transceiver 1518 may be powered by the battery 1508 when it is determined that the voltage level of the battery 1508 is present above a threshold value indicating that the battery 1508 is not present in a deep-discharge state.
Upon determining presence of the charging gun 1502, the second electromagnetic coil 1514 of the vehicle inlet 1504 may be energized from the battery 1508. As the voltage level of the battery 1508 is detected to be present above the threshold value, the second electromagnetic coil 1514 may be energized from the battery 1508 i.e., Input 2. Energization of the second electromagnetic coil 1514 would generate an electromagnetic force for attracting the charging gun 1502. The electromagnetic force would guide the charging gun 1502 towards the vehicle inlet 1504, for achieving the magnetic locking between the charging gun 1502 and the vehicle inlet 1504. In addition, the first electromagnetic coil 1512 would also generate an electromagnetic force for achieving the magnetic locking between the charging gun 1502 and the vehicle inlet 1504. Further, for generating the electromagnetic force, the first electromagnetic coil 1512 would draw power from the charging station 1506.
When a user/operator tries to bring the charging gun 1502 towards the vehicle inlet 1504 for mating the charging gun 1502 with the vehicle inlet 1504, the second electromagnetic coil 1514 is energized from the battery 1508 after detecting the charging gun 1502 in proximity. The energization of the first electromagnetic coil 1512 and the second electromagnetic coil 1514 assist the user/operator in guiding for proper mating of the charging gun 1502 with the vehicle inlet 1504. After the mating of the charging gun 1502 and the vehicle inlet 1504 is completed, availability of Input 1 at C+ terminal of the charging gun 1502 may be determined by a switching unit 1522 present in the magnetic locking system 1500. Upon identification of availability of the Input 1, the switching unit 1522 may switch power from the battery 1508 to the external power source i.e., the charging station 1506 for energizing the second electromagnetic coil 1516 for magnetic locking. Successively, a control unit, such as a Vehicle Control Unit (VCU) 1524 present in the magnetic locking system 1500 may communicate with the charging station 1506 to determine if the charging station 1506 supports a fast-charging mode or a slow charging mode. Upon determining the charging mode supported by the charging station 1506, the VCU 1524 may send a control signal to control the amount of current flowing through the second electromagnetic coil 1514 as per the supported charging mode to generate accordingly, a predefined magnetic force required for the magnetic locking.
The switching unit 1522 may include a power multiplexer 1526 and a current modulator 1528. The current modulator 1528 may be a part of the EV or the vehicle inlet 1504. The current modulator 1528 may control an amount of current flowing through the second electromagnetic coil 1514 for managing the amount of electromagnetic force generated by the second electromagnetic coil 1514 according to the supported charging mode of the charging station 1506. Similarly, a current modulator 1530 may be provided in the charging station 1506 also known as an Electric vehicle supply Equipment (EVSE). In other implementations, the current modulator 1530 may be a part of a housing of the charging gun 1502 or the power cable 1510. The current modulator 1530 may control an amount of current flowing through the first electromagnetic coil 1512 for controlling the amount of electromagnetic force generated by the first electromagnetic coil 1512. The current modulator 1528 and the current modulator 1530 may include various active/passive constant current sources, such as SEPIC converter, Buck converter, transistor based constant current circuits like current mirror circuits, or any other type of suitable current modulator circuits.
In one scenario, the power detector 1520 may detect that the voltage level of the battery 1508 is present below the threshold value indicating that the battery 1508 is present in a deep-discharge state. In such a scenario, an auxiliary power source 1532 connected with the vehicle inlet 1504 may be used to power the second transceiver 1518 to detect presence of the first transceiver 1516 in vicinity. Successively, the second transceiver 1518 may communicate the voltage level of the battery 1508 to the first transceiver 1516 to enable magnetic locking of the charging gun 1502 with the vehicle inlet 1504. With battery voltage information received from the second transceiver 1518, the charging station 1506 knows that the battery 1508 is present in deep-discharge state, following which the charging station 1506 sends a control signal to the current modulator 1530. Based on the control signal, the current modulator 1530 energizes the first electromagnetic coil 1512 to generate an electromagnetic force sufficient to facilitate guiding of the charging gun 1502 towards the vehicle inlet 1504. In one embodiment, once the charging gun 1502 is mated with the vehicle inlet 1504, the current modulator 1530 facilitates the first electromagnetic coil 1512 to generate sufficient electromagnetic force thereby enabling magnetic locking of the charging gun 1502 with the vehicle inlet 1504. However, it must be noted that the electromagnetic force generated by the first electromagnetic coil 1512 during presence of the battery 1508 in deep-discharge state would be sufficiently greater than the electromagnetic force generated by the first electromagnetic coil 1512 when the battery 1508 is not present in deep-discharge state as the second electromagnetic coil 1514 also generates some amount of the electromagnetic force in such a condition i.e., when the battery 1508 is not in a deep-discharge state.
Once the magnetic locking of the charging gun 1502 with the vehicle inlet 1504 is established, the battery 1508 may start charging with power derived from the charging station 1506. The battery 1508 may be charged in a fast-charging mode or a slow-charging mode based on the charging mode supported by the charging station 1506.
The VCU 1524 may also be adapted to send a control signal to the current modulator 1528 for stopping current flow through the second electromagnetic coil 1514 upon receiving an input from a user when charging of the battery 1508 is in progress in the fast-charging mode. The input received from the user may correspond to the EV being turned ON. Alternatively, the VCU 1524 may also communicate details of the ON state of the EV to a control unit (not illustrated) provided in the charging station 1506. The VCU 1524 may communicate the details of the ON state of the EV to the charging station 1506 through CAN pins present on the vehicle inlet 1504 and the charging gun 1502. Upon receiving the details of the ON state of the EV, the control unit provided in the charging station 1506 may stop current flow through the first electromagnetic coil 1514. Stopping the current flow through the first electromagnetic coil 1512 and/or the second electromagnetic coil 1514 would result in absence of the electromagnetic force and would thus enable the user to detach the charging gun 1502 from the vehicle inlet 1504. In a similar manner, the VCU 1524 may enable the user to detach the charging gun 1502 from the vehicle inlet 1504 when the battery 1508 is fully charged. The switching unit 1522 and the VCU 1524 may be a part of the vehicle inlet 1504 or may be separate elements electrically connected with the vehicle inlet 1504. Figures 16a, 16b, and 16c cumulatively illustrate a flow chart showing a method of charging by utilizing a magnetic locking system during deep-discharge of a battery, in accordance with an embodiment of the present invention. At step 1602, it is determined whether a battery connected with a vehicle inlet is present in a deep-discharge state. When it is determined that the battery is not present in a deep-discharge state, a second transceiver present in the vehicle inlet continuously performs proximity detection i.e., detecting presence of a charging gun in vicinity of the vehicle inlet, at step 1604. When the second transceiver does not determine presence of the charging gun 1502, battery health is checked again at step 1602 and the proximity detection is performed at step 1604 when the battery is not present in a deep-discharge state.
Alternatively, at step 1604, when the charging gun is detected in vicinity of the vehicle inlet, a Vehicle Control Unit (VCU) sends a control signal to energize a second electromagnetic coil present in the vehicle inlet to generate electromagnetic force, at step 1606. The electromagnetic force assists in guiding the charging gun towards the vehicle inlet. To energize the second electromagnetic coil, a switching unit present in the vehicle inlet selects Input 2 i.e., power from the battery, at step 1608. Upon energization of the second electromagnetic coil, the charging gun is expected to connect or mate with the vehicle inlet. At step 1610, it is determined whether the charging gun is mated or connected with the vehicle inlet or not. When the mating or connection isn’t determined, the proximity detection is performed again, at step 1604. Alternatively, when it is determined that the charging gun is properly mated or connected with the vehicle inlet at step 1610, the switching unit 1522 as shown in Fig. 15 shifts from Input 2 to Input 1 to energize the second electromagnetic coil, at step 1612.
At step 1602, when the battery is determined to be present in a deep-discharge state, the second transceiver is powered from an auxiliary power source connected with the vehicle inlet, to send a signal to a first transceiver present in the charging gun, at step 1614. From the received signal from the second transceiver, the charging gun determines the presence of the battery in a deep-discharge state, at step 1616. Thereafter, the charging station powering the charging gun sends a control signal to its current modulator to generate an electromagnetic force sufficient to facilitate guiding of the charging gun towards the vehicle inlet, at step 1618. Successively, at step 1620, it is determined whether the charging gun is properly mated or connected with the vehicle inlet or not. In the absence of mating of the charging gun with the vehicle inlet, the charging gun again determines the presence of the battery in a deep-discharge state, at step 1616. Alternatively, at step 1620, when it is determined that the charging gun is properly mated or connected with the vehicle inlet, the switching unit 1522 as shown in Fig. 15 shifts from Input 2 to Input 1 to energize the second electromagnetic coil, at step 1612.
After switching the source for energizing the second electromagnetic coil from Input 2 to Input 1, the VCU determines an amount of current required to be passed through the second electromagnetic coil based on vehicle state i.e., ON/OFF state and/or a charging mode i.e., fast-charging mode or slow-charging mode, at step 1622. Based on the vehicle state and/or the charging mode determined at step 1622, the VCU sends a control signal to the current modulator for controlling the amount of current required to be passed through the second electromagnetic coil, at step 1624. Using the current provided by the current modulator, the second electromagnetic coil generates a predefined magnetic field required for magnetic locking of the charging gun and the vehicle inlet, at step 1626. Also, VCU can send a control signal to current modulator(s) in the vehicle and/or current modulator(s) of the external charging station via the control unit of the charging station for de-energizing the first coil and/or the second coil.
When charging of the vehicle’s battery is in progress and an error occurs, the VCU stops flow of current through the second electromagnetic coil, at step 1628. The error may be anyone from the following, such as over-voltage, over-temperature, and unintentional disconnection of the charging gun. Alternatively, when charging of the vehicle’s battery gets completed, the VCU stops flow of current through the second electromagnetic coil, at step 1630. Alternatively, when charging of the vehicle’s battery is in progress in a slow-charging mode or a fast-charging mode, and an error or a user intervention is detected, the VCU stops flow of current through the second electromagnetic coil, at step 1632. It must be noted that the VCU stops flow of current through the second electromagnetic coil by operating the current modulator. Stopping the flow of current through the second electromagnetic coil would result in absence of the electromagnetic force present earlier. Further, the VCU may also communicate details of the error or the user intervention to a charging station through CAN pins present on the vehicle inlet and the charging gun. Upon receipt of the details of the error or the user intervention by the charging station, a control unit present in the charging station stops flow of current through a first electromagnetic coil present in the charging gun. Stopping the flow of current through the first electromagnetic coil would result in absence of the electromagnetic force present earlier. By stopping the flow of current through the first electromagnetic coil and/or the second electromagnetic coil, a user may be enabled to safely detach the charging gun from the vehicle inlet.
The main advantage of the present invention is that a magnetic locking system and method employed in electric charging systems is provided, thereby avoiding physical damage to the charging gun and/or the vehicle inlet socket in case of accidental or forceful disconnection of the charging gun.
Another advantage of the present invention is that a magnetic locking system and method employed in electric charging systems is provided in which an accidental disconnection of the charging gun may not pose any danger, such as arcing.
Another advantage of the present invention includes allowing usage of variable pull-out force/strength by a user during different charging modes.
Yet another advantage of the present invention is that an electric charging system without any moving parts is provided, which reduces wear and tear thereby ensuring higher overall life of the charging system.
Still another advantage of the present invention includes energization of the second electromagnetic coil provided in a second unit/vehicle inlet after detecting presence of a first unit/charging gun, for magnetic locking. In this manner, unnecessary energization of the second electromagnetic coil is prevented and vehicle battery power saving is achieved.
Yet another advantage of the present invention includes guiding the first unit/charging gun towards the second unit/vehicle inlet through an electromagnetic force for achieving magnetic locking of the first unit/charging gun with the second unit/vehicle inlet.
Yet another advantage of the present invention includes facilitating proper self-alignment or guiding of the charging connector (i.e., charging gun) with the vehicle inlet during mating.
Yet another advantage of the present invention includes switching of a source for energizing the second electromagnetic coil after the first unit/charging gun mates with the second unit/vehicle inlet. Switching of the source for energizing the second electromagnetic coil enables saving of power in a battery connected with the second unit/vehicle inlet.
Yet another advantage of the present invention includes stopping of current flow through the first electromagnetic coil and/or the second electromagnetic coil when the battery connected with the second unit/vehicle inlet is fully charged or charging of the battery is in progress in a fast charging mode. Stopping of the current flow through the first electromagnetic coil and/or the second electromagnetic coil enables a user to safely detach the first unit/charging gun from the second unit/vehicle inlet.
Yet another advantage of the present invention includes enabling working of a charging system when a battery powering the vehicle inlet is present in a deep-discharge state. An auxiliary power source utilized in the charging system enables working of the charging system when the battery is present in a deep-discharge state.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily configure and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Reference labels:

102 Power source
104 First unit, charging gun
106 Second unit, vehicle inlet
108 Electric charge storing unit
110 Control unit
112 Current modulating unit
200 Charging gun
202 Housing
204, 206a, 206b, 208, 210 Plurality of terminals
220 Temperature sensor
300 Energy refilling system
302 External power supply
304 Electric vehicle
306 Electric vehicle inlet
308 Battery
310 Vehicle control unit
702 Electromagnetic coil
704 Metallic element/ Magnet
1002 Connector 1
1004 Connector 2
1300a, 1300b Magnetic locking system
1302 First unit
1304 Second unit
1306 Power source
1308 Electric charge storing units
1310 Power cable
1312 Magnet
1314 First electromagnetic coil
1316 Second electromagnetic coil
1318 Receiver
1320 Transmitter
1322 Switching unit
1324 Power multiplexer
1326 Current modulator
1328 Current modulator
1330 Vehicle Control Unit (VCU)
1500 Magnetic locking system
1502 First unit, charging gun
1504 Second unit, vehicle inlet
1506 Power source, charging station
1508 Electric charge storing units, battery
1510 Power cable
1512 First electromagnetic coil
1514 Second electromagnetic coil
1516 First transceiver
1518 Second transceiver
1520 Power detector
1522 Switching unit
1524 Control unit, Vehicle Control Unit (VCU)
1526 Power multiplexer
1528 Current modulator
1530 Current modulator
1532 Auxiliary power source
, Claims:We claim:
1. A magnetic locking system (1500), comprising:
a first unit (1502) connected to a power source (1506), the first unit (1502) comprises a first transceiver (1516) and a first electromagnetic coil (1512);
a second unit (1504) connected to one or more electric charge storing units (1508), the second unit (1504) comprises a second transceiver (1518) and a second electromagnetic coil (1514);
an auxiliary power source (1532); and
a power detector (1520) to detect a voltage level of the one or more electric charge storing units (1508), wherein when the voltage level is below a threshold value, the auxiliary power source (1532) powers the second transceiver (1518) to detect presence of the first transceiver (1516) in vicinity, and the second transceiver (1518) communicates the voltage level to the first transceiver (1516) to enable magnetic locking of the first unit (1502) with the second unit (1504).

2. The magnetic locking system (1500) as claimed in claim 1, wherein the first transceiver (1516) and the second transceiver (1518) are Infrared based, ultrasonic based or Radio Frequency based.

3. The magnetic locking system (1500) as claimed in claim 1, wherein the first unit (1502) generates an electromagnetic force to assist in guiding the first unit (1502) towards the second unit (1504) for the magnetic locking of the first unit (1502) and the second unit (1504).

4. The magnetic locking system (1500) as claimed in claim 1, wherein the voltage level below a threshold value indicates a deep-discharge state of the one or more electric charge storing units (1508).

5. The magnetic locking system (1500) as claimed in claim 1, wherein the magnetic locking of the second unit (1504) with the first unit (1502) causes charging of the one or more electric charge storing units (1508) by the power source (1506).

6. The magnetic locking system (1500) as claimed in claim 1, wherein the second electromagnetic coil (1514) is energized by the power source (1506) after the first unit (1502) is connected with the second unit (1504).

7. The magnetic locking system (1500) as claimed in claim 1, wherein the first electromagnetic coil (1512) is laid around a circumference of the first unit (1502) and the second electromagnetic coil (1514) is laid around a circumference of the second unit (1504).

8. The magnetic locking system (1500) as claimed in claim 6, further comprising one or more current modulators (1528, 1530) connected with at least one of the first unit (1502) and the second unit (1504) for controlling current flow through one or more of the first electromagnetic coil (1512) and the second electromagnetic coil.

9. The magnetic locking system (1500) as claimed in claim 5, wherein the one or more electric charge storing units (1508) are charged in one of a fast-charging mode and a slow-charging mode.

10. The magnetic locking system (1500) as claimed in claim 8, wherein a control unit (1524) is adapted to send a control signal to the one or more current modulators (1528, 1530) for stopping current flow through one or more of the first electromagnetic coil (1512) and the second electromagnetic coil (1514) upon receiving an input from a user, thereby enabling the user to detach the first unit (1502) from the second unit (1504) while the charging of the one or more electric charge storing units (1508) is in progress in the fast-charging mode.

11. The magnetic locking system (1500) as claimed in claim 8, wherein a control unit (1524) is adapted to send a control signal to the one or more current modulators (1528, 1530) for stopping current flow through one or more of the first electromagnetic coil (1512) and the second electromagnetic coil (1514) when the one or more electric charge storing units (1508) are fully charged, thereby enabling the user to detach the first unit (1502) from the second unit (1504).

12. The magnetic locking system (1500) as claimed in claim 5, wherein the first unit (1502) is a charging gun (1502) and the second unit (1504) is a vehicle inlet (1504) present on an Electric Vehicle (EV).

13. A method of magnetic locking, comprising:
determining, by a power detector (1520), a voltage level of one or more electric charge storing units (1508) connected to a second unit (1504);
determining, by a second transceiver (1518) present in the second unit (1504), presence of a first transceiver (1516) of a first unit (1502) in vicinity;
communicating, by the second transceiver (1518), the voltage level to the first transceiver (1516); and
energizing, by a power source (1506) connected with the first unit (1502), a first electromagnetic coil (1512) of the first unit (1502) to enable magnetic locking of the first unit (1502) with the second unit (1504).

14. The method as claimed in claim 13, wherein the power source (1506) connected to the first unit (1502) generates an electromagnetic force to assist in guiding the first unit (1502) towards the second unit (1504) for the magnetic locking of the first unit (1502) and the second unit (1504).

15. The method as claimed in claim 13, wherein the voltage level below a threshold value indicates a deep-discharge state of the one or more electric charge storing units (1508).

16. The method as claimed in claim 13, wherein the magnetic locking of the second unit (1504) with the first unit (1502) causes charging of the one or more electric charge storing units (1508) of the second unit (1504) by the power source (1506).

17. The method as claimed in claim 13, further comprising controlling current flow, by one or more current modulators (1528, 1530) connected with at least one of the first unit (1502) and the second unit (1504), through one or more of the first electromagnetic coil (1512) and the second electromagnetic coil.

18. The method as claimed in claim 13, further comprising de-energizing the second electromagnetic coil (1514) for detaching the first unit (1502) from the second unit (1504) when the one or more electric charge storing units (1508) are completely charged.

19. The method as claimed in claim 16, wherein the first unit (1502) is a charging gun (1502) and the second unit (1504) is a vehicle inlet (1504) present on an Electric Vehicle (EV).

20. The method as claimed in claim 19, further comprising de-energizing the second electromagnetic coil (1514) for detaching the charging gun (1502) from the vehicle inlet (1504) when the user turns ON the EV.

21. A charging gun (1502) for an Electric Vehicle (EV), comprising:
one or more terminals;
a first transceiver (1516); and
a first electromagnetic coil,
the first electromagnetic coil (1512) is energized to produce a magnetic field sufficient for magnetic locking of the charging gun (1502) with a vehicle inlet (1504) for charging one or more electric charge storing units (1508) present in the EV by a power source (1506) powering the charging gun (1502),
wherein the first electromagnetic coil (1512) is energized to produce sufficient magnetic force based on receipt of, by the first transceiver (1516) from a second transceiver (1518) present in the vehicle inlet (1504), a voltage level of the one or more electric charge storing units (1508) connected to the vehicle inlet (1504).

22. The charging gun (1502) as claimed in claim 21, wherein the first transceiver (1516) and the second transceiver (1518) are Infrared based, ultrasonic based or Radio Frequency based.

23. The charging gun (1502) as claimed in claim 21, wherein the first electromagnetic coil (1512) is laid around the circumference of the charging gun (1502).

24. The charging gun (1502) as claimed in claim 21, further comprising a current modulator (1530) for controlling current flow through the first electromagnetic coil.

25. The charging gun (1502) as claimed in claim 24, wherein a control unit (1524) is adapted to send a control signal to the current modulator (1530) for stopping the current flow through the first electromagnetic coil (1512) upon receiving an input from a user, thereby enabling the user to safely detach the charging gun (1502) from the vehicle inlet (1504) while the charging of the one or more electric charge storing units (1508) is in progress in the fast-charging mode.

26. The charging gun (1502) as claimed in claim 24, wherein a control unit (1524) is adapted to send a control signal to the current modulator (1530) for stopping the current flow through the first electromagnetic coil (1512) when the one or more electric charge storing units (1508) are fully charged, thereby enabling the user to detach the charging gun (1502) from the vehicle inlet (1504).

27. A vehicle inlet (1504) for electric charging of an EV, comprising:
one or more terminals connected with one or more electric charge storing units (1508) present in the EV;
a second electromagnetic coil;
a second transceiver (1518);
an auxiliary power source (1532); and
a power detector (1520) to detect a voltage level of the one or more electric charge storing units (1508),
wherein when the voltage level is below a threshold value, the auxiliary power source (1532) powers the second transceiver (1518) to detect presence of a first transceiver (1516) of a charging gun (1502) in vicinity, and the second transceiver (1518) transmits, to the first transceiver (1516), the voltage level to enable magnetic locking of the charging gun (1502) with the vehicle inlet (1504).

28. The vehicle inlet (1504) as claimed in claim 27, wherein the first transceiver (1516) and the second transceiver (1518) are Infrared based, ultrasonic based or Radio Frequency based.

29. The vehicle inlet (1504) as claimed in claim 27, wherein the magnetic locking of the charging gun (1502) with the vehicle inlet (1504) causes charging of the one or more electric charge storing units (1508) by a power source (1506) powering the charging gun (1502).

30. The vehicle inlet (1504) as claimed in claim 27, wherein the second electromagnetic coil (1514) is laid around the circumference of the vehicle inlet (1504).

31. The vehicle inlet (1504) as claimed in claim 27, further comprising a current modulator (1528) for controlling current flow through the second electromagnetic coil.

32. The vehicle inlet (1504) as claimed in claim 31, wherein a vehicle control unit (1524) is adapted to send a control signal to the current modulator (1528) for stopping the current flow through the second electromagnetic coil (1514) upon receiving an input from a user, thereby enabling the user to detach the charging gun (1502) from the vehicle inlet (1504) while the charging of the one or more electric charge storing units (1508) is in progress in the fast-charging mode.

33. The vehicle inlet (1504) as claimed in claim 31, wherein a control unit (1524) is adapted to send a control signal to the current modulator (1528) for stopping the current flow through the second electromagnetic coil (1514) when the one or more electric charge storing units (1508) are fully charged, thereby enabling the user to detach the charging gun (1502) from the vehicle inlet (1504).