Apparatus for reducing force required to automatically insert / remove connector attached to electric vehicle charger into / from electric vehicle socket

Abstract

The invention relates to a device for disconnecting a connector of an electric vehicle charger from a socket on an electric vehicle in a predetermined position and orientation, comprising a connector operating mechanism comprising an actuated positioning mechanism, an actuated positioning mechanism for moving the connector in at least two degrees of freedom relative to the fixed frame of reference, and at least one compliance assembly configured to allow compliant movement of the connector in at least two degrees of freedom relative to the fixed frame of reference, wherein the at least one compliant assembly is kinematically connected in series with the positioning mechanism between the fixed frame of reference and the connector and has a compliant stroke defined as an effective displacement between an actual connector position and orientation and a current / instantaneous virtual position and orientation of the connector; wherein, in order to disconnect the connector, the connector operating mechanism is configured to exert on the connector: a first torque and / or force in a movement direction for moving the connector in the movement direction; and at least a second torque and / or force superimposed on the first torque and / or force, the second torque and / or force having a directional component or direction different from the unique direction of movement, the second torque and / or force being guided towards an unconstrained position and orientation of the connector.

Description

Background of the Invention

[0001] The present invention relates to a device for reducing the force required to automatically insert / extract a connector attached to an electric vehicle charger into / from an electric vehicle socket, respectively. Throughout this application, the terms "inserting" and "extracting" may be replaced by "connecting" and "disconnecting", respectively, or may be replaced by "plugging in" and "plugging out", respectively.

[0002] In recent years, the automatic insertion or removal of charging connectors in electric vehicle sockets has become a new goal for owners of large fleets. Many electric vehicles have vehicle sockets for manual plugging, such as vehicle sockets according to IEC 62196. The combination of connector and vehicle socket usually has a close-fitting geometry. Therefore, automatically plugging the connector requires a certain degree of accuracy in positioning, orienting, and inserting or removing the connector. When inserting or removing, the combination will always experience friction, where the contact force between the conductors in the connector and the socket is the main contributing factor. Many factors can cause friction, such as design and manufacturing tolerances, weather conditions, wear and other design features of the connector and the socket. Another major contributing factor may be misalignment between the connector and the socket when inserting or removing, for example due to past or present movement of the vehicle, misestimation of the socket position, or control inaccuracies of the automatic mechanism (e.g., charging robot) used for insertion / removal.

[0003] Such misalignment may cause the electric vehicle charger to require auxiliary force (beyond specifications) to insert or remove the connector from the electric vehicle socket, with corresponding risk of damage to the vehicle, the charging robot, or unexpected objects or people present between or around the charging robot and the electric vehicle.

[0004] Removing a connector that is significantly misaligned is difficult (imagine pulling a block out of a narrow hole using a rope that is angled to the direction of removal). Misalignment between the connector and the robot only occurs when the system is able to facilitate significant compliance travel. In the context of the present disclosure, compliance travel refers to the distance that the system or its components can move in response to external forces. For example, this may occur due to loading / unloading of the vehicle when the suspension of the vehicle is compressed or released due to added weight. This may be the result of using a dedicated device: when a person plugs the connector, the dedicated device plugs the connector and holds the connector, and releases the connector, but it may also occur when the device simulates human operation (subsequently plugging the connector, releasing the connector, waiting for charging to complete, reattaching to the connector, and finally removing the connector). During the automatic charging process, the described problem may be experienced at all times when the mechanism holds the connector (partially) inserted into the vehicle socket. Brief description of the prior art

[0005] So far, several solutions have been proposed in the art. International patent application WO2019166234 A1 discloses a method for automatically inserting or removing a connector into or from a vehicle socket by using a vibration unit that excites the charging connector to vibrate. While vibration may help reduce the required insertion or removal force, it also complicates the design requirements of both the manipulator that operates the connector and the vehicle with the socket. On both sides, the vibration should be attenuated to avoid undesirable effects. Although the document does mention attenuation on the connector side, it does not mention attenuation on the socket side. In addition, the document mentions a dedicated actuator on the connector side to generate vibrations. It is not desirable to add components to the end effector of the manipulator, i.e., increase weight, complexity and cost. Finally, vibration cannot solve obvious misalignment, i.e., clamping problems.

[0006] Chinese patent application CN108790916A discloses an electric vehicle charging system, which includes a square airbag that is inflated when the charging head approaches the socket to overcome the problem of position change caused by the change of the car during the charging process.

[0007] German patent application DE 10 2012 014 936 A1 discloses a system for compensating for positional and orientation offsets when positioning a connector.

[0008] Finally, the article of DOI 10.1109 / SSD.2015.7348200 discloses a strategy to reduce the force required for insertion. It describes the use of an industrial robot with a six-degree-of-freedom force sensor to facilitate combined position and force control when inserting a connector. This solution can allow for reduced force, but has many disadvantages. Force control requires sufficient computing power to allow a sufficiently high control frequency, a deterministic control loop, and a fast and accurate response from a motor controller and a motor. These requirements increase weight and cost, and it is difficult (if not impossible) to obtain certification for use in a public environment. In addition, the use of force control rather than significant physical compliance to implement the manipulator requires continuous control of the manipulator during the entire charging process. In addition to wasting energy, if the controller stops for some reason, part of the system (manipulator, connector, socket) will brake, and the electric vehicle may still move passively due to its suspension. SUMMARY OF THE INVENTION

[0009] Systems according to the prior art generally have one or more of the following disadvantages. Systems according to the prior art are only used to compensate for orientation or positional offsets and do not address potential pinching due to misalignment during removal. Systems according to the prior art generally include additional devices (sensors or actuators) to function. Systems according to the prior art are also only applicable to insertion of connectors, and systems according to the prior art do not address potential pinching due to misalignment during removal. Generally, systems according to the prior art may not provide their effect of reducing at least the average force required to insert a connector into a socket.

[0010] The object of the present invention is to propose a method and system for reducing the force required to insert or remove a socket attached to an electric vehicle charger into or from an electric vehicle socket, which method and system eliminate the disadvantages of the prior art or at least form a useful alternative to the prior art.

[0011] Another object of the invention is to propose a method for controlling an autonomous charging device (ACD) for autonomously connecting / disconnecting a connector to / from a socket in an electric vehicle, the ACD comprising a connector operating mechanism comprising an actuated connector positioning mechanism and a compliance assembly, the compliance assembly allowing the connector to achieve compliant connection / disconnection by movement in the connection / disconnection direction. Another object of the invention is to provide a reliable and safe solution. A further object is to reduce the forces in the insertion direction for safety purposes. Yet another object is to reduce costs, maintainability, achieve a less complex system and increase the robustness of the system.

[0012] Therefore, the present invention proposes an apparatus and a method according to the independent claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 A connector in a socket is shown; FIG2 a shows a connector operating mechanism having compliant components distributed in a kinematic chain; FIG2 b shows a connector operating mechanism having a compliant assembly proximate the connector; FIG3a shows a connector operating mechanism with a compliant stroke caused by insertion according to the present invention; FIG3 b shows the connector in the socket slightly displaced relative to normal insertion within the tolerance allowed by the socket; FIG4a shows a connector operating mechanism with a compliant stroke caused by insertion according to the present invention; and Figure 4b shows the connector in the socket slightly displaced relative to normal insertion within the tolerance allowed by the socket. Detailed Description of the Invention

[0014] During the insertion or extraction phase, there is physical contact between the connector and the socket. The physical contact results in at least friction. Friction and other effects caused by misalignment or general conditions, such as pinching by pressing on intentional or unintentional features (ridges, scratches, etc.), require a higher push or pull force, respectively, in the direction of the socket centerline than the nominal push or pull force (as described, for example, in the standard) to successfully complete the insertion or extraction.

[0015] In other words, the tight-fitting geometry of the connector-receptacle combination often results in pinching or increased friction (static and dynamic). This can be the result of misalignment between the connector and receptacle, but can also occur without connector and receptacle misalignment. This requires increased force to insert or remove the connector, which presents a safety issue or risk of damage to the receptacle, connector, or robot. There is also a risk of an incorrect connection between the receptacle and connector or that the receptacle and connector will not connect at all.

[0016] One aspect of the present invention is to apply a torque and / or force on the connector in a direction other than one of the insertion or removal directions to produce a prying motion of the connector in the receptacle.

[0017] The fit between the socket and the connector, and therefore the friction between the socket and the connector, depends on several factors. These include the design and manufacture of the connector and socket, for example, manufacturing tolerances, contact pressure of the electrical contacts, geometric design to accommodate human insertion and / or removal (such as self-seeking features), material properties (stiffness, roughness, etc.). Other factors include general wear and tear, misuse, and exposure to weather conditions or other conditions in which they are used (dust or elements introduced into the socket).

[0018] Another contributing factor to friction is misalignment due to movement of the car (and therefore the socket) at the moment of insertion / removal, or errors or inaccuracies in the motion control of the positioning mechanism. Vehicle movement can occur for several reasons (such as loading / unloading, wind loads, adjusting vehicle suspension, etc.). Charging stations that facilitate automatic connection must be able to cope with these slight vehicle movements to avoid damage to the infrastructure or the vehicle. The present invention uses a device that combines an active positioning mechanism with physical compliance to solve the problem of introducing the possibility of misalignment.

[0019] In all cases, the socket-connector combination is designed to be a tight fit, so friction and possible pinching will be experienced when inserting or removing the connector.

[0020] To avoid these problems, an alternating moment and / or an alternating force in at least a direction different from the centerline direction (P) of the socket is applied to the connector, thereby causing a prying motion of the connector in the socket, which prying motion results in friction reduction and / or a lever-like motion. In the context of the present disclosure, the insertion / removal direction may also be referred to as the plugging direction, and may correspond to a direction that is substantially or essentially parallel to the centerline direction of the pin and the hole. In the context of the present invention, the terms "insertion", "connection" and "plugging" may be used interchangeably. Similarly, the terms "removal", "disconnection" and "unplugging" may be used interchangeably.

[0021] The forces or moments applied to reduce the insertion or extraction forces are not necessarily in directions that will resolve the misalignment, as their purpose is not to directly overcome the misalignment itself or to completely overcome the misalignment itself, but to reduce friction that may be indirectly caused by the misalignment. Using the direction of the misalignment will have the additional benefit that the misalignment will be resolved, even if only temporarily.

[0022] The alternation of moments and / or forces results in multiple prying actions. Therefore, these alternating moments or forces can also (intentionally or unintentionally) bring the connector into the most favorable orientation alignment multiple times, thus promoting a reduction in the required force.

[0023] Simultaneously with the insertion or removal motion, a controlled quasi-static motion is performed using the positioning mechanism, which will cause the connector to move relative to the receptacle in a direction different from that of insertion / removal when at least partially not inserted into the receptacle, effectively causing additional or greater compliance travel. The second movement may include at least one of: linear motion along an axis having a maximum dimension, rotational motion about an axis orthogonal to the axis having a maximum dimension and the insertion / removal direction; and / or movement about a point that will resolve the misalignment.

[0024] The apparatus according to the present disclosure includes a connector operating mechanism, the connector operating mechanism including an actuated positioning mechanism for moving the connector in at least two degrees of freedom relative to a fixed reference frame; and at least one compliant component, the at least one compliant component configured to allow the connector to compliantly move in at least two degrees of freedom relative to the fixed reference frame. Thus, the at least one compliant component can be configured to facilitate correct connection under misalignment, which occurs during insertion (e.g., due to miscalculation of the socket position and / or orientation) and / or after insertion (e.g., due to passive vehicle movement caused by loading (or unloading) the vehicle during a charging session).

[0025] All of this helps reduce the force required to connect and / or disconnect the connector and the receptacle compared to the force required to connect the connector using only force in the insertion / removal direction. For example, this allows the connector to be inserted and removed in the center of the receptacle direction with lower force than would be possible without lateral movement.

[0026] Lateral translation and / or rotational movement will result in compliance at a point with significantly less (or no) misalignment, making it easier to pull out.

[0027] Some devices suitable for configuration according to the present invention are described in patent applications of the same applicant, in particular application numbers NL2023019, NL2024952, NL2025959, NL2026365, NL2026710 and NL2028169. These applications are incorporated herein by reference. The devices described therein can all be configured to perform the method according to the present invention.

[0028] In one embodiment, for connecting the connector, the connector operating mechanism may be configured for limiting the second torque and / or force to such an extent that a controlled quasi-static movement of the connector is obtained.

[0029] According to the present invention, quasi-static motion refers to slow and controlled motion that is almost stationary or moves very slowly to allow the system to maintain a stable position. In quasi-static motion, the driving force is usually applied slowly and steadily enough so that dynamic forces such as acceleration and inertia can be ignored.

[0030] When the connector is inside the socket, there is little room for movement; only design and manufacturing tolerances and material properties can provide such room. Dynamic movement inside the socket is difficult to achieve, but in particular, vibrations may inadvertently cause unnecessary wear on the vehicle as well as the socket and connector. Moreover, the movement according to the present application is intended to be quasi-static.

[0031] Throughout this application, the term "quasi-static" is used for those motions in which inertial effects are negligible. When the motion is performed without the connector being constrained by, for example, a socket, the compliant travel caused by the inertial effects of the mass of the compliant support is negligible. For one direction simplified to a mass-spring system, quasi-static behavior is considered to be any motion that satisfies the following conditions:

[0032] m*omg^2 / k <sqrt(2)-1 in: m = mass of the compliant actuator support k = stiffness of the compliant component OMG = exercise frequency Transfer function = 1 / (1+m*omg^2 / k) = 1 / sqrt(2) The cutoff / breakpoint for the dominant behavior in the frequency response is located at -3dB=20 log(1 / sqrt(2)). This simplification applies to devices where the compliant component is placed only after the final actuator (end compliant actuator) and damping is omitted.

[0033] In another embodiment, the connector operating mechanism is configured for superimposing a second moment and / or force along or about a single axis.The most advantageous second moment and / or force generally depends on the particular connector-receptacle combination under consideration, and may also depend on the exact circumstances in which it is used.

[0034] For example, a connector having its largest lateral (facing a plane orthogonal to the insertion direction) dimension along a vertical axis may benefit most from moments and resulting controlled rotation about a lateral horizontal axis to leverage the connector dimensions into or out of a receptacle.

[0035] In another example, in addition to the prying motion, a moment or force only in the direction of the misalignment that may have occurred or has occurred has the added benefit of instantly resolving the misalignment.

[0036] In another embodiment, the connector operating mechanism is configured for alternating the direction of the superimposed second torque or force at least once, in particular in a controlled manner.

[0037] Often, applying additional torque or force along an axis in one direction may not be sufficient. Alternating along one axis, or generally creating other patterns (ie, circular or something more complex) improves the overall success rate of the invention.

[0038] In yet another embodiment, the connector operating mechanism is configured to set the second moment and / or force to an amount preferably greater than 0.03 m for translation, and / or greater than 3 degrees for rotation, more preferably greater than 0.01 m for translation, and / or greater than 2 degrees for rotation, and most preferably greater than 0.005 m for translation, and / or greater than 1 degree for rotation. These values ​​have been experimentally determined to be beneficial for the present invention.

[0039] In another embodiment, the second torque and / or force is applied only when it is determined that the connector is stuck. If the second torque and / or force is applied at the wrong time, adverse effects may occur. For example, compliance travel can only be achieved by actuating the positioning mechanism when the connector is in the socket or otherwise constrained. By only employing this method when a higher than nominal force is noted for insertion or removal, adverse effects can be avoided.

[0040] In yet another embodiment, the second moment and / or force is based on an input or measured misalignment from a sensor such as a force sensor or a camera. Different use cases may require different strategies. By adapting the second moment and / or force to a specific use case, the controller can select the right strategy to address the specific situation.

[0041] Different effects may hinder insertion or removal. For example, a horizontal ridge in the socket may prevent an edge on the connector from passing due to a slight accidental misalignment. This may cause the connector to rotate slightly in the socket. Controlled movement of the connector within the tolerance of the socket as the connector moves the edge over the ridge may solve this problem, while movement along the ridge may not help.

[0042] In yet another embodiment, the second moment and / or force is applied in a direction in which the major component of the measured misalignment is reduced. At the point of minimum misalignment, the force required for insertion or removal may be minimal. Thus, by selecting a direction that will resolve a portion of the measured misalignment, the controller will minimize the insertion or removal force by resolving the misalignment and by the prying motion.

[0043] More particularly, the invention relates to a device for connecting a connector of an electric vehicle charger to a socket on an electric vehicle in a predetermined position and orientation, wherein: -Connectors and sockets: o each having a plurality of poles which can be electrically connected to each other by establishing electrically conductive pin and hole connection pairs, wherein the connector comprises the pins and the socket comprises the associated holes, and / or the connector comprises the holes and the socket comprises the associated pins, wherein: o each pin and hole pair has a centerline extending axially from the center of the associated pin or hole, the centerlines being parallel; - can be connected by a movement towards each other having: o a direction substantially parallel to the centerline direction of the pin and the hole, and o a mutual orientation of the connector and the socket wherein the respective center lines of the pins and holes of at least two pin and hole connection pairs coincide; - each comprising a housing; wherein the connector housing and the socket housing: o can be connected by movement directed towards each other; o comprising a mechanical guide portion which protrudes beyond the end of the pin in a direction parallel to the centerline direction; o wherein the connector housing and the receptacle housing include manufacturing and / or operating tolerances that facilitate limited movement in at least one degree of freedom; The device includes: - A connector operating mechanism comprising: o an actuated positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference system; o at least one compliant component configured to allow the connector to compliantly move in at least two degrees of freedom relative to a fixed reference frame, Wherein the at least one compliant component: o in series kinematically with the positioning mechanism, between the fixed reference frame and the connector; and o includes a compliance travel defined as an effective displacement between an actual connector position and orientation and a neutral position and orientation of the connector, the neutral position and orientation being defined by at least a connector operating mechanism carrying the connector when the connector is not constrained by the receptacle; and Wherein, in order to connect the connector, the connector operating mechanism is configured to apply on the connector: - a first torque and / or force in the direction of movement for moving the connector in the direction of movement; and at least a second moment and / or force superimposed on the first moment and / or force, the second moment and / or force having a directional component or direction different from the direction of movement, wherein the second moment and / or force is directed towards a neutral position and orientation; The connector operating mechanism is configured to apply at least a second torque and / or force on the connector when and in particular only when the connector is at least partially inserted into the socket, wherein the second torque and / or force is applied by generating or expanding the compliance stroke by actuating the positioning mechanism.

[0044] In more detail, the invention also relates to a device for disconnecting a connector of an electric vehicle charger from a socket on an electric vehicle in a predetermined position and orientation, wherein: -Connectors and sockets: o each having a plurality of poles which can be electrically connected to each other by establishing electrically conductive pin and hole connection pairs, wherein the connector comprises the pins and the socket comprises the associated holes, and / or the connector comprises the holes and the socket comprises the associated pins, wherein: o each pin and hole pair has a centerline extending axially from the center of the associated pin or hole, the centerlines being parallel; - can be disconnected by a movement directed away from each other, the movement having: o a direction substantially parallel to the centerline direction of the pin and the hole, and o a mutual orientation of the connector and the socket wherein the respective center lines of the pins and holes of at least two pin and hole connection pairs coincide; - each comprising a housing; wherein the connector housing and the socket housing: ο can be disconnected by the same movement directed away from each other; o comprising a mechanical guide portion which protrudes beyond the end of the pin in a direction parallel to the centerline direction; in o the connector housing and the receptacle housing include manufacturing and / or operating tolerances that facilitate limited movement in at least one degree of freedom; The device includes: - A connector operating mechanism comprising: o an actuated positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference system; o at least one compliant component configured to allow the connector to compliantly move in at least two degrees of freedom relative to a fixed reference frame, Wherein the at least one compliant component: o in series kinematically with the positioning mechanism, between the fixed reference frame and the connector; and o includes a compliance travel defined as an effective displacement between an actual connector position and orientation and a neutral position and orientation of the connector, the neutral position and orientation being defined by at least a connector operating mechanism carrying the connector when the connector is not constrained by the receptacle; and Wherein, in order to disconnect the connector, the connector operating mechanism is configured to apply on the connector: - a first torque and / or force in the direction of movement for moving the connector in the direction of movement; and at least a second moment and / or force superimposed on the first moment and / or force, the second moment and / or force having a directional component or direction different from the direction of movement, wherein the second moment and / or force is directed towards a neutral position and orientation; The connector operating mechanism is configured to apply the at least second torque and / or force on the connector when and in particular only when the connector is at least partially inserted into the socket, wherein the second torque and / or force is applied by generating or expanding the compliance stroke by actuating the positioning mechanism.

[0045] In one embodiment, for connecting or disconnecting the connector, the connector operating mechanism may be configured to limit the second torque and / or force to such an extent that a controlled quasi-static movement of the connector is obtained.

[0046] In one embodiment, the connector operating mechanism is configured to superimpose a second moment and / or force along or about a single axis.

[0047] In one embodiment, the connector operating mechanism is configured for alternating the direction of the superimposed second torque or force at least once, in particular in a controlled manner.

[0048] In one embodiment, the connector operating mechanism is configured to apply a second torque and / or force by setting the compliance stroke to the following amount: preferably, for translation, greater than 0.02m, and / or for rotation, greater than 2 degrees; more preferably, for translation, greater than 0.01m, and / or for rotation, greater than 1 degree; and most preferably, for translation, greater than 0.005m, and / or for rotation, greater than 0.5 degrees.

[0049] In one embodiment, the second torque and / or force is applied only when it is determined that the connector is stuck.

[0050] In one embodiment, the invention includes controlling the second torque and / or force based on input from a sensor, such as a force sensor or a camera, or the measured misalignment.

[0051] In one embodiment, the second moment and / or force is applied in a direction in which a dominant component of the measured misalignment is reduced.

[0052] In one embodiment, the actuator for applying the second torque and / or force is also used to control at least one degree of freedom of the positioning mechanism.

[0053] In one embodiment, the second movement includes at least one of: · Linear motion along an axis with the largest dimension orthogonal to the direction of movement, · rotational movement about an axis orthogonal to the axis of greatest dimension and the direction of movement; and / or Movement around the point that will resolve the misalignment.

[0054] The invention also relates to a method for controlling an autonomous charging device (ACD) for autonomously connecting a connector to a socket in an electric vehicle, the ACD comprising a connector operating mechanism including an actuated connector positioning mechanism and a compliant assembly allowing a compliant connection of the connector by movement in a connecting direction, wherein the method comprises controlling the ACD so as to: a) applying a first torque and / or force on the connector in a direction substantially parallel to the connection direction by means of a connector operating mechanism; b) applying a second torque and / or force on the connector by the connector operating mechanism in a direction different from the direction of the first torque and / or force, The second moment and / or force is applied by: - when the connector is at least partially inserted into the EV socket, superimposed on the first moment and / or force, and -By creating and / or expanding the compliant travel of the connector.

[0055] The method according to the invention allows reducing the forces required to connect the connector and the EV socket.

[0056] The present invention also relates to a method for controlling an autonomous charging device (ACD) for autonomously disconnecting a connector from a socket in an electric vehicle, the ACD comprising a connector operating mechanism including an actuated connector positioning mechanism and a compliant assembly allowing a compliant disconnection of the connector by movement in a disconnecting direction, wherein the method comprises controlling the ACD so as to: c) applying a first torque and / or force on the connector in a direction substantially parallel to the disconnection direction by the connector operating mechanism; d) applying a second torque and / or force to the connector by means of a connector operating mechanism in a direction different from the direction of the first torque and / or force, The second moment and / or force is applied by: - when the connector is at least partially inserted into the EV socket, superimposed on the first moment and / or force, and -By creating and / or expanding the compliant travel of the connector.

[0057] The method according to the invention allows reducing the force required to disconnect the connector from the socket.

[0058] In one embodiment, the method comprises controlling the second torque and / or force such that a controlled quasi-static movement of the connector is obtained.

[0059] In one embodiment, the method includes applying a second torque and / or force on the connector when the interaction force between the partially inserted connector and the socket exceeds a predetermined threshold. In particular, the method allows controlling the application of the second torque and / or force only when the interaction force exceeds the threshold so as to allow the compliant component to compensate for this interaction force without having to generate and / or expand the compliance stroke of the connector. The interaction force according to the present invention represents a force applied by one object on another object as a result of their interaction with each other. A non-limiting example is friction, which is caused by the interaction of the surfaces of the socket and the connector when they are in contact.

[0060] In one embodiment, the method includes applying a second moment and / or force on the connector in at least one direction substantially resisting interaction forces between the partially inserted connector and the receptacle.

[0061] In one embodiment, the method includes applying a second torque and / or force on the connector when the interaction force between the partially inserted connector and the socket in the insertion / extraction direction exceeds a first predetermined threshold.

[0062] In one embodiment, the method includes applying a second torque and / or force on the connector when an interaction force between the partially inserted connector and the receptacle in a direction other than the insertion / removal direction exceeds a second predetermined threshold.

[0063] It is important to note that the interaction forces may have different directions, which may affect the threshold for controlling the application of the second force or torque. Therefore, in order to account for different interaction forces, the method also includes determining appropriate thresholds for different types of interaction forces (such as interaction forces in the plugging / unplugging direction or in directions other than the plugging / unplugging direction).

[0064] In one embodiment, the method includes applying a second torque and / or force until it is determined that the interaction force between the partially inserted connector and the socket is below a predetermined threshold, while continuing to apply the first torque and / or force on the connector in a direction substantially parallel to the plugging direction.

[0065] In one embodiment, the method comprises applying a second torque and / or force such that at least one of the following movements of the connector is obtained: - linear movement along an axis having the largest dimension orthogonal to the direction of movement, - a rotational movement about an axis orthogonal to the axis having the greatest dimension and to the direction of movement; - Movement around the point that will resolve the misalignment.

[0066] -quasi-static square-diamond motion; - Sine wave motion.

[0067] In one embodiment, the method includes alternating between the motions when it is determined that applying a second torque and / or force will not reduce the interaction force between the partially inserted connector and the receptacle.

[0068] In one embodiment, the method includes applying a first torque and / or force and / or a second torque and / or force until an electrical connection between the socket and the connector is established.

[0069] In one embodiment, the method includes receiving a signal that the connector and the socket are clamped before applying the second torque and / or force. The present invention will be explained in more detail with reference to the following drawings, in which:

[0070] Figure 1 A connector (1) is shown normally inserted into a socket (6), and also shows the insertion direction (P), the vertical axis (C) fixed to the connector, the vertical axis (S) fixed to the socket, and the slight tolerance (11) that exists when the connector is normally inserted. Usually, electrical contacts (not shown) facilitate symmetrical (or at least constant) use of tolerances by a (passive) mechanism that provides sufficient contact pressure between the conductors, such as a leaf spring type mechanism for one side of the pin-hole pair.

[0071] Figures 2a and 2b show two embodiments of a connector operating mechanism. They show a connector (1) positioned by a positioning mechanism including an actuator (2), wherein a compliant component (3) is kinematically connected in series with the actuator (2) between a fixed reference system (5) and the connector (1), wherein the compliant component is distributed throughout the mechanism in Figure 2a, or concentrated near the connector (1) in Figure 2b. The figures also show the position and orientation of the connector (1) and the compliant position (4) of the compliant component (3) when the connector (1) is not constrained by the socket (i.e., the neutral position and orientation of the connector (1)).

[0072] 3a and 3b illustrate the results of applying the invention within a connector operating mechanism by translation orthogonal to the insertion direction (Fig. 3a), and the results of an enlarged connector-receptacle interaction (Fig. 3b).

[0073] Figure 3a shows a connector operating mechanism having a compliance travel (7) relative to the normal compliant position (4) of the compliant assembly (3) when the connector (1) is not constrained by the receptacle (6), ie the neutral position and orientation of the connector (1).

[0074] Figure 3b shows the connector (1) partially inserted into the socket (6). Figure 3b also shows the force (F) and force (I) exerted on the connector (1) by the compliant assembly (3) caused by the compliant stroke (7) (as shown in Figure 3a), wherein the force (I) in the insertion direction is intended to provide the insertion movement, while the force (F) orthogonal to the insertion direction is intended to reduce the requirement for (I). The force (F) orthogonal to the insertion direction causes a slight displacement (12) of the connector (1) within the tolerance of the socket (6) relative to the symmetry of the tolerance (11). Figure 3b effectively shows an example during a prying movement.

[0075] Although Figures 3a and 3b show the effect of insertion, the same effect can be achieved for removal by using a compliant stroke that will result in a force in the opposite direction of I.

[0076] 4a and 4b illustrate the result of applying the invention in a connector operating mechanism by rotation about an axis orthogonal to the insertion direction (Fig. 4a), and the result of an enlarged connector-receptacle interaction (Fig. 4b).

[0077] FIG. 4 a shows the connector operating mechanism with the compliance travel ( 8 ) of the compliance assembly ( 3 ) when the connector ( 1 ) is to be freed from the socket ( 6 ).

[0078] Figure 4b shows the connector (1) partially inserted into the socket (6). Figure 4b also shows the moment (M) and force (I) exerted on the connector (1) by the compliant assembly (3) caused by the compliant stroke (8), wherein the force (I) in the insertion direction is intended to provide the insertion movement, and the moment (M) about an axis orthogonal to the insertion direction is intended to reduce the requirements of (I). The moment (M) about the axis orthogonal to the insertion direction causes the connector (1) to rotate slightly (13) relative to the insertion direction (P) within the tolerance of the socket (6). Figure 4b effectively shows an example during a prying motion. Although Figures 4a and 4b show the effect of insertion, the same effect can be achieved for removal by using a compliant stroke that will cause a force in the opposite direction of I.

[0079] Other variations to the disclosed embodiments may be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. An apparatus for connecting a connector of an electric vehicle charger to a socket on an electric vehicle in a predetermined position and orientation, wherein: The connector and the socket: Each having a plurality of poles which can be electrically connected to each other by establishing electrically conductive pin and hole connection pairs, wherein the connector comprises the pins and the socket comprises the associated holes, and / or the connector comprises the holes and the socket comprises the associated pins, wherein: Each pin and hole pair has a centerline extending axially from the center of the associated pin or hole, the centerlines being parallel; capable of being connected by movement towards each other, the movement having: a direction substantially parallel to the direction of the centerline of the pin and hole, and a mutual orientation of said connector and said socket wherein respective centerlines of said pins and holes of at least two pin and hole connection pairs coincide; Each comprises a housing; wherein the connector housing and the socket housing: able to connect by moving towards each other; including a mechanical guide portion that projects beyond an end of the pin in a direction parallel to the direction of the centerline; wherein the connector housing and the socket housing include manufacturing and / or operating tolerances that facilitate limited movement in at least one degree of freedom; The device comprises: A connector operating mechanism, comprising: an actuated positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference frame; at least one compliant assembly configured to allow the connector to compliantly move in at least two degrees of freedom relative to the fixed reference frame, wherein the at least one compliant component: kinematically in series with the positioning mechanism, between the fixed reference frame and the connector; and including a compliance travel defined as an effective displacement between an actual connector position and orientation and a neutral position and orientation of the connector, the neutral position and orientation being defined by at least the connector operating mechanism carrying the connector when the connector is not constrained by the receptacle; and Wherein, in order to connect the connector, the connector operating mechanism is configured to apply on the connector: A first torque and / or force in a moving direction for moving the connector in the moving direction; and at least a second moment and / or force superimposed on said first moment and / or force, said second moment and / or force having a directional component or direction different from said direction of movement, wherein said second moment and / or force is directed towards said neutral position and orientation; It is characterized in that The connector operating mechanism is configured to exert the at least second torque and / or force on the connector when, and in particular only when, the connector is at least partially inserted into the socket, wherein the second torque and / or force is exerted by generating or expanding the compliance stroke by actuating the positioning mechanism.

2. A device for disconnecting a connector of an electric vehicle charger from a socket on an electric vehicle in a predetermined position and orientation, wherein: The connector and the socket: Each having a plurality of poles which can be electrically connected to each other by establishing electrically conductive pin and hole connection pairs, wherein the connector comprises the pins and the socket comprises the associated holes, and / or the connector comprises the holes and the socket comprises the associated pins, wherein: Each pin and hole pair has a centerline extending axially from the center of the associated pin or hole, the centerlines being parallel; capable of being disconnected by a movement directed away from each other, said movement having: a direction substantially parallel to the direction of the centerline of the pin and hole, and a mutual orientation of said connector and said socket wherein respective centerlines of said pins and holes of at least two pin and hole connection pairs coincide; Each comprises a housing; wherein the connector housing and the socket housing: able to be disconnected by the same movement directed away from each other; including a mechanical guide portion that projects beyond an end of the pin in a direction parallel to the direction of the centerline; in The connector housing and the receptacle housing include manufacturing and / or operating tolerances that facilitate limited movement in at least one degree of freedom; The device comprises: A connector operating mechanism, comprising: an actuated positioning mechanism for moving the connector in at least two degrees of freedom relative to a fixed reference frame; at least one compliant assembly configured to allow the connector to compliantly move in at least two degrees of freedom relative to the fixed reference frame, wherein the at least one compliant component: kinematically in series with the positioning mechanism, between the fixed reference frame and the connector; and including a compliance travel defined as an effective displacement between an actual connector position and orientation and a neutral position and orientation of said connector, said neutral position and orientation being defined by at least said connector operating mechanism carrying said connector when said connector is not constrained by said receptacle; and Wherein, in order to disconnect the connector, the connector operating mechanism is configured to apply on the connector: A first torque and / or force in a moving direction for moving the connector in the moving direction; and at least a second moment and / or force superimposed on said first moment and / or force, said second moment and / or force having a directional component or direction different from said direction of movement, wherein said second moment and / or force is directed towards said neutral position and orientation; It is characterized in that The connector operating mechanism is configured to exert the at least second torque and / or force on the connector when, and in particular only when, the connector is at least partially inserted into the socket, wherein the second torque and / or force is exerted by generating or expanding the compliance stroke by actuating the positioning mechanism.

3. The device according to claim 1 or 2, wherein: For connecting or disconnecting the connector, the connector operating mechanism is configured for limiting the second torque and / or force to such an extent that a controlled quasi-static movement of the connector is obtained.

4. The device according to claim 1, 2 or 3, wherein: The connector operating mechanism is configured to superimpose a second moment and / or force along or about a single axis.

5. A device according to any one of the preceding claims, wherein: The connector operating mechanism is configured for at least once alternating the direction of the superimposed second torque or force, in particular in a controlled manner.

6. A device according to any one of the preceding claims, wherein: The connector operating mechanism is configured to apply the second torque and / or force by setting the compliance stroke to the following amount: preferably, for translation, greater than 0.02m, and / or for rotation, greater than 2 degrees; more preferably, for translation, greater than 0.01m, and / or for rotation, greater than 1 degree; and most preferably, for translation, greater than 0.005m, and / or for rotation, greater than 0.5 degrees.

7. A device according to any one of the preceding claims, wherein: The second torque and / or force is applied only when it is determined that the connector is stuck.

8. Apparatus according to any preceding claim, comprising controlling the second torque and / or force based on input from a sensor such as a force sensor or a camera or measured misalignment.

9. The device according to any one of the preceding claims, wherein: The second moment and / or force is applied in a direction in which a main component of the measured misalignment is reduced.

10. The device according to any one of the preceding claims, wherein: The actuator for applying the second torque and / or force is also used to control at least one degree of freedom of the positioning mechanism.

11. The device according to any one of the preceding claims, wherein: The second movement includes at least one of the following: a. linear motion along an axis having a maximum dimension orthogonal to the direction of movement, b. rotational movement about an axis orthogonal to the axis having the largest dimension and the direction of movement; and / or c. Movement around the point where the misalignment is to be resolved.

12. A method for controlling an autonomous charging device (ACD) for autonomously connecting a connector to a socket in an electric vehicle, the ACD comprising a connector operating mechanism, the connector operating mechanism comprising an actuated connector positioning mechanism and a compliant component, the compliant component allowing a compliant connection of the connector by movement in a connecting direction, It is characterized in that The method comprises: a. applying a first torque and / or force on the connector in a direction substantially parallel to the connection direction by the connector operating mechanism; b. applying a second torque and / or force on the connector by the connector operating mechanism in a direction different from the direction of the first torque and / or force, The second moment and / or force is applied by: when the connector is at least partially inserted into a socket of the electric vehicle, superimposed on the first moment and / or force, and By creating and / or expanding the compliant travel of the connector.

13. A method for controlling an autonomous charging device (ACD) for autonomously disconnecting a connector from a socket in an electric vehicle, the ACD comprising a connector operating mechanism, the connector operating mechanism comprising an actuated connector positioning mechanism and a compliant assembly, the compliant assembly allowing compliant disconnection of the connector by movement in a disconnecting direction, It is characterized in that The method comprises: a. applying a first torque and / or force on the connector in a direction substantially parallel to the disconnecting direction by the connector operating mechanism; b. applying a second torque and / or force on the connector by the connector operating mechanism in a direction different from the direction of the first torque and / or force, The second moment and / or force is applied by: when the connector is at least partially inserted into a socket of the electric vehicle, superimposed on the first moment and / or force, and By creating and / or expanding the compliant travel of the connector.

14. The method according to any one of claims 12 or 13, further comprising controlling the second moment and / or force such that a controlled quasi-static movement of the connector is obtained.

15. The method of claim 12 or 13, further comprising applying the second moment and / or force on the connector when the interaction force between the partially inserted connector and the socket exceeds a predetermined threshold.

16. The method of claim 15, further comprising applying the second moment and / or force on the connector in at least one direction to substantially resist interaction forces between the partially inserted connector and the receptacle.

17. The method according to claim 15 or 16, further comprising applying the second moment and / or force on the connector when the interaction force between the partially inserted connector and the socket in the insertion / extraction direction exceeds a first predetermined threshold.

18. The method according to claim 15 or 16, further comprising applying the second moment and / or force on the connector when the interaction force between the partially inserted connector and the socket in a direction other than the insertion / extraction direction exceeds a second predetermined threshold.

19. The method according to claim 15 also includes applying the second torque and / or force until it is determined that the interaction force between the partially inserted connector and the socket is below the predetermined threshold, while continuing to apply the first torque and / or force on the connector in a direction substantially parallel to the plugging direction.

20. The method according to any one of claims 12 to 19, further comprising applying the second moment and / or force such that at least one of the following movements of the connector is obtained: a. Linear motion along an axis with the largest dimension orthogonal to the direction of movement, b. rotational movement about an axis orthogonal to the axis having the largest dimension and the direction of movement; c. Movement around the point that will resolve the misalignment; d. Quasi-static square diamond motion; e. Sine wave motion.

21. The method of any one of claims 12 to 20, further comprising alternating between movements when it is determined that applying the second moment and / or force will not reduce the interaction force between the partially inserted connector and the socket.

22. The method according to any one of claims 12 to 21, further comprising applying the first torque and / or force and / or the second torque and / or force until an electrical connection between the socket and the connector is established.

23. The method of any one of claims 12 to 22, further comprising receiving a signal that the connector and the socket are clamped before applying the second torque and / or force.

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