Heavy truck charging pile gun line power assisting device

Abstract

The invention relates to the technical field of new energy automobile charging equipment, and discloses a heavy truck charging pile gun line power assisting device which comprises a mounting base, a rotary connecting seat, a rotary driving shaft and a rotatable suspension arm assembly, the rotatable suspension arm assembly comprises a main suspension arm and a telescopic auxiliary arm, one end of the main suspension arm is rotatably arranged on the rotary driving shaft in a sleeving mode, and the other end of the main suspension arm is rotatably arranged on the telescopic auxiliary arm in a sleeving mode; the telescopic auxiliary arm is arranged in the main suspension arm, can horizontally rotate around the main suspension arm and is telescopically arranged in the main suspension arm; the gun line hanging assembly is installed at one end of the telescopic auxiliary arm and used for bearing a charging gun line, and the gun line hanging assembly comprises a rotating connector allowing the whole gun line hanging assembly to freely rotate around a vertical axis and a buffer spring used for absorbing impact; the whole weight of the gun line is borne through the rotatable and telescopic suspension arm assembly, and the moment generated by the gravity of the gun line can be dynamically counteracted in combination with an intelligent resistance adjusting system based on real-time detection. And the charging operation efficiency and the personnel comfort are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle charging equipment technology, specifically a charging cable assist device for heavy-duty truck charging piles. Background Technology

[0002] Heavy-duty truck charging guns need to meet the demands of high-current, fast charging, so their charging cables typically have a thicker diameter and are heavier, with a single cable weighing 15-30 kg. During charging, operators need to manually drag the charging cable and precisely insert the charging gun into the heavy-duty truck's charging port. This process is not only physically demanding, but the weight of the cable can also cause operational imbalance, posing a safety hazard of the charging gun hitting the vehicle or injuring the operator.

[0003] During the charging process, operators need to manually drag the charging cable and precisely insert the charging gun into the heavy-duty truck's charging port. This process is not only physically demanding, but the weight of the charging cable can also cause operational imbalance, posing a safety hazard of the charging gun hitting the vehicle or injuring the operator. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a heavy-duty truck charging station gun cable assist device, which solves the problems of high labor intensity and easy safety accidents caused by the heavy cable and laborious operation of existing heavy-duty truck charging guns.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a heavy-duty truck charging station cable assist device, comprising: a mounting base, a rotating connecting seat, and a rotating drive shaft. A rotatable boom assembly includes a main boom and a telescopic auxiliary boom. One end of the main boom is rotatably mounted on the rotary drive shaft and can rotate horizontally around it. The telescopic auxiliary boom is telescopically disposed inside the main boom. A charging cable suspension assembly, installed at one end of the telescopic arm, is used to support the charging cable. The charging cable suspension assembly includes a rotary joint that allows it to rotate freely about a vertical axis, and a buffer spring for absorbing shock. A resistance adjustment module is disposed between the mounting base and the rotatable boom assembly, for providing an adjustable first damping force for the rotational movement of the main boom and an adjustable second damping force for the telescopic movement of the telescopic auxiliary boom; The detection module is used to acquire in real time the rotation angle and angular velocity of the main boom, the extension length and extension speed of the telescopic auxiliary boom, and the real-time tension of the charging gun cable. The control module is electrically connected to the detection module and the resistance adjustment module respectively. The control module has a pre-stored balance assist control algorithm, which is used to control the output damping force of the resistance adjustment module according to the parameters detected by the detection module in real time, so as to achieve dynamic balance assist for the charging gun cable in the rotation and extension directions.

[0006] Preferably, the rotary drive shaft is vertically fixed inside the rotary connecting seat, and one end of the main boom is rotatably mounted on the rotary drive shaft through a bearing disposed inside the rotary connecting seat.

[0007] Preferably, the gun wire suspension assembly further includes a suspension hook, and the rotary joint, the buffer spring and the suspension hook are fixedly connected in sequence from top to bottom, with the top of the rotary joint fixedly connected to the bottom surface of the telescopic auxiliary arm.

[0008] Preferably, the resistance adjustment module includes a first resistance unit and a second resistance unit; The first resistance unit is a magnetorheological damper, with its fixed end connected to the mounting base and its movable end linked to the rotary drive shaft or the main boom through a transmission mechanism to provide the adjustable first damping force. The second resistance unit is a linear damper, located between the main boom and the telescopic boom, for providing the adjustable second damping force.

[0009] Preferably, the detection module includes: An angle sensor, located at the rotary drive shaft, is used to detect the rotation angle and angular velocity of the main boom; A displacement sensor is installed on the main boom or telescopic boom to detect the extension length and extension speed of the telescopic boom; A tension sensor, integrated on the charging cable suspension assembly, is used to detect the real-time tension of the charging cable.

[0010] Preferably, the detection module further includes an attitude sensor disposed on the main boom for detecting the tilt angle of the main boom relative to the horizontal plane.

[0011] Preferably, the balance assist control algorithm pre-stored in the control module is configured to execute the following steps: Calculate the gravitational torque exerted by the charging gun cable on the boom assembly based on the real-time tension and the extension length; Based on the gravitational torque and the rotational angular velocity, the first damping force is adjusted through the first control logic; Based on the real-time tension and the extension / retraction speed, the second damping force is adjusted through the second control logic.

[0012] Preferably, the device further includes an emergency protection module; The emergency protection module is signal-connected to the control module and the resistance adjustment module; When the real-time tension detected by the detection module exceeds the preset safety threshold range, the control module controls the resistance adjustment module to lock the movement of the rotatable boom assembly through the emergency protection module.

[0013] Preferably, the device further includes a device health monitoring module; The equipment health monitoring module is used to collect vibration, temperature or current parameters of the resistance adjustment module and the rotatable boom assembly, and to evaluate the health status of the device or provide fault warnings based on the parameters.

[0014] Preferably, the device further includes a data communication module; The data communication module is communicatively connected to the control module and the equipment health monitoring module, and is used to send at least one of the detection data of the detection module, the processing data of the control module and the early warning data of the equipment health monitoring module to the remote management platform, and to receive configuration or control commands from the remote management platform.

[0015] Working principle: After the device is powered on, the control module controls the resistance adjustment module to reset to its initial state, and the magnetorheological damper operates at the preset initial damping coefficient. The detection module performs self-tests on each sensor. After the self-test passes, the control module collects initial parameters, including the initial rotation angle of the main boom, the initial extension length of the telescopic boom, and the initial suspension tension of the charging cable. Based on the initial suspension tension, the control module calculates and stores the real-time weight of the charging cable. During the charging operation, the detection module continuously operates. Angle sensors monitor the rotation angle and angular velocity of the main boom in real time. Displacement sensors monitor the extension length and extension speed of the telescopic boom in real time. Tension sensors monitor the suspension tension of the charging gun cable in real time. Attitude sensors monitor the tilt angle of the main boom in real time. Simultaneously, if equipped with an equipment health monitoring module, its vibration, temperature, and current sensors synchronously collect operating status data of relevant components. The control module receives all real-time data and runs the balance assist control algorithm. The algorithm first calculates the real-time gravitational torque generated by the charging gun cable based on the real-time tension, extension length, rotation angle, and tilt angle. Then, based on the gravitational torque and rotation angular velocity, it calculates the target first damping force required in the rotation direction through the first control logic. Simultaneously, based on the real-time tension and extension speed, it calculates the target second damping force required in the extension direction through the second control logic. Furthermore, the equipment health monitoring module's evaluation algorithm analyzes the status data to determine the equipment's health status. The control module, through its drive unit, outputs control signals to the resistance adjustment module, dynamically adjusting the current of the magnetorheological damper to match the target first damping force, and adjusting the valve opening of the linear damper to match the target second damping force. This process constitutes dynamic closed-loop control, providing significant assistance to the operator. Simultaneously, if the real-time tension exceeds a preset safety threshold, emergency protection is immediately triggered, locking all movement and triggering an alarm. All operational data, status assessment results, and alarm information are uploaded to the remote management platform via the data communication module, and the platform can receive remote commands. After charging is completed, the operator inserts the charging gun back into the charging station socket and removes it from the suspension hook. The control module detects the disappearance of tension and automatically retracts the telescopic boom to its initial position; the main boom can also rotate to the standby angle. The device enters a low-power standby state, awaiting the next operating command.

[0016] This invention provides a charging cable assist device for heavy-duty truck charging stations. It has the following beneficial effects: 1. In this invention, a rotatable and telescopic boom assembly bears the entire weight of the charging gun, and combined with an intelligent resistance adjustment system based on real-time detection, it can dynamically counteract the torque generated by the weight of the charging gun. Operators only need to apply a small guiding force to move the heavy charging gun smoothly and accurately, solving the problem of laborious operation of heavy truck charging guns and greatly improving charging efficiency and operator comfort.

[0017] 2. In this invention, the device integrates multiple types of sensors to perceive the boom's motion status and the force on the gun line in real time. The control module dynamically calculates and adjusts the damping force in the rotation and extension directions according to a preset algorithm. This dynamic closed-loop control makes the boom's motion response smooth and without swaying, and can automatically adapt to the weight of gun lines of different specifications, the operator's habitual force, and the inclination of non-horizontal installation sites. No manual adjustment is required, and it has strong versatility.

[0018] 3. In this invention, the optional equipment health monitoring and data communication module can monitor the vibration, temperature and other conditions of key components of the device to achieve predictive maintenance. At the same time, the data interconnection function supports remote monitoring of operating status, summarizing operation data and remotely updating parameters, which greatly improves the intelligent level of operation and maintenance and management efficiency of charging station equipment and provides data support for large-scale operation. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a schematic diagram of the control flow of the present invention; Figure 3 This is a schematic diagram of the communication and remote interaction process of the present invention; Figure 4 This is a schematic diagram of the health monitoring process of the present invention.

[0020] The components include: 1. mounting base; 2. rotating connecting seat; 3. rotating drive shaft; 4. main boom; 5. telescopic auxiliary boom; 6. swivel joint; 7. buffer spring; and 8. suspension hook. Detailed Implementation

[0021] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see the appendix Figure 1 - Appendix Figure 4 This invention provides a charging station cable assist device for heavy-duty trucks, comprising: a mounting base 1, a rotating connecting seat 2, and a rotating drive shaft 3. The rotatable boom assembly includes a main boom 4 and a telescopic auxiliary boom 5. One end of the main boom 4 is rotatably mounted on a rotary drive shaft 3 and can rotate horizontally around it. The telescopic auxiliary boom 5 is telescopically disposed inside the main boom 4. The charging cable suspension assembly, installed at one end of the telescopic arm 5, is used to support the charging cable. The charging cable suspension assembly includes a rotary joint 6 that allows it to rotate freely about a vertical axis, and a buffer spring 7 for absorbing shock. The resistance adjustment module is located between the mounting base 1 and the rotatable boom assembly. It provides an adjustable first damping force for the rotational movement of the main boom 4 and an adjustable second damping force for the telescopic movement of the telescopic auxiliary boom 5. The detection module is used to acquire the rotation angle and angular velocity of the main boom 4, the extension length and extension speed of the telescopic boom 5, and the real-time tension of the charging gun cable in real time. The control module is electrically connected to the detection module and the resistance adjustment module respectively. The control module has a pre-stored balance assist control algorithm, which is used to control the output damping force of the resistance adjustment module according to the parameters detected by the detection module in real time, so as to achieve dynamic balance assist for the charging gun cable in the rotation and extension directions.

[0023] Specifically, the mounting base 1 is made of high-strength steel and is used to securely install the entire device on the ground or the charging pile body. A rotating connecting seat 2 is fixedly installed on the top of the mounting base 1. A rotating drive shaft 3 is vertically positioned, with its lower end fixedly installed inside the rotating connecting seat 2. The rotatable boom assembly includes a main boom 4 and a telescopic auxiliary boom 5. One end of the main boom 4, its proximal end, is rotatably mounted on the rotating drive shaft 3 via the rotating connecting seat 2. Specifically, the rotating connecting seat 2 contains a bearing, through which the proximal end of the main boom 4 is supported and connected to the outside of the rotating drive shaft 3, allowing the main boom 4 to rotate horizontally around the rotating drive shaft 3. The telescopic auxiliary boom 5 is telescopically located inside the main boom 4 and can move linearly along the length of the main boom 4, thereby adjusting the working length of the boom. The end of the telescopic auxiliary boom 5, the end furthest from the main boom 4, has a connection interface. The charging cable suspension assembly is mounted at the end of the telescopic arm 5. This assembly supports the charging cable. The charging cable suspension assembly includes a swivel joint 6 and a buffer spring 7. The top of the swivel joint 6 is fixedly connected to the end of the telescopic arm 5. The swivel joint 6 allows the entire charging cable suspension assembly to rotate freely about a vertical axis. The buffer spring 7 is connected below the swivel joint 6 to absorb impact. The lower end of the buffer spring 7 is connected to a structure for suspending the charging cable. A resistance adjustment module is positioned between the mounting base 1 and the rotatable boom assembly. This module provides an adjustable first damping force for the rotational movement of the main boom 4 and an adjustable second damping force for the telescopic movement of the telescopic auxiliary boom 5. A detection module acquires real-time data on the rotation angle and angular velocity of the main boom 4, the extension length and telescopic speed of the telescopic auxiliary boom 5, and the real-time tension of the charging cable. A control module is electrically connected to both the detection module and the resistance adjustment module. The control module has a pre-stored balance assist control algorithm. Based on the parameters detected in real-time by the detection module, the control module controls the output damping force of the resistance adjustment module to achieve dynamic balance assist for the charging cable in both rotational and telescopic directions. The working principle of this embodiment is as follows: After the device is powered on and initialized, the detection module starts working continuously. When the operator drags the charging gun cable, the charging gun cable drives the cable suspension assembly to move, which in turn drives the telescopic auxiliary boom 5 and the main boom 4 to move. The detection module acquires motion parameters and tension parameters in real time and transmits them to the control module. The control module runs a balance assist control algorithm, calculates the gravitational torque generated by the current charging gun cable based on the rotation angle, extension length, and real-time tension, and calculates the target values ​​of the first damping force and the second damping force required to balance this gravitational torque and make the movement smooth, in combination with the angular velocity and telescopic speed. Subsequently, the control module sends a control command to the resistance adjustment module to dynamically adjust the magnitude of the first damping force and the second damping force. Through this closed-loop control, the resistance felt by the operator when dragging the charging gun cable is significantly reduced, thereby achieving a labor-saving and smooth operation effect.

[0024] Furthermore, the rotary drive shaft 3 is vertically fixed inside the rotary connecting seat 2, and one end of the main boom 4 is rotatably mounted on the rotary drive shaft 3 through a bearing installed inside the rotary connecting seat 2.

[0025] Specifically, the rotary connecting seat 2 is a hollow cylindrical structure, which is fixed to the center of the top surface of the mounting base 1 by welding or bolts. At least one set of rolling bearings is precisely installed in the inner cavity of the rotary connecting seat 2 along its axial direction, i.e., the vertical direction. These rolling bearings are preferably deep groove ball bearings or tapered roller bearings. The rotary drive shaft 3 is a high-strength steel shaft. Its lower end is fixedly connected to the inner ring of the rolling bearing in the rotary connecting seat 2 by interference fit, key connection, or flange connection. Therefore, the rotary drive shaft 3 is stationary relative to the mounting base 1 and the rotary connecting seat 2, forming the fixed central shaft for the entire rotational motion. A cylindrical connecting part is provided at the proximal end of the main boom 4. The inner diameter of this cylindrical connecting part matches the outer diameter of the rolling bearing in the rotary connecting seat 2. By bolting or interference fit, the cylindrical connecting part and the outer ring of the rolling bearing are rigidly fixedly connected. Thus, the main boom 4 is rotatably mounted on the periphery of the stationary rotary drive shaft 3 via the cylindrical connecting part at its proximal end and the rolling bearing in the rotary connecting seat 2. When the main boom 4 is subjected to a force from its distal end, the inner ring of the rolling bearing remains stationary with the rotary drive shaft 3, while the outer ring rotates around the central axis of the rotary drive shaft 3 along with the cylindrical connecting part of the main boom 4. This structure ensures that the main boom 4 can perform smooth 360-degree horizontal rotation, while stably transmitting the load of the main boom 4 and its load through the bearing and the rotary drive shaft 3, and ultimately bearing it on the mounting base 1.

[0026] Furthermore, the gun wire suspension assembly also includes a suspension hook 8, a rotary joint 6, a buffer spring 7, and a suspension hook 8, which are fixedly connected from top to bottom. The top of the rotary joint 6 is fixedly connected to the bottom surface of the telescopic auxiliary arm 5.

[0027] Specifically, the gun line suspension assembly includes a rotary joint 6, a buffer spring 7, and a suspension hook 8 arranged sequentially from top to bottom. The rotary joint 6, buffer spring 7, and suspension hook 8 are rigidly connected, forming a single moving unit. The rotary joint 6 has a slewing bearing inside its main body. The top of the rotary joint 6 has an upper connecting flange. The end of the telescopic boom 5, i.e., the end furthest from the main boom 4, has a corresponding lower connecting flange machined on its bottom surface. The upper connecting flange of the rotary joint 6 is bolted to the lower connecting flange on the bottom surface of the telescopic boom 5, thereby achieving a fixed installation of the entire gun line suspension assembly and the telescopic boom 5. The rotary joint 6 has a lower output flange at its bottom. The upper end of the buffer spring 7 is fixedly connected to the lower output flange of the rotary joint 6 via an upper connecting plate. The lower end of the buffer spring 7 is fixedly connected to the top of the suspension hook 8 via a lower connecting plate. The main body of the suspension hook 8 is a rigid C-shaped or U-shaped hook structure with its opening facing upward or sideways. The opening of this hook structure is equipped with an openable anti-dislodgement latch or elastic baffle to prevent accidental dislodgement when supporting the charging cable. The slewing bearing inside the rotary joint 6 has its inner ring fixed to the upper connecting flange and its outer ring fixed to the lower output flange. Therefore, when the charging cable tends to twist due to operation, the rotary joint 6 allows its lower output flange, the buffer spring 7 fixed thereto, and the suspension hook 8 to rotate freely around the vertical axis of the rotary joint 6 as a whole. This design effectively prevents the charging cable from tangling, and the buffer spring 7 provides an axial elastic connection between the rotary joint 6 and the suspension hook 8. When the charging gun cable is subjected to sudden tension or impact, the buffer spring 7 can undergo compression or stretching deformation to absorb the instantaneous impact energy, thereby protecting the charging gun cable, the suspension hook 8 and the upstream boom structure from rigid impact damage.

[0028] Furthermore, the resistance adjustment module includes a first resistance unit and a second resistance unit; The first resistance unit is a magnetorheological damper, whose fixed end is connected to the mounting base 1, and whose movable end is linked to the rotary drive shaft 3 or the main boom 4 through a transmission mechanism to provide an adjustable first damping force. The second resistance unit is a linear damper, located between the main boom 4 and the telescopic auxiliary boom 5, used to provide an adjustable second damping force.

[0029] Specifically, the first resistance unit is a magnetorheological damper. The cylinder end of this damper serves as the fixed end and is connected to the mounting base 1 via a hinged support. The piston rod end of the damper serves as the movable end and is linked to the rotating part of the rotary drive shaft 3 or the main boom 4 via a transmission mechanism, thereby providing an adjustable first damping force for the rotational movement of the main boom 4. A preferred transmission mechanism is a planetary gear set. The gear ring of this planetary gear set can be fixedly connected to the rotary drive shaft 3. The planet carrier of this planetary gear set rotates synchronously with the proximal sleeve-shaped connecting part of the main boom 4. The sun gear shaft of this planetary gear set is connected to the piston rod end of the damper via a coupling. When the main boom 4 rotates around the rotary drive shaft 3, it drives the planet carrier to rotate, thereby driving the sun gear shaft and the piston rod of the damper to perform linear motion. The damper is filled with magnetorheological fluid, and its damping force can be steplessly adjusted by changing the current flowing through its internal coil. The control module can precisely control the magnitude of the first damping force by changing the current value output to the coil. Optionally, an auxiliary motor can also be connected to the sun gear shaft to provide power when the main boom 4 requires active assisted rotation; The second resistance unit is a linear damper. This linear damper is located between the main boom 4 and the telescopic boom 5. Specifically, the cylinder end of the linear damper is hinged to a fixed point on the inner side of the main boom 4. The piston rod end of the linear damper is hinged to the telescopic boom 5. When the telescopic boom 5 extends or retracts relative to the main boom 4, it drives the piston rod of the linear damper to move, thereby generating a damping force. This linear damper can be a hydraulic damping cylinder, a gas spring, or an electric linear actuator. The magnitude of the second damping force can be controlled in real time by adjusting the opening of its hydraulic valve, air pressure, or motor current through the control module.

[0030] Furthermore, the detection module includes: An angle sensor is installed at the rotary drive shaft 3 to detect the rotation angle and angular velocity of the main boom 4; A displacement sensor is installed on the main boom 4 or the telescopic boom 5 to detect the extension length and telescopic speed of the telescopic boom 5. A tension sensor, integrated into the charging cable suspension assembly, is used to detect the real-time tension of the charging cable.

[0031] Specifically, the detection module includes an angle sensor. This angle sensor is specifically installed at the end of the rotary drive shaft 3 or on a component that rotates synchronously with the rotary drive shaft 3. The angle sensor is used to detect the real-time rotation angle θ of the main boom 4. By differentiating the rotation angle θ over time, the control module calculates the real-time rotational angular velocity ω of the main boom 4. The detection module also includes a displacement sensor. This displacement sensor is specifically a laser displacement sensor, installed at the end of the main boom 4. The laser displacement sensor emits a beam to the corresponding reflecting surface of the telescopic auxiliary boom 5, used to detect the real-time extension length L of the telescopic auxiliary boom 5 relative to the main boom 4. By differentiating the extension length L over time, the control module calculates the real-time extension speed v of the telescopic auxiliary boom 5. The detection module also includes a tension sensor. This tension sensor is integrated into the charging cable suspension assembly, specifically located on the force transmission path between the buffer spring 7 and the suspension hook 8. The tension sensor is used to detect the real-time suspension tension F of the charging cable. The real-time suspension tension F is the resultant force of the charging cable's own weight and the tension applied by the operator. All sensor signal outputs are connected to the control module's signal acquisition unit via a CAN bus or RS485 interface. The control module reads data from all sensors at a fixed sampling period, thereby acquiring rotation angle θ, rotational angular velocity ω, extension length L, extension speed v, real-time tension F, and tilt angle α in real time and synchronously, as inputs for subsequent control calculations.

[0032] Furthermore, the detection module also includes an attitude sensor, which is mounted on the main boom 4 to detect the tilt angle of the main boom 4 relative to the horizontal plane.

[0033] Specifically, the attitude sensor is installed at the middle of the main boom 4. The mounting axis of the attitude sensor is parallel to the length direction of the main boom 4 or has a defined mounting angle relationship. The attitude sensor is used to detect the real-time tilt angle α of the main boom 4 relative to the horizontal plane. The attitude sensor can be a dual-axis or single-axis inclinometer. The signal output of the attitude sensor is connected to the signal acquisition unit of the control module via a signal line. The control module reads the tilt angle α in real time. In the balance assist control algorithm, the tilt angle α is used to correct the gravity calculation error caused by the installation site not being absolutely level. Specifically, when calculating the rotational torque generated by the gravity of the charging gun cable, the tilt angle α needs to be substituted into the calculation formula for cosine compensation. That is, the component of gravity in the direction perpendicular to the boom plane needs to be multiplied by cosα to obtain the accurate effective gravity torque under the current tilt state. This allows the device to adapt to actual application scenarios where the ground is uneven or the charging pile is installed at an angle, ensuring the accuracy and universality of the assist control.

[0034] Furthermore, the balance assist control algorithm pre-stored in the control module is configured to execute the following steps: Calculate the gravitational torque exerted by the charging gun cable on the boom assembly based on the real-time tension and extension length; Based on the gravitational torque and rotational angular velocity, the first damping force is adjusted through the first control logic; Based on real-time tension and extension speed, the second damping force is adjusted through the second control logic.

[0035] Specifically, firstly, the control module calculates the gravitational torque exerted by the charging gun cable on the rotatable boom assembly based on the real-time tension F and extension length L obtained by the detection module. The specific calculation logic is as follows: During the initialization phase or in a static state, the control module determines the real-time weight G of the charging gun cable based on the initial static tension measured by the tension sensor. During the dynamic process, considering the current rotation angle θ and tilt angle α of the main boom 4, the gravitational torque M is calculated using the formula M = G × L × sinθ × cosα. Secondly, regarding the control of rotational motion, i.e., the first control logic, the control module, based on the calculated gravitational torque M and the real-time detected rotational angular velocity ω, uses a proportional-integral-derivative (PID) algorithm to adjust and calculate the target value R1 of the first damping force required to balance the current gravitational torque and achieve smooth rotation. The control logic is as follows: the target value of the first damping force R1 is set to a reference value that can offset most of the gravitational torque M, and a dynamic damping term related to the rotational angular velocity ω is added. When the rotational angular velocity ω is greater than a preset threshold, it indicates that the operator is rapidly rotating the main boom 4. At this time, the control module not only adjusts the damping force of the magnetorheological damper but also controls the start of the assist motor to provide auxiliary rotational torque, further reducing operating resistance. Next, regarding the control of the telescopic movement, i.e., the second control logic, the control module adjusts the second damping force based on the real-time detected tension F and telescopic speed v. The control logic is as follows: the real-time tension F is compared with the weight G of the charging cable. When the real-time tension F is greater than the cable weight G multiplied by a coefficient of 1.2, and the telescopic speed v is positive, it indicates that the operator is pulling the cable out forcefully. At this time, the control module reduces the damping force of the linear damper, i.e., reduces the second damping force R2, to provide extension assistance. When the real-time tension F is less than the cable weight G multiplied by a coefficient of 0.8, and the telescopic speed v is negative, it indicates that the operator is retrieving the cable. At this time, the control module increases the damping force of the linear damper, i.e., increases the second damping force R2, to buffer the retrieval process and prevent the cable and boom from colliding. Finally, the control module outputs control signals corresponding to the target values ​​R1 and R2 to the resistance adjustment module through its drive unit. For the first resistance unit, the control signal is a specific current value applied to the magnetorheological damper coil to change its magnetic field strength, thereby matching its damping coefficient to the target value R1. For the second resistance unit, the control signal is an instruction sent to the linear damper hydraulic valve or electronic control unit to adjust its opening or current, thereby matching its damping coefficient to the target value R2. Through the cyclic execution of the above steps, the device achieves dynamic and adaptive balancing assistance for the charging gun cable in the rotational and extension directions.

[0036] Furthermore, the device also includes an emergency protection module; The emergency protection module is connected to the control module and the resistance adjustment module via signal connections. When the real-time tension detected by the detection module exceeds the preset safety threshold range, the control module controls the resistance adjustment module to lock the movement of the rotatable boom assembly through the emergency protection module.

[0037] Specifically, the emergency protection module is connected to the control module and the resistance adjustment module via signals. The emergency protection module can be a standalone hardware circuit or a software functional unit integrated within the control module. The emergency protection module has a preset safety threshold range. This safety threshold range is set based on the real-time weight G of the charging cable. When the real-time pulling force F detected by the detection module exceeds the preset safety threshold range, the emergency protection mechanism is triggered. Specific triggering conditions include two abnormal situations: First, when the real-time pulling force F is greater than twice the weight G of the charging cable (F>2×G), it indicates that the charging cable may be stuck by an external object or subjected to abnormally strong excessive pulling. Second, when the real-time pulling force F is less than half the weight G of the charging cable (F<0.5×G), it indicates that the charging cable may have accidentally detached from the suspension hook 8. Once either of these conditions is met, the control module immediately outputs a highest-priority locking command to the resistance adjustment module through the emergency protection module. For the first resistance unit, the locking command controls the magnetorheological damper's coil to instantly pass through the maximum saturation current, causing its internal magnetorheological fluid to solidify and the piston rod to be completely locked, thus preventing any rotation of the main boom 4. For the second resistance unit, the locking command controls the linear damper's valve to be completely closed, preventing its piston rod from moving and thus preventing any extension or retraction of the telescopic boom 5. Through these actions, all movements of the rotatable boom assembly are instantly locked. Simultaneously, the emergency protection module triggers an audible and visual alarm, emitting an alarm signal to prompt on-site operators to immediately check and troubleshoot the fault. After the abnormal situation is resolved, the locking state of the emergency protection module can only be released through manual reset or by receiving a remote reset command from the control module, allowing the device to return to normal operation.

[0038] Furthermore, the device also includes an equipment health monitoring module; The equipment health monitoring module is used to collect vibration, temperature, or current parameters of the resistance adjustment module and the rotatable boom assembly, and to assess the health status of the device or provide fault warnings based on the parameters.

[0039] Specifically, the equipment health monitoring module is used to collect operating status parameters of the resistance adjustment module and the rotatable boom assembly. These parameters include vibration, temperature, or current. To achieve this function, the equipment health monitoring module includes one or more additional sensors. A triaxial vibration sensor is mounted on the outside of the bearing housing of the rotary drive shaft 3 to collect axial and radial vibration acceleration signals. One or more patch-type temperature sensors are attached to the housing surfaces of the magnetorheological damper, the auxiliary motor, and the lubrication points of the planetary gear set, respectively, to collect the real-time operating temperature of each component. A high-precision current transformer is connected in series in the power supply circuit of the auxiliary motor to collect the operating current of the auxiliary motor in real time. The sensor outputs of the equipment health monitoring module are connected to the extended signal acquisition unit of the control module via signal lines, or processed by a separate signal processing unit before communicating with the control module. The control module runs an equipment health assessment algorithm. This algorithm establishes a baseline characteristic model for each monitoring parameter based on historical normal operating condition data collected by the equipment health monitoring module, including vibration spectrum characteristics, temperature stability range, and current load curves. Simultaneously, the algorithm has a pre-stored database of typical fault characteristics. The workflow of the equipment health monitoring module is as follows: The control module periodically reads real-time data on vibration, temperature, and current. The equipment health assessment algorithm compares and analyzes the real-time data with the benchmark feature model and fault feature library. For example, when the vibration energy at the rotary drive shaft 3 is detected to be continuously increasing in the high-frequency range, the algorithm can determine that the bearing is at risk of wear. When the operating current required by the magnetorheological damper to achieve the same damping force is detected to be continuously increasing, the algorithm can determine that the performance of the magnetorheological fluid may be degrading. When the current of the assist motor is detected to be continuously exceeding the rated threshold, the algorithm can determine that the motor may be overloaded. When analysis results indicate that a health score falls below a preset threshold or matches a clear fault characteristic, the control module determines that the device has a potential fault risk. At this time, the control module generates an early warning message through the equipment health monitoring module. This warning message can be displayed in code form on the device's local simplified human-machine interface, such as "E01: Bearing inspection recommended," and can also be uploaded to a remote management platform via the subsequent data communication module. In addition, the equipment health monitoring module also records the cumulative operating hours of the magnetorheological damper and the cumulative start-stop count of the assist motor. When the cumulative value reaches the preset design life threshold, the control module will generate a maintenance reminder message in advance, prompting preventative maintenance or component replacement.

[0040] Furthermore, the device also includes a data communication module; The data communication module is connected to the control module and the equipment health monitoring module to send at least one of the detection data from the detection module, the processing data from the control module, and the early warning data from the equipment health monitoring module to the remote management platform, and to receive configuration or control commands from the remote management platform.

[0041] Specifically, the data communication module communicates with the control module. In embodiments including an equipment health monitoring module, the data communication module also communicates with the equipment health monitoring module, and the data communication module includes an industrial communication unit. This industrial communication unit integrates a hardware module supporting one or more communication protocols among 4G, 5G, Ethernet, and Wi-Fi. As an independent communication subsystem, the data communication module connects to the main processor of the control module via a Universal Asynchronous Receiver / Transmitter (UART) interface or a Serial Peripheral Interface (SPI). The data communication module is used for data interaction with the remote management platform. Its uplink communication function is as follows: the data communication module actively encapsulates local data into data packets of a specific format according to a preset period or event trigger and sends them to the remote management platform. The sent data includes at least one of the detection data from the detection module, the processing data from the control module, and the early warning data from the equipment health monitoring module. Specifically, the sent data may include real-time or historical rotation angle, extension length, real-time tension, system health score, emergency protection trigger records, and operation count statistics. Its downlink communication function is as follows: The data communication module continuously monitors the network and receives instruction data packets from the remote management platform. After receiving and verifying the instructions, the data communication module forwards them to the control module. Instructions include remote parameter configuration instructions, remote firmware upgrade instructions, and remote diagnostic instructions. For example, the remote management platform can issue instructions to batch update the PID control parameters of multiple devices within the site or adjust the boost curve. The control module parses and securely executes these instructions during non-real-time tasks. To ensure data reliability, the data communication module can be equipped with a local edge storage unit, such as a micro SD card. When the network connection is interrupted, the data to be uploaded can be temporarily cached in this storage unit and automatically resumed when the network is restored. In applications where multiple power-assist devices are located within a charging station, the data communication module can also support local area network (LAN) networking. The data communication modules of multiple devices can be connected to a station edge computing gateway via a switch. This gateway aggregates data and uploads it to the cloud platform to optimize network resources and management efficiency. The operation of the data communication module is independent of the core real-time control loop of the control module. Regardless of network communication status, the control module can independently and completely execute local dynamic balance assist control and emergency protection functions, ensuring the reliability and safety of the device's basic operation.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A charging cable assist device for heavy-duty truck charging piles, characterized in that, include: The mounting base (1), the rotating connecting seat (2), and the rotating drive shaft (3) are characterized in that, A rotatable boom assembly includes a main boom (4) and a telescopic auxiliary boom (5). One end of the main boom (4) is rotatably mounted on the rotary drive shaft (3) and can rotate horizontally around it. The telescopic auxiliary boom (5) is telescopically disposed inside the main boom (4). A charging cable suspension assembly is installed at one end of the telescopic arm (5) to support the charging cable. The charging cable suspension assembly includes a rotary joint (6) that allows it to rotate freely about a vertical axis, and a buffer spring (7) for absorbing shock. A resistance adjustment module is disposed between the mounting base (1) and the rotatable boom assembly, for providing an adjustable first damping force for the rotational movement of the main boom (4) and an adjustable second damping force for the telescopic movement of the telescopic auxiliary boom (5); The detection module is used to obtain the rotation angle and angular velocity of the main boom (4), the extension length and extension speed of the telescopic auxiliary boom (5), and the real-time tension of the charging gun cable in real time. The control module is electrically connected to the detection module and the resistance adjustment module respectively. The control module has a pre-stored balance assist control algorithm, which is used to control the output damping force of the resistance adjustment module according to the parameters detected by the detection module in real time, so as to achieve dynamic balance assist for the charging gun cable in the rotation and extension directions.

2. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The rotary drive shaft (3) is vertically fixed inside the rotary connecting seat (2), and one end of the main boom (4) is rotatably mounted on the rotary drive shaft (3) through a bearing installed inside the rotary connecting seat (2).

3. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The gun wire suspension assembly also includes a suspension hook (8). The rotary joint (6), the buffer spring (7), and the suspension hook (8) are fixedly connected from top to bottom. The top of the rotary joint (6) is fixedly connected to the bottom surface of the telescopic auxiliary arm (5).

4. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The resistance adjustment module includes a first resistance unit and a second resistance unit; The first resistance unit is a magnetorheological damper, whose fixed end is connected to the mounting base (1), and whose movable end is linked to the rotary drive shaft (3) or the main boom (4) through a transmission mechanism to provide the adjustable first damping force; The second resistance unit is a linear damper, which is located between the main boom (4) and the telescopic auxiliary boom (5) to provide the adjustable second damping force.

5. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The detection module includes: An angle sensor is installed at the rotary drive shaft (3) to detect the rotation angle and angular velocity of the main boom (4); A displacement sensor is installed on the main boom (4) or the telescopic boom (5) to detect the extension length and extension speed of the telescopic boom (5); A tension sensor, integrated on the charging cable suspension assembly, is used to detect the real-time tension of the charging cable.

6. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The detection module also includes an attitude sensor, which is mounted on the main boom (4) and is used to detect the tilt angle of the main boom (4) relative to the horizontal plane.

7. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The balance assist control algorithm pre-stored in the control module is configured to execute the following steps: Calculate the gravitational torque exerted by the charging gun cable on the boom assembly based on the real-time tension and the extension length; Based on the gravitational torque and the rotational angular velocity, the first damping force is adjusted through the first control logic; Based on the real-time tension and the extension / retraction speed, the second damping force is adjusted through the second control logic.

8. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The device also includes an emergency protection module; The emergency protection module is signal-connected to the control module and the resistance adjustment module; When the real-time tension detected by the detection module exceeds the preset safety threshold range, the control module controls the resistance adjustment module to lock the movement of the rotatable boom assembly through the emergency protection module.

9. The heavy-duty truck charging station cable assist device according to claim 1, characterized in that, The device also includes an equipment health monitoring module; The equipment health monitoring module is used to collect vibration, temperature or current parameters of the resistance adjustment module and the rotatable boom assembly, and to evaluate the health status of the device or provide fault warnings based on the parameters.

10. A heavy-duty truck charging station cable assist device according to claim 9, characterized in that, The device also includes a data communication module; The data communication module is communicatively connected to the control module and the equipment health monitoring module, and is used to send at least one of the detection data of the detection module, the processing data of the control module and the early warning data of the equipment health monitoring module to the remote management platform, and to receive configuration or control commands from the remote management platform.

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