Wireless power supply and mechanical clamping cooperative charging pile system and control method

Abstract

The invention discloses a wireless power supply and mechanical clamping cooperative charging pile system and a control method, and relates to the technical field of electric vehicle charging. The system comprises a mechanical clamping module, a wireless power supply module, a sensing detection module, a main control module and a power supply interface module. The mechanical clamping module achieves accurate positioning and fixing of a vehicle, the wireless power supply module is responsible for electric energy transmission, the sensing and detecting module collects signals of positions, postures and the like, and the main control module achieves cooperative control over all the modules. According to the control method, synchronous linkage of clamping and power supply is achieved through the processes of vehicle in-place detection, coil alignment deviation correction, precise clamping, cooperative power supply, real-time monitoring and adjustment and loosening after charging. The problems that an existing wireless charging pile coil is low in alignment precision, and a vehicle is prone to displacement in the charging process are solved, the charging efficiency and safety are improved, the full-automatic charging process is achieved, the wireless charging pile is suitable for different vehicle types, and the wireless charging pile has high practicability and popularization value.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle charging technology, specifically to a charging pile system and control method that combines wireless power supply and mechanical clamping. Background Technology

[0002] With the rapid development of the electric vehicle industry, wireless charging technology has gradually become a research hotspot in the field of electric vehicle charging due to its advantages such as no physical plugging and unplugging and ease of use. However, existing wireless charging stations still have many shortcomings in practical applications:

[0003] On the one hand, the efficiency of wireless power supply is highly dependent on the alignment accuracy of the primary and secondary coils. Misalignment of the vehicle parking can easily lead to a significant drop in power supply efficiency, or even prevent normal charging.

[0004] On the other hand, existing wireless charging stations lack effective mechanical positioning and clamping mechanisms. If a vehicle is displaced during charging due to external forces (such as strong winds or collisions), it will further exacerbate the coil misalignment problem, leading to safety hazards such as charging interruption and equipment overheating.

[0005] Currently, some related technologies attempt to combine clamping structures with wireless charging. For example, the four-clamp wireless charger disclosed in patent CN219041450U uses four clamping arms to hold the device to be charged for fixation. However, this technology is suitable for small devices such as mobile phones and cannot meet the heavy-load and high-precision positioning requirements of electric vehicles. The wireless charging base synchronous linkage clamping device in patent CN214755626U uses spring-driven clamping plates to achieve clamping, but its clamping force is uncontrollable and it does not achieve coordinated control of clamping and power supply, making it difficult to adapt to the complex scenario of wireless charging of electric vehicles.

[0006] Furthermore, while wireless charging systems for underwater AUVs (such as those in related X technology literature) have guidance and clamping functions, the technology is designed for the special underwater environment, and its structure and control logic cannot be directly transferred to land-based electric vehicle charging scenarios.

[0007] Therefore, developing a charging pile system and control method that can achieve precise coordination between mechanical clamping and wireless power supply, and ensure coil alignment accuracy and charging process stability, has become an urgent technical problem to be solved. Summary of the Invention

[0008] To address the shortcomings of existing wireless charging pile technologies, such as low coil alignment accuracy, easy vehicle displacement during charging, and lack of coordinated control between clamping and power supply, this invention provides a charging pile system and control method that coordinates wireless power supply and mechanical clamping. The mechanical clamping mechanism achieves precise positioning and stable fixation of the vehicle, and synchronously coordinates the start-up, operation, and shutdown of the wireless power supply module to ensure charging efficiency and safety.

[0009] To achieve the above objectives, the present invention provides the following technical solution:

[0010] A charging pile system that combines wireless power supply and mechanical clamping includes a mechanical clamping module, a wireless power supply module, a sensing and detection module, a main control module, and a power supply interface module.

[0011] The mechanical clamping module includes two sets of clamping units symmetrically arranged on both sides of the charging area. Each set of clamping units consists of a servo motor, a ball screw, a clamping arm, and a pressure sensor. The servo motor drives the ball screw to move the clamping arm in the horizontal direction, and the pressure sensor is installed on the inner side of the clamping arm.

[0012] The wireless power supply module includes a primary coil array, a power adjustment unit, and a coil drive circuit. The primary coil array is embedded in the ground of the charging area, and the power adjustment unit is used to dynamically adjust the output power.

[0013] The perception and detection module includes a parking space recognition sensor, a coil alignment detection unit, and a vehicle status sensor. The parking space recognition sensor is used to detect whether the vehicle has entered the preset charging area, and the coil alignment detection unit is used to obtain the relative positional deviation between the primary coil and the secondary coil of the vehicle.

[0014] The main control module is electrically connected to the mechanical clamping module, the wireless power supply module, the sensing and detection module, and the power supply interface module, respectively. It is used to receive the detection signals from the sensing and detection module, control the clamping and releasing actions of the mechanical clamping module, and synchronously adjust the operating status of the wireless power supply module.

[0015] The power supply interface module is used to connect to the external power grid and provide power input to the entire system.

[0016] Furthermore, the coil alignment detection unit adopts an electromagnetic induction detection method. By using the induced voltage signals of each sub-coil in the primary coil array, the deviation value between the center coordinates of the secondary coil and the center of the primary coil array is calculated, and the deviation detection accuracy is not less than ±2mm.

[0017] Furthermore, the servo motor of the mechanical clamping module has a power-off self-locking function, and an anti-slip rubber pad is provided on the inner side of the clamping arm, with a pressure sensor array on the surface of the anti-slip rubber pad.

[0018] Furthermore, the main control module incorporates a collaborative control strategy, including clamping-power supply linkage logic, deviation correction logic, and anomaly protection logic.

[0019] A control method based on the system of any one of claims 1-4, comprising the following steps:

[0020] S1: When a vehicle enters the charging area, the parking space recognition sensor detects the vehicle and sends a position signal to the main control module.

[0021] S2: After receiving the bit signal, the main control module controls the coil alignment detection unit to work and obtain the relative position deviation between the primary coil and the secondary coil.

[0022] S3: If the position deviation is greater than the preset threshold, the main control module controls the servo motor of the mechanical clamping module to start, driving the clamping arm to push the vehicle for fine adjustment until the position deviation is less than or equal to the preset threshold; if the position deviation is less than or equal to the preset threshold, then step S4 is executed directly.

[0023] S4: The main control module controls the clamping arms of the two clamping units to move closer together synchronously to clamp the vehicle chassis. When the clamping force reaches the preset clamping force range, the servo motor stops working and self-locks.

[0024] S5: After the mechanical clamping is completed, the main control module sends a start signal to the wireless power supply module, and the wireless power supply module starts and transmits power to the vehicle side;

[0025] S6: During the charging process, the sensing and detection module monitors the coil alignment deviation, vehicle attitude and system operating parameters in real time, and transmits the monitoring data to the main control module.

[0026] S7: The main control module dynamically adjusts based on monitoring data. If an abnormality is detected, it immediately controls the wireless power supply module to stop supplying power and controls the mechanical clamping module to release the clamping arm.

[0027] S8: After charging is complete, the wireless power supply module stops working. After a preset delay, the mechanical clamping module releases the clamping arm, and the vehicle drives out of the charging area.

[0028] Furthermore, in step S3, the vehicle fine-tuning process adopts a step-by-step adjustment method, with each adjustment displacement not exceeding 10mm, and the position deviation is re-detected after adjustment.

[0029] Furthermore, in step S7, the response time of the exception protection logic does not exceed 10ms.

[0030] Furthermore, the preset threshold is 5mm, the preset clamping force range is 500-800N, and the delay time in step S8 is 3-5 seconds.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. Achieve precise coordination between mechanical clamping and wireless power supply: Through the coordinated control strategy of the main control module, ensure that the vehicle is accurately positioned and clamped before power supply is started, and delay release after charging is completed, effectively avoiding low charging efficiency caused by coil misalignment and ensuring the stability of the charging process;

[0033] 2. High positioning accuracy and strong adaptability: The clamping unit driven by a servo motor and the electromagnetic induction coil alignment detection unit can achieve coil alignment accuracy within ±2mm. At the same time, the clamping arm fine adjustment function can adapt to the parking deviation of different vehicle models, improving the versatility of the system.

[0034] 3. High safety: Equipped with a pressure sensor array and abnormal protection logic, it can monitor the clamping force and system operating status in real time. In case of overload, overtemperature, or abnormal displacement, it can quickly respond, stop the power supply and release the vehicle to avoid equipment damage and safety accidents.

[0035] 4. Convenient operation: The entire process requires no manual intervention, realizing a fully automated process of vehicle entry, positioning, clamping, charging, release, and exit, improving the user experience. Attached Figure Description

[0036] Figure 1 This is a structural block diagram of the charging pile system with wireless power supply and mechanical clamping coordination according to the present invention;

[0037] Figure 2 This is a flowchart of the control method of the present invention. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0039] A charging pile system that combines wireless power supply and mechanical clamping includes a mechanical clamping module, a wireless power supply module, a sensing and detection module, a main control module, and a power supply interface module.

[0040] The mechanical clamping module includes two sets of clamping units symmetrically arranged on both sides of the charging area. Each clamping unit consists of a servo motor, a ball screw, a clamping arm, and a pressure sensor. The servo motor drives the ball screw to move the clamping arm in the horizontal direction to clamp and release the vehicle chassis. The pressure sensor is installed on the inside of the clamping arm to detect the clamping force.

[0041] The wireless power supply module includes a primary coil array, a power adjustment unit, and a coil drive circuit. The primary coil array is embedded in the ground of the charging area to transmit electrical energy to the secondary coil on the vehicle side. The power adjustment unit is used to dynamically adjust the output power according to the charging demand and the coil alignment.

[0042] The perception and detection module includes a parking space recognition sensor, a coil alignment detection unit, and a vehicle status sensor. The parking space recognition sensor is used to detect whether the vehicle has entered the preset charging area. The coil alignment detection unit is used to obtain the relative positional deviation between the primary coil and the secondary coil of the vehicle. The vehicle status sensor is used to monitor the attitude changes of the vehicle during the charging process.

[0043] The main control module is electrically connected to the mechanical clamping module, the wireless power supply module, the sensing and detection module, and the power supply interface module, respectively. It is used to receive the detection signals from the sensing and detection module, control the clamping and releasing actions of the mechanical clamping module, and synchronously adjust the operating status of the wireless power supply module to achieve coordinated control of clamping and power supply.

[0044] The power supply interface module is used to connect to the external power grid and provide a stable power input for the entire system.

[0045] Furthermore, the coil alignment detection unit adopts an electromagnetic induction detection method. By using the induced voltage signals of each sub-coil in the primary coil array, the deviation value between the center coordinates of the secondary coil and the center of the primary coil array is calculated, and the deviation detection accuracy is not less than ±2mm.

[0046] Furthermore, the servo motor of the mechanical clamping module has a power-off self-locking function, and an anti-slip rubber pad is provided on the inner side of the clamping arm. The surface of the anti-slip rubber pad is provided with a pressure sensor array, which can realize uniform detection and feedback of clamping force.

[0047] Furthermore, the main control module incorporates a collaborative control strategy, including clamping-power supply linkage logic, deviation correction logic, and abnormal protection logic. The clamping-power supply linkage logic controls the start of wireless power supply after mechanical clamping is completed, and the release action is performed after the power supply stops. The deviation correction logic controls the clamping arm to fine-tune the vehicle position based on the coil alignment deviation to ensure accurate coil alignment. The abnormal protection logic immediately stops the power supply and releases the clamping arm when overload, overtemperature, or abnormal clamping force is detected.

[0048] The present invention also discloses a control method based on the above system, comprising the following steps:

[0049] S1: When a vehicle enters the charging area, the parking space recognition sensor detects the vehicle and sends a position signal to the main control module.

[0050] S2: After receiving the bit signal, the main control module controls the coil alignment detection unit of the sensing and detection module to work and obtain the relative position deviation between the primary coil and the secondary coil.

[0051] S3: If the position deviation is greater than the preset threshold (the preset threshold is 5mm), the main control module controls the servo motor of the mechanical clamping module to start, driving the clamping arm to push the vehicle for fine adjustment until the position deviation is less than or equal to the preset threshold; if the position deviation is less than or equal to the preset threshold, then step S4 is executed directly.

[0052] S4: The main control module controls the clamping arms of the two clamping units to move closer together synchronously to clamp the vehicle chassis. The pressure sensor collects the clamping force signal in real time and feeds it back to the main control module. When the clamping force reaches the preset clamping force range (500-800N), the servo motor stops working and self-locks.

[0053] S5: After the mechanical clamping is completed, the main control module sends a start signal to the wireless power supply module. The power adjustment unit of the wireless power supply module initializes the output power, and the coil drive circuit drives the primary coil array to work and transmit electrical energy to the vehicle side.

[0054] S6: During the charging process, the sensing and detection module monitors the coil alignment deviation, vehicle attitude, and system operating parameters (such as temperature, current, and voltage) in real time, and transmits the monitoring data to the main control module.

[0055] S7: The main control module dynamically adjusts based on monitoring data: if the coil alignment deviation exceeds the threshold, it controls the clamping arm to fine-tune and correct it; if abnormal system operating parameters are detected, it immediately controls the wireless power supply module to stop supplying power and controls the mechanical clamping module to loosen the clamping arm.

[0056] S8: After charging is complete, the wireless power supply module sends a charging end signal to the main control module. The main control module controls the wireless power supply module to stop working. After a delay of 3-5 seconds, it controls the servo motor of the mechanical clamping module to rotate in the opposite direction, driving the clamping arm to release and allowing the vehicle to drive out of the charging area.

[0057] Furthermore, in step S3, the vehicle fine-tuning process adopts a step-by-step adjustment method, with each adjustment displacement not exceeding 10mm. After adjustment, the position deviation is re-detected until the deviation meets the standard.

[0058] Furthermore, in step S7, the response time of the abnormal protection logic does not exceed 10ms, ensuring that the system can quickly respond to sudden failures.

[0059] The present invention will be further described in detail below with reference to specific embodiments.

[0060] Example 1:

[0061] A charging pile system that combines wireless power supply and mechanical clamping

[0062] The wireless power supply and mechanical clamping coordinated charging pile system of this embodiment includes a mechanical clamping module, a wireless power supply module, a sensing and detection module, a main control module, and a power supply interface module.

[0063] Mechanical clamping module: Two sets of clamping units are symmetrically arranged, located on the left and right sides of the charging area respectively. Each clamping unit includes a servo motor of model SG-M202, a ball screw with a lead of 5mm, an L-shaped clamping arm, and a pressure sensor of model FSR402. The servo motor is connected to the ball screw through a coupling, and the clamping arm is fixedly connected to the nut seat of the ball screw. When the servo motor drives the ball screw to rotate, it drives the clamping arm to reciprocate in the horizontal direction. The pressure sensors are embedded in the anti-slip rubber pads on the inner side of the clamping arm. A total of 4 pressure sensors are set and distributed in a rectangular array to collect clamping force signals in real time.

[0064] Wireless power supply module: The primary coil array consists of six 200mm×200mm square coils embedded in a groove in the ground of the charging area, with a coil spacing of 50mm; the power adjustment unit uses a TDK-Lambda ZWS1000 DC regulated power supply with an output voltage range of 200-400V, which can dynamically adjust the output power according to the control signal; the coil drive circuit uses a full-bridge inverter circuit composed of IGBT transistors (model FF450R12ME4) to convert DC power into high-frequency AC power to drive the primary coils.

[0065] Perception and Detection Module: The parking space recognition sensor uses an E3Z-LS63 photoelectric sensor, which is installed at the entrance of the charging area; the coil alignment detection unit consists of each sub-coil in the primary coil array and a signal processing circuit. It calculates the relative position deviation by detecting the magnetic field signal of the secondary coil induced by each sub-coil; the vehicle status sensor uses an MPU6050 six-axis sensor, which is installed on the ground in the charging area to monitor changes in the vehicle's attitude.

[0066] Main control module: It uses an STM32H743 microcontroller as the core, with a built-in collaborative control strategy program. It communicates with the mechanical clamping module, wireless power supply module and sensing and detection module through the CAN bus, receives detection signals from each module and outputs control commands.

[0067] Power supply interface module: includes air switch, leakage current protector and AC / DC converter, input voltage is 220V AC, output is 24V DC, power supply for low voltage equipment such as servo motors and microcontrollers, and at the same time provide 220V AC input for the power adjustment unit of wireless power supply module.

[0068] Example 2:

[0069] A control method for coordinating wireless power supply and mechanical clamping

[0070] Based on the system of Embodiment 1, the control method of this embodiment includes the following steps:

[0071] S1: When the vehicle enters the charging area, the photoelectric sensor detects the vehicle obstruction signal and sends a position signal to the STM32H743 microcontroller.

[0072] S2: After receiving the bit signal, the microcontroller controls the coil alignment detection unit to work. Through the induced voltage signals of the 6 sub-coils in the primary coil array, the X-axis deviation and Y-axis deviation between the center of the secondary coil and the center of the primary coil array are calculated.

[0073] S3: The preset position deviation threshold is 5mm. If the X-axis deviation or Y-axis deviation is greater than 5mm, the microcontroller controls the servo motors on both sides to start and drive the clamping arm to push the vehicle for fine adjustment according to the deviation direction. Each adjustment displacement is 8mm. After the adjustment is completed, the position deviation is re-detected until the X-axis deviation and Y-axis deviation are both less than or equal to 5mm.

[0074] S4: After the position is corrected, the microcontroller controls the servo motors of the two clamping units to rotate synchronously in the forward direction, driving the clamping arms to move closer to the vehicle chassis. The pressure sensor collects the clamping force signal in real time and transmits it to the microcontroller. When the average clamping force of the four pressure sensors reaches 650N (the middle value of the preset clamping force range of 500-800N), the servo motor stops working and self-locks.

[0075] S5: The microcontroller sends a start signal to the wireless power supply module via the CAN bus. The power regulation unit initializes the output voltage to 300V. The full-bridge inverter circuit converts DC power into 85kHz high-frequency AC power, which drives the primary coil array to work and transmits electrical energy to the secondary coil on the vehicle side.

[0076] S6: During the charging process, the coil alignment detection unit detects the position deviation every 100ms, the six-axis sensor monitors the vehicle attitude in real time, and the power regulation unit collects the output current, voltage and temperature signals in real time. All monitoring data are transmitted to the microcontroller.

[0077] S7: If the position deviation is greater than 5mm, the microcontroller controls the clamping arm to make fine adjustments and corrections; if the temperature exceeds 85℃, the current exceeds 10A, or the voltage fluctuation exceeds ±10%, the microcontroller immediately sends a stop signal, the wireless power supply module stops working, and at the same time controls the servo motor to rotate in reverse to release the clamping arm.

[0078] S8: When the vehicle battery management system sends a charging completion signal to the microcontroller, the microcontroller controls the wireless power supply module to stop working. After a 4-second delay, it controls the servo motors on both sides to rotate in opposite directions, driving the clamping arms away from the vehicle until they return to their initial position. The vehicle then drives out of the charging area, and the system resets.

[0079] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A charging pile system that combines wireless power supply and mechanical clamping, characterized in that: It includes a mechanical clamping module, a wireless power supply module, a sensing and detection module, a main control module, and a power supply interface module; The mechanical clamping module includes two sets of clamping units symmetrically arranged on both sides of the charging area. Each set of clamping units consists of a servo motor, a ball screw, a clamping arm, and a pressure sensor. The servo motor drives the ball screw to move the clamping arm in the horizontal direction, and the pressure sensor is installed on the inner side of the clamping arm. The wireless power supply module includes a primary coil array, a power adjustment unit, and a coil drive circuit. The primary coil array is embedded in the ground of the charging area, and the power adjustment unit is used to dynamically adjust the output power. The perception and detection module includes a parking space recognition sensor, a coil alignment detection unit, and a vehicle status sensor. The parking space recognition sensor is used to detect whether the vehicle has entered the preset charging area, and the coil alignment detection unit is used to obtain the relative positional deviation between the primary coil and the secondary coil of the vehicle. The main control module is electrically connected to the mechanical clamping module, the wireless power supply module, the sensing and detection module, and the power supply interface module, respectively. It is used to receive the detection signals from the sensing and detection module, control the clamping and releasing actions of the mechanical clamping module, and synchronously adjust the operating status of the wireless power supply module. The power supply interface module is used to connect to the external power grid and provide power input to the entire system.

2. The charging pile system with wireless power supply and mechanical clamping coordination according to claim 1, characterized in that, The coil alignment detection unit adopts an electromagnetic induction detection method. It calculates the deviation between the center coordinates of the secondary coil and the center of the primary coil array by using the induced voltage signals of each sub-coil in the primary coil array. The deviation detection accuracy is not less than ±2mm.

3. The charging pile system with wireless power supply and mechanical clamping coordination according to claim 1, characterized in that, The servo motor of the mechanical clamping module has a power-off self-locking function, and an anti-slip rubber pad is provided on the inner side of the clamping arm. The surface of the anti-slip rubber pad is equipped with a pressure sensor array.

4. The charging pile system with wireless power supply and mechanical clamping coordination according to claim 1, characterized in that, The main control module has a built-in collaborative control strategy, including clamping-power supply linkage logic, deviation correction logic, and abnormal protection logic.

5. A control method based on the system according to any one of claims 1-4, characterized in that, Includes the following steps: S1: When a vehicle enters the charging area, the parking space recognition sensor detects the vehicle and sends a position signal to the main control module. S2: After receiving the bit signal, the main control module controls the coil alignment detection unit to work and obtain the relative position deviation between the primary coil and the secondary coil. S3: If the position deviation is greater than the preset threshold, the main control module controls the servo motor of the mechanical clamping module to start, driving the clamping arm to push the vehicle for fine adjustment until the position deviation is less than or equal to the preset threshold; if the position deviation is less than or equal to the preset threshold, then step S4 is executed directly. S4: The main control module controls the clamping arms of the two clamping units to move closer together synchronously to clamp the vehicle chassis. When the clamping force reaches the preset clamping force range, the servo motor stops working and self-locks. S5: After the mechanical clamping is completed, the main control module sends a start signal to the wireless power supply module, and the wireless power supply module starts and transmits power to the vehicle side; S6: During the charging process, the sensing and detection module monitors the coil alignment deviation, vehicle attitude and system operating parameters in real time, and transmits the monitoring data to the main control module. S7: The main control module dynamically adjusts based on monitoring data. If an abnormality is detected, it immediately controls the wireless power supply module to stop supplying power and controls the mechanical clamping module to release the clamping arm. S8: After charging is complete, the wireless power supply module stops working. After a preset delay, the mechanical clamping module releases the clamping arm, and the vehicle drives out of the charging area.

6. The control method according to claim 5, characterized in that, In step S3, the vehicle fine-tuning process adopts a step-by-step adjustment method, with each adjustment displacement not exceeding 10mm, and the position deviation is re-checked after adjustment.

7. The control method according to claim 5, characterized in that, In step S7, the response time of the exception protection logic shall not exceed 10ms.

8. The control method according to claim 5, characterized in that, The preset threshold is 5mm, the preset clamping force range is 500-800N, and the delay time in step S8 is 3-5 seconds.

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