Stereo garage electric vehicle automatic charging connection device and charging method thereof

Abstract

The present application relates to electric vehicle garage charging technical field, especially a kind of automatic charging connection device of electric vehicle of stereo garage and charging method thereof.The automatic charging connection device of electric vehicle of stereo garage includes first connection component arranged on the vehicle carrying piece and second connection component arranged on the garage fixed position, including active docking assembly arranged in the garage fixed position, active docking assembly is through servo drive unit, transmission mechanism, docking tray and the multi-stage guide and centering module integrated on tray, sequentially execute macro positioning wedge based on geometric constraint and micro compliant docking based on force-position closed-loop control, and is equipped with mechanical locking mechanism of electromechanical unlocking interlocking.The present application realizes high-precision, high-reliability full-automatic docking, effectively compensates the positioning error of carrier, greatly improves the safety and intelligent level of stereo garage charging.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle garage charging technology, and in particular to an automatic charging connection device and charging method for electric vehicles in a multi-level parking garage. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the current construction of parking spaces and charging stations cannot meet the actual demand. Against this backdrop, mechanical multi-level parking garages, which can significantly improve space utilization, are seen as an effective solution to urban static traffic problems and are increasingly favored by society and the market. However, most electric vehicle multi-level parking garages on the market currently have limited functionality, only providing parking and failing to offer convenient charging options while parking. This forces many new energy vehicle users to rely on a limited number of ground-based charging stations and wait in line when they need to charge. This prevents multi-level parking garages from meeting the urgent need for simultaneous charging during parking, greatly limiting their market value and application prospects.

[0003] In automated parking systems, the moving and placing of vehicle platforms inevitably involves positioning errors on the order of ±10mm. Meanwhile, the docking of high-power charging interfaces demands extremely high precision and contact reliability, a contradiction that has traditionally been difficult to resolve. While some attempts have been made in existing technologies, they all have significant limitations. For example, passive mechanical docking solutions using simple flared guides, positioning pins and conical holes, or carbon brush sliding contacts, as seen in existing patents with publication numbers CN107217896B and CN107965187A, generally rely on the vehicle platform's own movement or spring buffering for passive docking. These solutions suffer from inherent defects such as high docking impact, limited fault tolerance, lack of precise force control, and easy wear and tear leading to poor contact over long-term use. They cannot meet the stringent requirements of high-power charging for connection reliability and safety, and also affect the equipment's lifespan.

[0004] Therefore, there is an urgent need for a solution that can overcome the above-mentioned technical problems, proactively and intelligently compensate for the inherent positioning errors of multi-level parking garages, and achieve a smooth, accurate and fully monitored automatic docking, so that multi-level parking garages can truly become a modern infrastructure integrating parking and charging. Summary of the Invention

[0005] The technical problem to be solved by the present invention is: in order to solve the problems of the existing technology in the background art, such as the large safety hazards of manual operation in electric vehicle parking spaces, the inability to automatically connect, and the difficulty of implementing charging operations, an automatic charging connection device for electric vehicles in a multi-level parking garage is provided. By setting a servo-driven active docking assembly and a multi-level guide centering module at a fixed position in the garage, the precise, smooth, automatic docking and locking of the docking components can be achieved.

[0006] The technical solution adopted by this invention to solve its technical problem is: an automatic charging docking device for electric vehicles in a multi-level parking garage, comprising a first docking component mounted on a vehicle carrier and a second docking component mounted on a fixed position in the parking garage. The vehicle carrier is transported by a transporter of the multi-level parking garage and parked in the parking space where the fixed position is located. The automatic charging docking device includes an active docking assembly installed at a fixed location in the garage, the active docking assembly comprising: A servo drive unit rigidly mounted in a fixed position in the garage; A transmission mechanism directly driven by the servo drive unit; A docking tray fixedly connected to the output end of the transmission mechanism, and the second docking assembly fixedly installed on the docking tray; A multi-level guiding and centering module integrated on the docking tray; The active docking assembly performs the following operations in sequence: a. By cooperating with the four corner auxiliary mechanisms set on the vehicle carrier and the guide mechanism set on the docking tray, the macroscopic positioning and initial wedge engagement of the vehicle carrier and the garage fixed position are achieved; b. The centering mechanism on the docking tray works in conjunction with the first docking component to perform secondary positioning and centering calibration, and pushes the second docking component to complete the electrical connection with the first docking component.

[0007] The servo drive unit is located on the fixed side of the garage. Through multi-level guidance and centering modules, it sequentially performs macroscopic preliminary positioning and microscopic precise positioning. By placing the complex active drive system on the fixed side, the complexity and cost of the moving vehicle components are reduced. This realizes the transformation from passively relying on the movement of the vehicle platform to active and precise docking, thereby improving the reliability of automatic charging.

[0008] According to one embodiment of the present invention, the device further includes a pressure sensor for detecting docking pressure and a position sensor for detecting docking position. The pressure sensor and the position sensor are signal-connected to the servo drive unit to form a closed-loop control loop for controlling the force and position during the docking process.

[0009] By introducing pressure and position sensors, a closed-loop control circuit is formed to control the force and position during the docking process. This can prevent damage to the docking parts due to excessive rigid impact and avoid poor connection caused by poor contact.

[0010] According to one embodiment of the present invention, the centering mechanism includes a double-layer sliding groove plate and a deep groove ball array disposed therein, wherein the deep groove ball array contacts the first connecting component in step b and the relative position of the two is adaptively adjusted by rolling.

[0011] Deep groove balls roll under pressure, which can dynamically eliminate the slight concentricity deviation of the two parties in the final stage of docking, ensuring that the docking components are smoothly introduced under stress-free or low-stress conditions, and achieving docking with long service life and low wear.

[0012] Furthermore, the deep groove ball array is installed in the double-layer sliding groove plate by an elastic preload, giving it floating adaptive capability.

[0013] Elastic preload ensures the reliability of the initial contact between the ball and the docking assembly, while also allowing for yielding displacement in all directions, making the docking process smoother and more precise.

[0014] According to one embodiment of the present invention, a mechanical locking mechanism is further included, the mechanical locking mechanism including a pin driven by a rotary drive unit that can slide laterally into a slot on the first docking assembly to achieve mechanical locking against torsion and separation after docking.

[0015] Relying solely on contact elasticity may loosen under long-term vibration. Mechanical locking provides a second layer of physical protection, enhancing the long-term stability and safety of the charging process.

[0016] Furthermore, the mechanical locking mechanism is activated only when the pressure sensor detects that the docking pressure is within a preset range, and / or the position sensor reports that the docking is in place.

[0017] Mechanical locking is only permitted after confirming that the electrical connection has been stably established, thus preventing accidental locking when the connection is not properly established or is not properly established, and thus preventing equipment damage.

[0018] According to one embodiment of the present invention, a hydraulic damper is further included, which is disposed at the end of the stroke of the docking tray to absorb the impact energy when docking is completed.

[0019] The hydraulic damper and the force control of the servo motor complement each other to form a double buffer, which can effectively suppress impact, reduce noise, and improve the durability of the device.

[0020] According to one embodiment of the present invention, the transmission mechanism is a ball screw pair or a precision gear rack pair, and the docking tray is connected to the base of the garage fixed position through a linear guide rail.

[0021] Precision transmission pairs such as ball screws or racks and pinions are used with linear guides to ensure that the rotational motion of the servo motor can be smoothly converted into the linear motion required for docking with the tray. This provides high rigidity, low friction, and backlash-free transmission performance, achieving high repeatability and long-term stable operation.

[0022] According to one embodiment of the present invention, the device is provided with a modular protective housing that isolates the active docking assembly from the external environment.

[0023] For the harsh working environment of automated parking garages, characterized by high dust, high humidity, and susceptibility to foreign object intrusion, physical protection is provided to effectively prevent contaminants from affecting the performance of precision transmission and sensing components, thereby reducing maintenance frequency and failure rate.

[0024] A charging method for an automatic charging docking device for electric vehicles in a multi-level parking garage as described above is also provided, comprising the following steps: S1: Connect the electric vehicle charging port to the first connection component on the vehicle carrier; S2: Transport vehicle-mounted components carrying electric vehicles to designated storage locations in the automated parking system using intelligent transporters; S3: The vehicle-mounted component and the garage fixing position are initially positioned and wedge together through the four corner auxiliary mechanisms and guide mechanisms; S4: Start the servo drive unit to drive the docking tray to move, and the centering mechanism will perform secondary positioning and centering calibration. S5: The transmission mechanism continues to push the second connecting component to connect with the first connecting component. After the electronic sensor feeds back the signal of arrival, the connection stops. S6: Confirm that the data from the pressure sensor and servo drive unit are within the normal range; S7: Controls the mechanical locking mechanism to rotate the pin and slide it into the slot to lock the connecting component; S8: The communication test system performs communication and current tests to confirm connection stability; S9: The connection component is powered on, and the electric vehicle is charged by a high-power charging device.

[0025] The beneficial effects of this invention are: This invention replaces the traditional passive mechanical docking method by setting an active docking assembly consisting of a servo drive unit and a precision transmission mechanism on the fixed side of the garage, realizing active and controllable drive of the docking process and providing a power basis for high-precision operation; By setting up multi-level guidance and centering modules, the four corner auxiliary mechanisms are used to achieve macroscopic initial positioning, and the deep groove ball array is used to complete microscopic fine centering. With the help of hydraulic buffer and sensor closed-loop control system, the problems of small single guidance fault tolerance space and rigid impact are effectively solved. It realizes the inclusive correction of macroscopic deviation and adaptive compliant docking of microscopic deviation, which significantly improves the docking success rate and the service life of the device. By adding a mechanical locking mechanism and forming a safety interlocking mechanism with the sensing system, a secondary mechanical fixing guarantee is provided on the basis of electrical connection, which completely solves the safety hazard of easy loosening by relying solely on contact elasticity, and forms a dual guarantee of electrical connection and mechanical locking. This invention solves the technical bottleneck of high-precision automatic charging in automated parking garages through the synergistic effect of active driving, multi-level fault tolerance, flexible buffering, and safety interlocking. It achieves full automation, high reliability, and high safety throughout the charging connection process, ultimately realizing the transformation of automated parking garages from a single parking function to one that can both park and charge. Attached Figure Description

[0026] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0027] Figure 1 This is a schematic diagram of the device of the present invention in a multi-level parking garage.

[0028] Figure 2 A schematic diagram of the installation of the device of the present invention.

[0029] Figure 3 This is a schematic diagram of the active docking assembly in the device of the present invention.

[0030] Figure 4 for Figure 3 Side view sectional view.

[0031] Figure 5 This is a flowchart of the method of the present invention.

[0032] In the diagram: 100, vehicle carrier; 200, first connecting assembly; 300, garage fixing position; 400, second connecting assembly; 1, servo drive unit; 2, transmission mechanism; 3, docking tray; 4, pressure sensor; 5, position sensor; 71, double-layer sliding groove plate; 72, deep groove ball array; 73, elastic preload; 8, mechanical locking mechanism; 81, rotary drive unit; 82, pin; 83, slot; 9, hydraulic buffer. Detailed Implementation

[0033] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0034] like Figure 1 As shown, in the automated parking garage, the vehicle carrier 100 is placed in the parking space by a transporter, and its first docking component 200 is connected to the active docking assembly on the fixed position 300 of the garage. The active docking assembly is connected to the supercharging device via a cable. Through an intelligent active docking assembly located on the fixed side, the error problem caused by coarse positioning on the moving side (i.e., the vehicle carrier 100 side) is systematically solved.

[0035] Example 1 like Figure 2 and Figure 3As shown, an automatic charging docking device for electric vehicles in a multi-level parking garage mainly uses materials such as 60 aluminum alloy and Q235 steel plate. The docking insulation material is Polysilicon PA66FR2400, which has excellent properties such as (CTI (tracking index) 600V > CTI, halogen-free flame retardant UL94-V 0-0.4mm, high temperature resistance, high strength, and good thermal stability). It includes a first docking component 200 mounted on a vehicle carrier 100 and a second docking component 400 mounted on a fixed position 300 in the parking garage. The vehicle carrier 100 is transported and parked by a transporter in the multi-level parking garage. The automatic charging docking device, placed in the garage fixed position 300, includes an active docking assembly set in the garage fixed position 300. The active docking assembly includes a servo drive unit 1, a transmission mechanism 2, a docking tray 3, and a multi-level guiding and centering module. The servo drive unit 1 is rigidly installed on the garage fixed position 300. The transmission mechanism 2 is directly driven by the servo drive unit 1. The docking tray 3 is fixedly connected to the output end of the transmission mechanism 2. The second docking component 400 is fixedly installed on the docking tray 3. The multi-level guiding and centering module is integrated on the docking tray 3.

[0036] The servo drive unit 1, as the core power source, provides controllable and precisely modulated torque and speed output to achieve subsequent flexible docking. The transmission mechanism 2 converts the rotational motion of the servo motor 1 into high-rigidity, high-precision linear motion, achieving a positioning accuracy of ±0.01mm, providing a foundation for micro-alignment. The docking tray 3 is connected to the base via linear guides, serving as the end-effector platform. The second docking component 400, fixed to the docking tray 3, is the power output port.

[0037] It also includes a pressure sensor 4 for detecting docking pressure, a position sensor 5 for detecting docking position, a mechanical locking mechanism 8, and a hydraulic buffer 9. The pressure sensor 4 and position sensor 5 are signal-connected to the servo drive unit 1, forming a closed-loop control circuit for controlling the force and position during the docking process. The mechanical locking mechanism 8 includes a pin 82 driven by a rotary drive unit 81, which can slide laterally into the slot 83 of the first docking assembly 200 to achieve mechanical locking against torsion and separation after docking. The mechanical locking mechanism 8 is activated only when the pressure sensor 4 detects that the docking pressure is within a preset range, and / or when the position sensor 5 reports that the docking is in place. The hydraulic buffer 9 is located at the end of the stroke of the docking tray 3 to absorb the impact energy when docking is completed. The device is equipped with a modular protective shell that isolates the active docking assembly from the external environment, effectively isolating dust, oil, and accidental impacts, ensuring the long-term stable operation of the internal precision mechanisms.

[0038] like Figure 4As shown, the centering mechanism includes a double-layer sliding groove plate 71 and a deep-groove ball array 72 disposed therein. When the deep-groove ball array 72 contacts the first connecting component 200, it adaptively adjusts the relative position of the two by rolling. The deep-groove ball array 72 is also installed in the double-layer sliding groove plate 71 by an elastic preload member, giving it floating adaptive capability. The transmission mechanism 2 is a ball screw pair or a precision gear rack pair, and the docking tray 3 is connected to the base of the garage fixing position 300 through a linear guide rail.

[0039] Deep groove ball bearings and elastic preload constitute the inherent mechanical resistance, characterized by the stiffness matrix. and damping matrix The pressure sensor 4 and the servo controller constitute an external normal active impedance; Total impedance manifested externally Through design and The proportional relationship allows for differentiated impedance characteristics in different directions. In the tangential and tilting directions, mechanical impedance is mainly used to achieve rapid response and vibration suppression, while in the docking direction, electronic impedance is used to achieve precise force tracking.

[0040] After the vehicle carrier 100 is placed in the parking space by the transporter, the servo drive unit 1 drives the transmission mechanism 2 according to a preset program, pushing the docking tray 3 and the second docking assembly 400 fixed thereon toward the vehicle carrier 100. Specifically, the four corner auxiliary mechanisms on the vehicle carrier 100 and the guide mechanism on the docking tray 3 together form a spatial kinematic funnel, wherein the four corner auxiliary mechanisms can be a pair of tapered pin sleeves. According to the principle of rigid body kinematics, when inclined plane contact occurs, regardless of the initial deviation of the vehicle carrier 100 in the plane, the normal force at the contact point can be decomposed into a corrective force that forces the relative positions of both parties back to the ideal axis. This process does not depend on sensor feedback, and its convergence is guaranteed by the geometric parameters of the mechanical structure.

[0041] Once the initial positioning is complete, the deep groove ball array 72 and the elastic preload 73 form a passive compliant unit equivalent to six degrees of freedom. When the balls contact the first docking assembly 200, the docking tray 3 is allowed to generate minute translations and rotations in three-dimensional space to offset the remaining millimeter- to sub-millimeter-level concentricity and angular deviations. At the same time, the contact force is monitored in real time by the pressure sensor 4, forming a force feedback closed loop. The controller adopts an admittance control algorithm, the core objective of which is to adjust the docking force so that it smoothly approaches and stabilizes at the optimal set value. At this stage, the hydraulic buffer 9, together with the active force control, forms a dual buffering mechanism.

[0042] For a typical DC charging interface, the optimal contact force can be set to 150N to 250N. When the measured force is below the lower limit, the controller command slowly increases the push; when it is above the upper limit, the command slightly retracts. This force-guided docking method simulates the most delicate hand-eye coordination of humans, eliminates rigid collisions, and ensures zero damage to the terminal contact surface and minimizes contact resistance.

[0043] The selection of the location and parameters of the hydraulic buffer 9 is based on the energy analysis method of impact dynamics. By calculating the maximum kinetic energy of the system and the elastic potential energy of the contact materials during the docking process, the maximum energy that the hydraulic buffer 9 needs to absorb is determined. Then according to The optimal damping coefficient is calculated by back-calculation, where C is the damping coefficient, v is the impact velocity, and t is the buffer time, ensuring that all impact energy is absorbed smoothly in the shortest possible time.

[0044] After docking is completed, the control system continuously collects data from each sensor and holds it briefly to confirm that the state is stable. Only when the pressure sensor 4 detects that the docking pressure is within the preset range, and / or the position sensor 5 reports that the docking is in place, the mechanical locking mechanism 8 is triggered. The mechanical locking mechanism 8 drives the pin 82 to slide into the 83 on the first docking assembly 200 through the rotary drive unit 81, thereby achieving independent mechanical locking.

[0045] Example 2 Card slots Figure 5 As shown, the charging method for the automatic charging docking device for electric vehicles in a multi-level parking garage includes the following steps: Step 1: Connect the electric vehicle charging port to the first connection component 200 on the vehicle carrier 100; Step 2: Use an intelligent transporter to transport the vehicle carrier 100, which is loaded with electric vehicles, to the designated storage location in the automated parking garage. Step 3: The vehicle carrier 100 and the garage fixing position 300 are initially positioned and wedge together using the four corner auxiliary mechanisms and guide mechanisms; Step 4: Start the servo drive unit 1 to drive the docking tray 3 to move, and the centering mechanism will perform secondary positioning and centering calibration. Step 5: The transmission mechanism 2 continues to push the second connecting component 400 to connect with the first connecting component 200. After the electronic sensor sends a signal indicating that the connection is in place, the connection stops. Step 6: Confirm that the data from pressure sensor 4 and servo drive unit 1 are within the normal range; Step 7: Control the mechanical locking mechanism 8 to rotate and slide the pin 82 into the slot 83 to lock the connecting component; Step 9: The communication testing system performs communication and current tests to confirm connection stability; Step 10: Power on the connection components, and the high-power charging device will charge the electric vehicle.

[0046] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. An automatic charging docking device for electric vehicles in a multi-level parking garage, comprising a first docking component (200) disposed on a vehicle carrier (100) and a second docking component (400) disposed on a fixed position in the parking garage (300), wherein the vehicle carrier (100) is transported by a transporter of the multi-level parking garage and parked in the parking space where the fixed position in the parking garage (300) is located, characterized in that: The automatic charging docking device includes an active docking assembly disposed at a fixed position (300) in the garage, the active docking assembly comprising: A servo drive unit (1) is rigidly mounted in a garage fixed position (300). A transmission mechanism (2) directly driven by the servo drive unit (1); A docking tray (3) is fixedly connected to the output end of the transmission mechanism (2), and the second docking assembly (400) is fixedly installed on the docking tray (3); A multi-level guiding and centering module integrated on the docking tray (3); The active docking assembly performs the following operations in sequence: a. By cooperating with the four corner auxiliary mechanisms set on the vehicle carrier (100) and the guide mechanism set on the docking tray (3), the macroscopic positioning and initial wedge of the vehicle carrier (100) and the garage fixed position (300) are realized; b. By cooperating with the centering mechanism on the docking tray (3) and the first docking component (200), secondary positioning and centering calibration are performed, and the second docking component (400) is pushed to complete the electrical connection with the first docking component (200); The centering mechanism includes a double-layer sliding groove plate (71) and a deep groove ball array (72) disposed therein. The deep groove ball array (72) contacts the first connecting component (200) in step b and adjusts the relative position of the two by rolling adaptively. The deep groove ball array (72) is installed in the double-layer sliding groove plate (71) by an elastic preload, so that it has the ability to float and adapt. It also includes a mechanical locking mechanism (8), which includes a pin (82) driven by a rotary drive unit (81) and capable of sliding laterally into a slot (83) on the first docking assembly (200) to achieve mechanical locking against torsion and separation after docking.

2. The automatic charging docking device for electric vehicles in a multi-level parking garage according to claim 1, characterized in that: It also includes a pressure sensor (4) for detecting docking pressure and a position sensor (5) for detecting docking position. The pressure sensor (4) and the position sensor (5) are connected to the servo drive unit (1) to form a closed-loop control loop for controlling the force and position during the docking process.

3. The automatic charging docking device for electric vehicles in a multi-level parking garage according to claim 2, characterized in that: The mechanical locking mechanism (8) is activated only when the pressure sensor (4) detects that the docking pressure is within the preset range and / or the position sensor (5) reports that the docking is in place.

4. The automatic charging docking device for electric vehicles in a multi-level parking garage according to claim 1, characterized in that: It also includes a hydraulic buffer (9), which is located at the end of the stroke of the docking tray (3) and is used to absorb the impact energy when docking is completed.

5. The automatic charging docking device for electric vehicles in a multi-level parking garage according to claim 1, characterized in that: The transmission mechanism (2) is a ball screw pair or a precision gear rack pair, and the docking tray (3) is connected to the base of the garage fixed position (300) through a linear guide rail.

6. The automatic charging docking device for electric vehicles in a multi-level parking garage according to claim 1, characterized in that: The device is equipped with a modular protective shell that isolates the active docking assembly from the external environment.

7. A charging method for an automatic charging docking device for electric vehicles in a multi-level parking garage as described in any one of claims 1-6, characterized in that, Includes the following steps: S1: Connect the electric vehicle charging port to the first connection component (200) on the vehicle carrier (100); S2: Transport the vehicle carrier (100) loaded with electric vehicles to the designated storage location in the automated parking garage using an intelligent transporter; S3: The vehicle carrier (100) and the garage fixing position (300) are initially positioned and wedge together through the four corner auxiliary mechanism and the guide mechanism; S4: Start the servo drive unit (1) to drive the docking tray (3) to move, and the centering mechanism will perform secondary positioning and centering calibration; S5: The transmission mechanism (2) continues to push the second connecting component (400) to connect with the first connecting component (200). After the electronic sensor feeds back the signal of arrival, the connection stops. S6: Confirm that the data from the pressure sensor (4) and the servo drive unit (1) are within the normal range; S7: Control the mechanical locking mechanism (8) to rotate and slide the pin (82) into the slot (83) to lock the connecting component; S8: The communication test system performs communication and current tests to confirm connection stability; S9: The connection component is powered on, and the electric vehicle is charged by a high-power charging device.

Images