Method for controlling a system for autonomous charging of electric vehicle

Abstract

The invention relates to a method for controlling a system for autonomous charging of an electric vehicle. The invention also relates to a system for autonomous charging of an electric vehicle. The method generally includes guiding a connector assembly toward a vehicle charging port by actuating a robotic arm; allowing the robotic arm to transition from the unlocked state to the locked state; fitting of the connector with the charging port is achieved by moving the connector assembly while monitoring and analyzing the operational data and / or sensor data; and initiating a corrective action if the analysis of the operational data and / or sensor data indicates a need for the corrective action to allow the system to complete mating of the connector with the charging port.

Description

[0001] This invention relates to a method for controlling a system for autonomous charging of electric vehicles. The invention also relates to a system for autonomous charging of electric vehicles.

[0002] The method typically includes: guiding the connector assembly toward the vehicle's charging port via actuation of a robotic arm; allowing the robotic arm to transition from an unlocked state to a locked state; achieving connector mating with the charging port by moving the connector assembly while monitoring and analyzing operational data and / or sensor data; and initiating a correction action if analysis of the operational data and / or sensor data indicates the need for a correction action to allow the system to complete connector mating with the charging port.

[0003] The system for autonomously charging an electric vehicle according to the present invention includes: a base unit; a connector assembly for supporting a connector for mating with a charging port of the vehicle; a robotic arm positioned between the base unit and the connector assembly, the robotic arm including multiple arm segments; and a control system configured to receive operational and / or sensor data to guide the robotic arm and the connector assembly toward the charging port of the vehicle.

[0004] The system also includes a control system to control the movement and positioning of the robotic arm based on operational data and / or sensor data. Technical Field

[0005] This invention generally relates to methods and related systems for controlling robotic systems to autonomously charge electric vehicles. Background of the Invention

[0006] With the increasing adoption of electric vehicles, the demand for autonomous charging solutions, or autonomous charging devices (ACDs), has increased significantly. These systems utilize robotic arms with multiple segments connected by joints, providing flexibility to navigate the spatial complexities of EV charging. The robotic arm aims to position and align the charging connector with the EV's charging port to achieve a reliable connection without human intervention.

[0007] Apparatus and related methods for this purpose are known in the art, for example from international patent applications PCT / NL2020 / 050266, PCT / NL2021 / 050115, PCT / NL2021 / 050410, PCT / NL2021 / 050495, PCT / NL2021 / 05061, PCT / EP2022 / 062233 and PCT / EP2022 / 088101 from the same applicant, all of which are incorporated herein by reference.

[0008] Autonomous electric vehicles represent a significant leap forward for the automotive industry, operating without human intervention. They can perform tasks independently, such as finding parking spaces, navigating tight spaces, and locating charging stations. Robotic EV charging systems complement these capabilities by providing seamless, automated charging. As these vehicles advance, a reliable infrastructure, including automated charging, is essential.

[0009] Robotic systems for EV charging can also improve charging at home, not just at public stations or in autonomous vehicles. However, making these systems suitable for home use requires a balance between reliability and affordability. Automated home charging offers convenience and efficiency, but designing cost-effective solutions for smaller, cost-sensitive residential environments presents unique challenges.

[0010] Furthermore, the integration of robotic systems for facilitating electric vehicle (EV) charging holds immense potential for large industrial and transportation fleets. These fleets typically consist of vehicles with similar configurations and charging requirements, providing an ideal scenario for scaling up automated charging systems with standardized needs. Establishing a consistent robotic charging infrastructure becomes more feasible when a fleet of vehicles shares similar charging port locations and connector designs.

[0011] The goal is to develop flexible and customizable autonomous charging solutions as a platform for implementation in diverse use cases. For example, some scenarios may require a high degree of automation with minimal human intervention, while others may require more manual control for specialized tasks. The ability to adapt system configurations to meet these different needs can enhance its versatility and applicability across a wide range of applications.

[0012] The goal is to provide a cost-effective autonomous charging system that can adapt to the inherent variables of the charging process without relying on complex components. This system is expected to manage differences in EV positioning, charging port placement, and various connector designs. Furthermore, it is desirable to provide a system capable of handling real-time changes, including unexpected EV movement, variations in environmental conditions, and the potential presence of obstacles.

[0013] The present invention aims to provide a method and system for addressing many of the challenges described herein. Invention Overview

[0014] In a first embodiment, a method for controlling a robotic system for autonomously charging an electric vehicle is disclosed. The method includes: guiding a connector assembly toward a vehicle charging port by actuating a robotic arm; allowing the robotic arm to switch between an unlocked state and a locked state before engaging the connector with the charging port based on operational data and / or sensor data, wherein in the locked state, movement of at least one arm segment is prevented; and wherein such movement is allowed in the unlocked state; achieving engagement of the connector with the charging port by moving the connector assembly while monitoring and analyzing such operational data and / or sensor data; and initiating a correction action when a correction action is required.

[0015] According to an exemplary embodiment, the method includes comparing operational data and / or sensor data with at least one predetermined operational data and / or sensor data, and using the result of the comparison to determine whether a correction action is required.

[0016] According to an exemplary embodiment, the method includes allowing the robotic arm to switch between an unlocked state and a locked state when such operational data or sensor data is within a predetermined range.

[0017] According to an exemplary embodiment, the method includes performing at least one of the following actions to enable the system to complete the mating of the connector with the charging port: i) switching the robot arm to the unlocking phase; ii) switching the robot arm to the locking phase; iii) repositioning the robot arm; or iv) obtaining new or updated operational data or sensor data; or v) re-attempting mating.

[0018] According to an exemplary embodiment, the method includes receiving: sensor data associated with at least one of the following: the orientation of a charging port, the orientation of a connector assembly, the distance between the connector and the charging port, the physical or electrical connection between the electric vehicle connector and the charging port, an external force applied to the robot arm, and physical deflection of components of the system; and / or operational data associated with at least one of a signal from a vehicle, an instruction from an operator, or a signal from a remote system.

[0019] According to an exemplary embodiment, the method includes receiving attitude data of a charging port or connector assembly, and allowing the robotic arm to transition from an unlocked state to a locked state when such attitude data is within a predetermined threshold for mating.

[0020] According to an exemplary embodiment, during the locked state, at least two arm segments are prevented from moving, and at least one arm segment is allowed to move, both relative to an adjacent arm segment or the base unit.

[0021] According to an exemplary embodiment, the method includes allowing the robotic arm to undergo more than one transition between a locked state and an unlocked state before engagement.

[0022] According to an exemplary embodiment, the method includes receiving sensor data associated with an external force acting on the connector, and initiating a correction action when such sensor data deviates from a predetermined range, wherein such threshold depends on the position of the connector relative to the charging port.

[0023] According to an exemplary embodiment, the method includes allowing the robotic arm to switch between a retracted position and an extended position; wherein, during the retracted position, the connector assembly, and preferably the charging connector, is at least partially engaged by the connector housing, and during the extended position, the connector or the connector assembly is not engaged by the connector housing.

[0024] According to an exemplary embodiment, the method includes: during the locked state, engaging the connector with the charging port by allowing the robotic arm to apply a temporarily higher force than when the robotic arm is in the unlocked state.

[0025] According to an exemplary embodiment, the method includes allowing the robotic arm to transition from a locked state to an unlocked state at any time after the charging connector has engaged with the charging port. This can be advantageous because it allows, for example, the system to adapt to any movement or adjustments made by the electric vehicle (EV) during the charging process and reduces the need for a constant energy supply to hold the robotic arm in the locked position.

[0026] According to an exemplary embodiment, the method includes allowing the robotic arm to transition to a locked state before disengagement. This facilitates the disengagement step. Furthermore, once the connector has disengaged, the robotic arm can transition back to an unlocked state. This transition to the unlocked state can be used for a variety of purposes, including safely retracting the robotic arm as needed or preparing to initiate another engagement cycle.

[0027] According to a second embodiment, a system for autonomously charging an electric vehicle is disclosed, comprising: a base unit; a connector assembly supporting a connector for mating with a charging port of the vehicle; and a robotic arm positioned between the base unit and the connector assembly and comprising a plurality of arm segments. Specifically, the robotic arm is configured to switch between an unlocked state and a locked state before mating the connector with the charging port based on received operational data and / or sensor data, wherein in the locked state, at least one arm segment is prevented from moving relative to an adjacent arm segment or the base unit; and wherein in the unlocked state, such movement is permitted. Furthermore, the control system is configured to monitor and analyze such operational data and / or sensor data, and to initiate a correction action if the analysis of the operational data and / or sensor data indicates that a correction action is needed to allow the system to complete the mating of the connector with the charging port.

[0028] In an exemplary embodiment, the system includes a plurality of joint assemblies configured to move between a first position and a second position, thereby adjusting the position of the connector assembly relative to the base unit.

[0029] In an exemplary embodiment, at least one joint assembly is configured to enable rotation, pivoting, and / or linear movement between at least one of the connector assembly and arm segments, between two adjacent arm segments, or between an arm segment and a base unit.

[0030] In an exemplary embodiment, at least one joint assembly includes an actuator member mounted on an arm segment and a joint portion connected to the actuator member via a transmission assembly.

[0031] In an exemplary embodiment, the system includes one or more sensors configured to generate sensor data and means for receiving operational data.

[0032] In an exemplary embodiment, at least one of the base unit and the arm segment includes a connector housing that defines a geometry for at least partially accommodating a connector assembly and preferably accommodating a charging connector. The robotic arm is configured to switch between a retracted position and an extended position, in which the connector assembly is at least partially engaged by the connector housing, and in the extended position, the connector assembly is disengaged from the connector housing.

[0033] In an exemplary embodiment, at least one of the base unit and the arm segment includes a connector housing that defines a geometry for at least partially accommodating the connector assembly and preferably accommodating the charging connector.

[0034] In an exemplary embodiment, the robotic arm is configured to switch between a retracted position and an extended position, wherein in the retracted position the connector assembly is at least partially engaged by the connector housing, and in the extended position the connector assembly is disengaged from the connector housing.

[0035] In an exemplary embodiment, at least one joint component includes a joint member and a braking member, and the control system is configured to activate and deactivate such braking member to switch the robot arm between a locked state and an unlocked state, and vice versa.

[0036] In an exemplary embodiment, the control system is configured to receive attitude data from a charging port or connector assembly, and when such attitude data is within a predetermined engagement threshold, allow the robotic arm to transition from an unlocked state to a locked state.

[0037] In an exemplary embodiment, the control system is configured to receive sensor data relating to an external force acting on the connector, and to initiate a correction action when such sensor data deviates from a predetermined range, wherein such threshold depends on the position of the connector assembly relative to the charging port.

[0038] In an exemplary embodiment, the control system is configured to limit the speed of at least one system component when the robot arm is in the deployed position.

[0039] In an exemplary embodiment, the control system is configured to engage the connector with the charging port when the distance between the connector and the charging port is less than or equal to a predetermined threshold.

[0040] In an exemplary embodiment, the control system can selectively lock and unlock individual joint components, and subsequently lock and unlock individual arm segments within the robot arm, to allow, for example, correction of the position of the robot arm or connector assembly during a charging cycle. By operating in this manner, in certain cases where minute misalignment, displacement, or external force is detected, the control system can trigger the locking and unlocking of individual joint components to make small, localized corrections to the position of the arm or the orientation of the connector assembly.

[0041] In an exemplary embodiment, the control system may activate the locking mechanism in response to input received from at least one sensor or in response to a predetermined command. In some cases, the control system utilizes sensors located within or in communication with the system to acquire sensor data or to obtain operating parameters, environmental conditions, or external factors. Upon processing sensor data and identifying specific conditions or scenarios requiring a certain level of stability, accuracy, or security, the control system is configured to trigger a transition from one stage to another as appropriate.

[0042] In an exemplary embodiment, the control system may be configured to trigger a short-term partial lock of the joint assembly to effectively reduce any momentum that the robotic arm may experience, especially in the event of rapid pivoting or sudden movement.

[0043] In an exemplary embodiment, a safety system may be integrated to provide emergency stop capability and / or deactivate the power supply to the system or any system component (e.g., braking components). When such a safety system is activated, the robotic arm can rapidly transition from a locked state to an unlocked state. Brief description of the attached diagram

[0044] Figure 1 This is an illustrative method according to an embodiment of the present invention.

[0045] Figure 2 This is an illustrative system according to an embodiment of the present invention, which includes a base unit 20, a robotic arm 40, a control system 60, and a connector assembly 30.

[0046] Figure 3 This is an illustrative system according to an embodiment of the present invention, which includes a base unit 20, a robot arm 40, a connector housing 70, and a connector assembly.

[0047] Figure 4 This is an illustrative system according to an embodiment of the present invention, which includes a base unit 20, a robot arm 40, a connector housing 70, and a connector assembly 30. The robot arm 40 is capable of vertical displacement along the z-axis.

[0048] Figure 5a and Figure 5b Two implementations of the invention are depicted, wherein the robotic arm is in a retracted position and an extended position, respectively.

[0049] Figure 6 This is an illustrative system according to an embodiment of the present invention, which includes a base unit 20 and a robot arm 40, the robot arm 40 having two arm segments 42 and 44 connected to the base unit 20.

[0050] Figure 7 This is an illustrative system according to an embodiment of the present invention, which includes a connector changer 90.

[0051] Figure 8a An implementation of the invention is described, wherein the system includes cable support devices 110, 111, and Figure 8b The implementation of the system, including the support arm 113, is shown.

[0052] Figure 9a and Figure 9bAn illustrative system according to an embodiment of the present invention is depicted, which includes a base unit 20, a robotic arm, a compliance component 100, a connector housing 70, and a connector assembly 30.

[0053] Figure 10a and Figure 10b An illustrative system according to an embodiment of the present invention is depicted, which includes a base unit 20 and a robotic arm 40 capable of vertical displacement along the z-axis.

[0054] Figure 11 An illustrative system according to an embodiment of the present invention is depicted, comprising a base unit 20 and a robotic arm 40, wherein the base unit is capable of horizontal displacement along the x-axis.

[0055] Figure 12 This is an illustrative system according to an embodiment of the present invention, wherein the robotic arm 40 is in a retracted position, and wherein the connector assembly is engaged by the connector housing 70.

[0056] Figure 13a and Figure 13b An enlarged view of a connector housing according to several embodiments of the present invention is depicted.

[0057] Figure 14a and Figure 14b Enlarged views of arm segments according to several embodiments of the present invention are depicted.

[0058] Figure 15a and Figure 15b This is a schematic diagram of system 10 according to an embodiment of the present invention.

[0059] Brief description of existing technology Some existing systems have various drawbacks for certain applications. Therefore, further contributions are still needed in this technological field.

[0060] WO2019219339A1 describes a charging robot for a motor vehicle, and a method, apparatus, and computer-readable storage medium for controlling the charging robot, the storage medium containing instructions for controlling the charging robot. The charging robot has a robot structure formed by two or more structural elements, and a plug receiver for a charging plug. A self-locking actuator allows the plug receiver to move relative to a charging socket on the motor vehicle. A sensor system detects a force applied to the plug receiver or the charging plug. A control device controls the charging robot in response to the force applied to the plug receiver or the charging plug detected by the sensor system. This document does not describe a system or method according to embodiments of the invention, but focuses on a non-self-locking design such that after the plug is inserted into the vehicle and the charging robot is connected to the plug, the robot's actuator is de-energized. Therefore, when the vehicle is lowered, the charging robot also descends.

[0061] Detailed description of the invention The invention will now be described more fully below with reference to the accompanying drawings, which illustrate presently preferred embodiments of the invention. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; furthermore, these embodiments are provided for thoroughness and completeness and to fully convey the scope of the invention to those skilled in the art.

[0062] Figure 1 This is a flowchart of a method for controlling an autonomous charging system for an electric vehicle, according to the present disclosure. The method includes, among other steps, allowing a robotic arm to transition from an unlocked state to a locked state before mating a connector with a charging port based on received operational data and / or sensor data. By transitioning to the locked state before connecting the charging connector to the charging port of the electric vehicle, the control system allows a predetermined arm configuration to be maintained, preventing misalignment. Furthermore, locking the arm segments in place during deployment facilitates orientation to improve the connection and charging cycle, thereby reducing the total force exerted by system components. This transition from one stage to another can further allow the system to use camera sensors to collect attitude information of the charging port, enabling movement throughout the arm's workspace. In the locked state, actuators at the distal end of the arm can be activated to mate and align the charging connector with the vehicle's port, while the remaining joints and segments remain locked, thereby reducing resistance and forces during mating.

[0063] Figures 2 to 1 5. An exemplary embodiment of a system 10 for autonomous charging of an electric vehicle according to the present invention is depicted, the system comprising: a base unit 20; a connector assembly 30 configured to support an electric vehicle connector 31; a robotic arm 40 located between the base unit 20 and the connector assembly 30 and including a plurality of arm segments 41 and a plurality of joint assemblies 50; and a control system 60 configured to control the movement and positioning of the robotic arm 40, the connector assembly 30, and other components of the system.

[0064] refer to Figure 2 The robotic arm is preferably a multi-jointed controllable arm, which allows the connector assembly 30 to achieve the desired position and orientation. Suitable robotic arms include, but are not limited to, six-axis robotic arm systems, selectively compliant articulated robotic arm (SCARA) systems, parallel robotic arms, Cartesian robotic arms, delta robotic arms, articulated robotic arms, industrial robotic arms, Steward platforms, hexapod platforms, etc., wherein the degrees of freedom of the connector assembly can depend on the robotic arm kinematics, the number of arm links, the number and type of joint assemblies, and combinations of these factors.

[0065] refer to Figure 2 Factors that may affect the degrees of freedom of the robotic arm 40 and / or connector assembly 30 include the number of arm segments 41, the number and type of joint assemblies 50 incorporated in such an arm, and the combination of their spatial arrangement. Arm segments can have any size and shape, but their form typically depends on factors such as the expected degrees of freedom, usage, vehicle type, connector type, connector cable weight, load capacity, maneuverability, alignment accuracy, and adaptability to the charging environment of electric vehicles.

[0066] refer to Figures 2 to 1 Any of the 5, the system includes a base unit 20, which is typically configured to support other components of the system 10, and may include at least one of a robot arm 40, a control system 60, a connector housing 70, and a connector cable 80. Figure 2 A base unit 20 is depicted, configured to directly or indirectly support a robotic arm 40 and the movement associated with such a robotic arm 40 and connector assembly 30. The base unit 20 may be mechanically configured to support the weight and movement of the robotic arm. The base unit 20 may advantageously include a stabilizing device configured to fix the base relative to the ground and at least partially support the weight of the base and the robotic arm (not shown). For example, the base unit 20 may be coupled to a fixed structure such as a wall, floor, or ceiling. Alternatively, the base unit 20 may have a mass and geometry such that, when the base unit 20 is independent, it will support the robotic arm 40. In some embodiments, the base unit 20 may further include a movable trolley to provide movement to the system (e.g., around a vehicle).

[0067] In addition to providing structural support, the base unit 20 can accommodate various other system components, such as mechanical controllers, electrical controllers, or combinations thereof. The base unit may also include a display screen (not shown) or other mechanisms through which the operator can view information about system operation. Electrical or electromagnetic signals can be received from external input devices to control the movement of any component of the system via a control system.

[0068] In such Figures 2 to 1 In at least one of the exemplary embodiments shown in 5, the system includes a plurality of joint components 50. Figure 2The joint assembly 50 is depicted being positioned between at least one of the following: between adjacent arm segments 41, between arm segments 41 and base unit 20, or between arm segments 41 and connector assembly 30. The joint assembly 50 includes means configured to move between at least first and second positions, thereby adjusting the position of at least one arm segment 41 relative to base unit 20 or the position of connector assembly 30 relative to base unit 20.

[0069] The robotic arm may include combinations of joint assemblies, including but not limited to linear joint assemblies, rotary joint assemblies, or other suitable joint assemblies. Other suitable joint assemblies include revolute joints, prismatic joints, ball joints, cylindrical joints, planar joints, continuous joints, universal joints, hinge joints, slider-crank joints, pivot joints, helical joints, ball joints, flexural joints, sliding contact joints, cam-follower joints, and bearing joints. When used in combination, such joint assemblies enable the robotic arm, and preferably the connector assembly, to achieve multiple degrees of freedom to facilitate mating of the charging connector with the EV charging port. In this disclosure, the terms charging port, socket, and charging inlet (or simply inlet) are used interchangeably.

[0070] The characteristics and configurations of joint assemblies can vary depending on the specific design and operational requirements of the system. Linear joint assemblies facilitate translational motion, thereby allowing arm segments to translate relative to another arm segment, connector assembly, base unit, or a combination thereof. Rotary joint assemblies enable rotational movement, thereby facilitating the pivoting or rotation of one or more robot arm segments, another arm segment, connector assembly, base unit, or a combination thereof.

[0071] like Figure 2 As shown, the exemplary system 10 includes a connector assembly 30 configured to support an electric vehicle connector 31. The connector assembly 30 is configured to support the electric vehicle connector 31 in a fixed or releasable manner. The connector assembly may include a release mechanism that allows the EV connector to be controlled to detach from the connector assembly. This controlled detachment can be achieved rapidly in the event of an operator-triggered event, such as an emergency.

[0072] The connector assembly 30 can be implemented as any suitable device supporting the electric vehicle connector, such as a fixed or movable flange, receptacle, or interface structure. In some embodiments, the connector assembly includes a flange assembly, which can be fixed or movable. The flange can be designed with a set of locking mechanisms or clamps to securely hold the electric vehicle connector in place during the charging process. Depending on the specific requirements of the charging station, the flange assembly can be oriented vertically or horizontally. The connector assembly can be configured as a receptacle interface, including alignment guides, locking pins, or magnetic locks to ensure reliable support and connection between the connector assembly and the connector. In some cases, the connector assembly can utilize an interface structure comprising geometry, surfaces, or channels that interact with corresponding features on the electric vehicle connector. In this implementation, the connector assembly supports the connector and prevents it from disengaging during charging. The connector assembly can include a quick-release mechanism to allow the electric vehicle connector 31 to disengage quickly and in a controlled manner from the connector assembly or from at least a portion thereof. It can be manually or automatically actuated, providing flexibility to disconnect the connector in emergency situations or when the charging process is complete.

[0073] Further reference Figure 2 The system includes a compliant assembly 100 located between the robotic arm and the connector assembly 30. This compliant assembly 100 enhances the system's ability to compensate for unintended movement during the charging process, thereby ensuring reliable and efficient charging of the electric vehicle. In this example, the compliant assembly 100 serves as an intermediate component between the robotic arm 40 and the connector assembly 30 and is designed to provide a degree of flexibility and adaptability in controlling the movement of the connector assembly, enabling it to respond to unforeseen changes in the positioning and orientation of the electric vehicle's charging port.

[0074] Compliant components may include compliant elements selected from at least one of the following: compliant ball mechanism, mechanical spring, pneumatic element, pneumatic actuator, rubber / silicone element, flexure, and combinations thereof.

[0075] Compliance components can be distributed throughout the system, between the base unit and the connector assembly. Preferably, the compliance device is configured to achieve compliance in different degrees of freedom, including, for example, at least one of: i) translation along at least one of the X, Y, and Z axes, and ii) rotation about at least one of the X, Y, and Z axes. In this implementation, the connector assembly can adjust its orientation to match the angle of the charging port. The compliance component can include a Stewart platform configuration comprising multiple pre-tensioned springs, such as linear springs. These springs can be mechanically coupled to the connector assembly at one end and to a robot arm at the other, thereby giving the connector assembly controlled compliance in multiple directions. Each spring is attached to both the robot arm and the connector assembly, forming a hexapod structure. The Stewart platform configuration with linear springs can provide compliance in at least three and up to six degrees of freedom, allowing compensation for unintended movement in any direction, whether it be lateral displacement, tilting, or rotation of the connector assembly. These springs can be individually tensioned at different levels to modify the compliance characteristics to suit specific usage conditions. For example, in cases where precise compliance with translation or rotation is required, the tension in the corresponding spring can be selectively adjusted. In some embodiments, the compliance component includes a force sensor selected from at least one of a piezoelectric sensor, a strain gauge, or a load cell, the force sensor being configured to provide feedback on compressive force and tension.

[0076] Further reference Figure 2 The system also includes a control system 60, a connector assembly 30, and a compliance assembly 100. The control system 60 is designed to autonomously manage and supervise the various operations and functions involved in the charging of the electric vehicle (EV). The control system comprises a combination of hardware components, software algorithms, and other components that together enable it to monitor, analyze, and make decisions based on data received from various sources, including sensors, operating parameters, and external inputs. The control system can communicate with external systems or operators as needed, exchange data, and provide status updates, thereby facilitating remote monitoring and management of the charging process.

[0077] refer to Figure 3 The image depicts a system comprising a base unit 20 positioned substantially horizontally, and a plurality of arm segments 41 connected in series via a joint assembly 50. The system also includes a control system 60 (not shown), a connector assembly 30, and a compliance assembly 100. The base unit 20 further includes a connector housing 70 defining a geometry for at least partially accommodating the connector assembly 30 (preferably, a connector charging interface 31).

[0078] refer to Figure 4The image describes a system comprising a generally elongated base unit 20 positioned vertically and a series of arm segments 41, 42, and 43. The system includes joint assemblies 50, 51, and 52. In this embodiment, arm segments 42 and 43 are preferably connected by a linear joint assembly 51 that enables linear displacement of the arm segments, and also by a rotary joint assembly 52 that enables pivoting movement of the arm segments. Joint assemblies 51 and 52 are positioned between the base and the arm segments 42, allowing for generally linear displacement of the arm segments 42 along the Z-axis, which can be achieved in various ways, including manual or actuated displacement. The rotary joint assembly 52 enables the arm segments 42 to pivot about the Y-axis. The rotary joint assembly 52 also enables the base unit to pivot about the Z-axis. In each case, this rotation can be achieved by manual or actuated rotation.

[0079] Figure 5a and Figure 5b An embodiment of the system is shown, in which the robotic arm 40 is in a retracted position 5a and an extended position 5b, respectively. The rotary joint assembly 52 allows the base unit to pivot about the Z-axis.

[0080] refer to Figure 6 The system includes multiple arm segments 41, 42, 43, 44, and 45, and rotary joint assemblies 52 and linear joint assemblies 51 between two arm segments 42 and 43 and between arm segments 44 and 45, allowing vertical displacement of the base unit 20 and the linear joint assemblies 51 of the arm segments 42 and 44. The rotary joints 52 between the base unit 20 and the arm segments 42 and 44 allow for further pivoting movements of these arm segments.

[0081] Figure 7 A connector replacement system 90 is depicted, comprising a connector connector 91, a connector replacement 92, and a connector mounter 93. The connector mounter 93 may be supported by various means, including any type of support 94, or it may be attached to an external support, such as a wall, ceiling, or other suitable structure (not shown).

[0082] The robotic arm and / or connector assembly is designed to manipulate multiple electric vehicle connectors, facilitating the engagement, disengagement, and positioning of different EV connectors, for example... Figure 7 As shown. To enable conversion between different EV connectors, the system includes a tool replacement system, referred to herein as connector replacement system 90. In one embodiment, connector replacement system 90 includes three main components: connector connector 91, connector changer 92, and connector mounter 93.

[0083] Connector connector 91 includes means for coupling to charging connector 31 and can be used with various types of charging connector 31. Connector connector 91 is designed to selectively and securely fasten to connector changer 92, which in turn can be coupled to connector assembly 30. Additionally, connector connector 91 can be mounted to or removed from mounter 93. Connector changer 92 is typically mounted at the distal end of robotic arm 40.

[0084] The connector changer 92 is designed to manipulate the connector connector 91, including tasks such as installing the connector 91 onto the mounter 93 or removing it as needed.

[0085] On the other hand, the mounter 93 is responsible for securing the connector 91 and preferably can accommodate multiple connectors 91, each of which can be operated by a changer based on specific charger requirements. In some embodiments (not shown), the mounter 93 can also be fixed to a structure such as a wall, bracket, or shelf. With this implementation, the system can switch between various EV connectors, enhancing the system's versatility in serving multiple EVs simultaneously.

[0086] like Figure 8a As shown, the base unit 20 may include at least one charging cable attachment device 110, 111, which is configured to position one end of the charging cable 80 at a location that effectively counteracts any undesirable effects of the cable 80 on the movement of the robot arm 40, the movement of the connector assembly 30, or any step of the mating process, such as preventing the cable weight from hindering the operation of the robot arm.

[0087] Attachment devices 110 and 111 can be configured to position the end of the charging cable at a variable height and at a variable distance from the robot arm 40 or a portion thereof to accommodate different vehicle charging cables and connectors. The attachment devices may include a pivoting joint at which they are connected to the base unit 20. This pivoting joint facilitates rotational movement, enabling attachment devices 110 and 111 to adapt to various charging scenarios and further reducing the impact of cable weight or stiffness on the movement of the robot arm or connector assembly. It ensures that the charging connector 31 can be aligned with the charging port of the electric vehicle, regardless of the port's location or orientation.

[0088] For example Figure 8aAs depicted, the charging cable 80a can be fully integrated into the robotic arm 40. This integration reduces external cable exposure, effectively isolates the cable from potential operator contact, and reduces associated safety risks. In this implementation, the system also eliminates the need for a liquid cooling system that traditionally dissipates heat generated during high-power charging, allowing the robotic arm itself to act as a protective barrier against any direct external contact with the high-temperature cable.

[0089] For example, such as Figure 8b As shown, a support arm 113 is provided to support the charging cable 80 and provide further range of motion for the cable. The support arm 113 is mechanically coupled to the base unit 20 and configured to pivot within a pivot range to position the charging cable 80, allowing the connector 31 to be manipulated by the robotic arm while minimizing the impact of the weight of the charging cable 32. Preferably, the support arm 113 is coupled to the base unit 20 via a rotary joint 112. The support arm 113 allows the charging cable 80 to be held in an elevated, above-ground position, protecting the cable from the ground, contamination, abrasions / wear, dirt, snow, and ice, preventing pedestrians from tripping over it, preventing vehicles from driving over the cable 80, and protecting the end connectors / fittings from damage and contamination.

[0090] The support arm can be mechanically attached to a fixed structure such as a wall, floor, or ceiling (not shown) and connected using a similar coupling device such as a rotary joint. The support arm may include one or more joints, such as rotary or linear joints. In some embodiments, the support arm may be an articulated arm, a telescopic arm, a rotary arm, etc. The support arm 113 may also include a cable attachment device 114, such as... Figure 8b As depicted, it can be configured to rotate or translate along or about such a support arm 113. The support arm 113 may also include a biasing device (not shown), such as a spring-loaded mechanism, to return the support arm 113 to a desired position, such as a retracted or extended position. The biasing device is positioned such that when the support arm 113 is not actively holding or manipulating the charging cable 80, a force is applied to retract the support arm to its retracted position. When the support arm 113 extends or pivots to position the charging cable 80 for use by the robotic arm, the biasing device stores potential energy in a helical spring. Once the robotic arm has completed its task and retracted the connector, the energy stored in the spring causes the support arm to retract to its return position, effectively “winding up” the spring. This retraction minimizes the risk of the charging cable dangling or causing obstruction when not in use.

[0091] like Figure 9aAs shown, the exemplary system includes two arm segments 42 and 43 and a rotary joint assembly 52 between these arm segments, as well as a rotary joint 52 assembly between the base unit 20 and the nearest side arm segment 42, thereby forming a SCARA-type arm. Figure 9a As shown, the exemplary system includes two arm segments 44 and 45 at the distal end of the robotic arm and a linear joint assembly 51 between these arm segments, which allows linear displacement of the distal arm segment 45. Such an assembly, including the two arm segments 44, 45 and the linear joint assembly 51, may be referred to as the mating part of the robotic arm.

[0092] The mating parts can be connected to adjacent arm segments and / or connector assemblies via linear and / or rotary joint assemblies, which can impart several degrees of freedom to the connector assemblies. Depending on the specific application, these joint assemblies can be fixed (static), actuated, or manually adjustable, and they can give the connector assemblies additional pitch, roll, and yaw capabilities. In some configurations, the mating parts can be positioned at a pitch angle greater than zero, thereby facilitating greater vertical displacement of the connector assembly along the z-axis. This implementation combines the vertical displacement along the z-axis generated by SCARA movement with the displacement along the x-axis. Through this implementation, the system can compensate for any constraints originating from the vertical displacement along the z-axis of the base unit or robot arm.

[0093] refer to Figure 9a and Figure 9b An exemplary system is depicted, including a base unit 20 and a plurality of arm segments 42, 43, 44, 45, 46 connected by joint assemblies 50, 51, 54 to form a SCARA-type robotic arm. The system according to this embodiment also includes a connector housing 70. The system also includes a connector assembly 30 and a compliance assembly 100. Figure 9b This illustrates the degrees of freedom that connector assembly 30 can achieve given this configuration. (Reference) Figure 9a The system includes a rotary joint 52 and a linear joint 51 between the connector assembly 30 and the arm segment 44. In such an embodiment, the combination of different joint assemblies can allow the connector assembly 30 to move with at least six degrees of freedom, such as... Figure 9b As shown.

[0094] refer to Figure 10a The diagram describes a system comprising a base unit 20 and multiple arm segments 42, 43, 44, 45, 46, and 47 connected by joint assemblies 50, 51, and 52. The linear joint assembly 51 between the base 20 and the arm segments 42 allows for vertical displacement of the robotic arm 40, and thus allows for additional degrees of freedom of motion of the connector assembly 30, such as… Figure 10b As shown.

[0095] refer to Figure 11 The image depicts a system comprising a base unit 20 supported on a base 21. A linear displacement device 51 allows for linear displacement of the base unit 20.

[0096] like Figure 11 As shown, the exemplary robotic arm includes a shoulder joint assembly 50a, an elbow joint assembly 50b, and a wrist joint assembly 50c. At the distal end of the wrist joint assembly 50c, a connector assembly 30 is mechanically coupled.

[0097] Joint assemblies can be designed to be fixed or static, serving as structural connectors between two arm segments, between a base and an arm segment, or between a robot arm and a connector assembly, without allowing movement or jointing between them. Such static joint assemblies can be any type of linear or rotary joint that is configured to be fixed or static, or any joint assembly that is designed to be static or fixed.

[0098] Joint components can be actuated by active or passive means. As used herein, active actuation involves the deliberate application of external force or energy to initiate and control the movement of the joint component. Actuating components include any suitable means, such as electromagnetic actuators, motorized actuators (electric motors, stepper motors, or other motorized components for actively driving and controlling the joint component), piezoelectric actuators, solenoid actuators (using a solenoid to apply magnetic force for actuation purposes), hydraulic actuators, pneumatic actuators, etc.

[0099] Passive actuation refers to the inherent response of joint components to environmental or intrinsic factors (such as mechanical forces or temperature gradients), resulting in movement without the explicit application of external forces.

[0100] The actuator component can be any suitable actuation device for driving the joint component, and is preferably an electric drive device, such as a stepper motor, servo motor, hydraulic motor, pneumatic motor, or combination thereof.

[0101] refer to Figure 12 The robot arm 40 is in the retracted position, and thus the connector assembly 30 is engaged at least partially by the connector housing 70.

[0102] Figure 13a and Figure 13b An embodiment of a connector housing is depicted, comprising an outer housing 70a, an inner housing 70b, and a compartment 70c for power contacts. Figure 13b A cross-section of the connector assembly 30 according to an embodiment of the present invention is depicted. The connector assembly supports the charging connector 34.

[0103] like Figure 13a and Figure 13bAs shown, the connector housing 70 may include at least one of the following: an outer housing 70a, an inner housing 70b, and a compartment 70c for power contacts, such as... Figure 13a As shown. The functions of the inner housing include ensuring electrical insulation, mechanical strength, and / or preventing water and dirt contamination. The inner housing 70b may include protective materials such as soft epoxy resin and / or silicone-based materials. In this embodiment, the connector housing can protect the connector assembly when the system is not in operation. Preferably, when the robot arm 40 is in the retracted position, the inner housing 70b allows the connector assembly 30 and / or connector 31 to be effectively sealed to prevent the ingress of water and dust (preferably achieving IP rating 24, 44 or other suitable ratings).

[0104] The connector housing 70 can be attached to a plate or any similar component connected to the base unit 20, and can be opened or closed via a hinged door assembly or door folding assembly, depending on specific design requirements. In this configuration, the plate of the connector housing is attached to the base unit or arm segment and is designed to pivot or fold about a predetermined axis. When the robot arm 40 is in the retracted position or not in use, this plate can be closed, thereby sealing the connector assembly 30 within the housing 70. In some variations of this embodiment, the connector assembly 30 can be used to cause the plate of the connector housing to open or close. This movement can trigger the plate to open or close automatically when the robot arm moves forward or backward.

[0105] refer to Figure 14a It depicts the base unit 20, two arm segments 41, and joint assembly 50. Figure 14b The diagram depicts a joint member 55, an actuator member 54, a transmission member 56, and a braking member 57. A motor unit is positioned on the arm segment; and a joint unit is connected to the motor unit via a transmission assembly.

[0106] refer to Figure 14b An unfolded view of an exemplary arm segment 41 and joint assembly 50 is depicted. Figure 14b The diagram depicts a joint member 55, an actuator member 54, a transmission member 56, and a braking member 57. In this example, the joint member 55 is a rotary joint, enabling rotational movement between two adjacent arm segments 41 or between the base unit 20 and adjacent arm segments, such as... Figure 14aAs shown. Joint member 55 provides a pivotal connection. In this example, actuator member 54 is mounted on each arm segment and is therefore configured to transmit rotational forces to drive joint movement, and preferably, to provide control over the rotational movement of the robot arm. The actuator member is controlled by a control system. Transmission member 56 allows the torque generated by actuator 54 to be transmitted to joint member 55. Depending on specific design requirements, transmission member 56 may include various components such as gears, pulleys, belts, or other mechanical elements. Braking member 57 is designed to fix or restrict the movement of joint member 55, and thus restrict the movement of the corresponding arm segment relative to any adjacent arm segment or base unit. Braking member 57 may be any type of brake, such as an electromagnetic brake, a spring-loaded brake, or any other suitable braking mechanism.

[0107] Braking member 57 can be any suitable braking member that allows for the prevention of movement of the joint assembly, arm segment, connector assembly, or any combination thereof relative to another moving or non-moving part of the system, such as the base. The braking member can be at least one of joint braking types and motor braking types, or a combination thereof. The braking member can be selected from any of electromagnetic brakes, friction brakes, hydraulic brakes, spring-loaded brakes, and combinations thereof. As used herein, such joint assembly is locked when movement of the joint assembly is partially or completely restricted.

[0108] The robotic arm is configured to transition from a locked state to an unlocked state and vice versa. Locking prevents movement of components, such as movement of adjacent arm segments relative to each other, or movement of an arm segment relative to the base unit, or movement of the connector assembly relative to an arm segment or base unit. Locking is achieved by locking one or more joint assemblies that couple these components.

[0109] One or more joint components can be selectively and independently of other joint components. Alternatively, all joint components of the system can be locked or unlocked simultaneously.

[0110] The joint assembly preferably includes a locking mechanism, wherein the joint members connecting adjacent arm segments of the robotic arm are preferably locked via a braking member (such as an electromechanical brake). In some embodiments, the robotic arm includes multiple joint assemblies, such as rotary joint assemblies and linear joint assemblies. In some embodiments, at least two of the multiple joint assemblies are locked simultaneously. Optionally, all joint assemblies are locked simultaneously. In some embodiments, locking of the joint assemblies is performed locally at such joints, for example, by mechanical and / or electromechanical components physically located at the joints.

[0111] In some implementations, the braking component is configured as an electromagnetic brake, which utilizes electromagnetic principles to control motion. An electromagnetic brake typically comprises a fixed housing and an electromagnetic coil. The fixed housing is attached to the arm structure and positioned adjacent to the moving part to be controlled, such as a joint. When current is applied to the coil, it generates a magnetic field. This magnetic field interacts with the joint, generating an attractive or repulsive force and restricting joint movement. When the electromagnetic brake is activated, current is supplied to the electromagnetic coil, energizing it, and the coil generates a magnetic field that interacts with the moving part, allowing the arm segment or joint to remain in a fixed position. When the electromagnetic brake is deactivated, the current to the electromagnetic coil is cut off, thereby stopping its magnetic field generation; in the absence of electromagnetic force, the brake releases its grip on the moving part, allowing the arm segment or joint to move freely as instructed by the control system. Thus, throughout the cycle, the robotic arm can switch between locked and unlocked states, and vice versa.

[0112] like Figure 3 , Figure 9a and Figure 12 As shown in Figure a, at least one of the base unit 20 and arm segment 41 includes a connector housing 70, which defines a geometric volume for at least partially accommodating the connector assembly 30 (preferably, the connector charging interface 31). The connector housing 70 may include a box-like structure, but may be of any geometry, which allows for, preferably when the robot arm is in the retracted position, accommodating or at least partially accommodating or supporting the connector charging interface, such as... Figure 12 As shown. The connector housing 70 may include one or more openings and plates or any suitable structure on which the connector assembly may be placed and attached. The connector housing 70 may be fixed (i.e. attached) to the base unit, or it may be movable to accommodate connector assemblies of different types, sizes, and locations.

[0113] refer to Figure 5a and Figure 12 The "retracted position" refers to the state of the robotic arm when it is not actively involved in a charging cycle or any operational task. It is the configuration of the robotic arm in a retracted or withdrawn position, typically positioned in a safe and compact manner. In the retracted position, the robotic arm is retracted when not in use, typically awaiting deployment for charging, maintenance, or other tasks. In this position, the arm is preferably held securely to prevent accidental movement. This allows the robotic arm to remain securely held in place, preventing any accidental movement that could potentially lead to damage or misalignment, optimizing the use of available space, and ensuring that the arm does not unnecessarily protrude when not in use. Preferably, during the retracted position, and for example referring to... Figure 12 The connector housing 70 is configured to at least partially accommodate the connector assembly 30, preferably accommodating the connector charging interface.

[0114] In the retracted position, the robotic arm can be held in this position by any mechanism suitable for maintaining the arm in this configuration, such as a pin (actuated or passive), a latch, or a magnetic hook. Therefore, the arm can be switched to the unlocked position while remaining stationary, thus preventing any unintentional movement.

[0115] refer to Figure 12 In the retracted position, preferably, the arm segments are positioned substantially parallel to each other to allow for a particularly compact configuration. This arrangement can be achieved by mounting actuator component 54, joint component 55, and braking component 57 to optimize the distribution of weight and usable space within the robotic arm, such as... Figure 14a and Figure 14b As shown, this configuration allows the arm segments to be constructed in a compact and short form when retracted, while also enabling the arm to exhibit a significant range of extension when extended. This arrangement of joint components significantly contributes to the system's ability to adapt to limited space and reach distant target locations while maintaining structural integrity.

[0116] In the context of the described embodiments, "deployed position" refers to the state of the robotic arm when it actively participates in a charging cycle or any other operational activity, such as, for example, in Figure 2 , Figure 3 , Figure 4 , Figure 5b and Figure 9a As shown in any of the above. The deployed position encompasses situations where the robotic arm initiates a charging cycle, moves toward the charging port of an electric vehicle, or engages in a specific task (e.g., connecting or disconnecting a charging connector). In the deployed position, the robotic arm primarily and actively performs its intended function, which may involve joint movement, rotation, translation, or other movements required for its manipulation. The term "deployed position" does not refer to a single fixed static position, but rather encompasses a range of possible positions and orientations that the robotic arm can take during various operational scenarios. Preferably, the deployed position includes multiple deployed positions. These variations in deployed positions are characterized by varying degrees of extension, rotation, and joint movement, depending on the specific task and requirements at hand.

[0117] The system preferably includes or communicates with at least one sensor device, which is configured to generate sensor data. Sensors include, but are not limited to, camera sensors, force sensors, optical sensors, proximity sensors, lidar sensors, ultrasonic sensors, infrared sensors, and magnetic sensors.

[0118] Sensor data can be parameters associated with system components or the environment in which the system operates. Sensor data may include at least one of the following: vehicle attitude, vehicle charging port attitude, distance between connector and charging port, physical or electrical connection between electric vehicle connector and charging port, external forces applied to the robot arm, and physical deflection of system components. Sensor data may include the attitude of the vehicle or vehicle inlet relative to any part of the system. Sensor data may include temperature data indicating the thermal state of charging components; voltage and current data reflecting the electrical characteristics of the charging process; battery state of charge (SoC) information; environmental data such as ambient temperature, humidity, or air quality; safety interlock status indicating whether safety mechanisms are activated; component wear data; time and timestamp data; communication signal strength; error codes or fault data; alignment or calibration data, and combinations thereof.

[0119] A camera sensor can be coupled to a base unit, robotic arm, or connector assembly, enabling it to acquire attitude information about the autonomous electric vehicle charging system and its surrounding environment. This camera sensor is positioned to capture attitude data, including the location of system components and the environment surrounding the charging station. Preferably, the camera sensor is oriented to collect attitude information about the electric vehicle and its charging ports.

[0120] As used herein, an object's pose describes how the object is positioned in the three-dimensional space in which it is used. An object's pose can be determined relative to a viewpoint, such as a camera viewpoint or camera coordinate system. The pose of an electric vehicle's charging port can be understood as the position and orientation of the vehicle's charging port, and in some embodiments is represented by the 3D Cartesian position and yaw angle (x, y, θ) of the receptacle. In some embodiments, the pose is a 6D pose, where the position is defined by a 3D Euclidean distance, and the orientation is defined by the receptacle's roll, pitch, and yaw. Determining the electric vehicle's inlet pose helps describe the pose and orientation of the charging port relative to the camera position of the ACD, so as to guide the EV connector supported by the connector assembly to the charging port and complete the mating process.

[0121] The pose of a vehicle charging port can be obtained from a single image, from multiple images assuming the same pose, from multiple images assuming different poses, or using a previously determined pose. Alternatively or additionally, the pose of the object can be obtained from multi-view images or videos. In several embodiments of this disclosure, the pose determination of the socket can be performed by a neural network based on a computer vision unit.

[0122] Preferably, a neural network can be trained to determine the pose by analyzing one or more images. The estimated socket pose may include estimates of the socket's dominant axis, roll, elevation, angular position, attitude, and azimuth. Alternatively, the neural network can be trained to detect geometric features of the socket, which can be used as a reference marker, based on which the pose estimation algorithm can determine the socket's pose relative to the camera.

[0123] In addition to determining the orientation of the charging port of the electric vehicle, the neural network can also provide information related to the distance between the connector assembly and the charging port, or between the charger connector and the charging port. Preferably, the neural network is trained to analyze one or more images captured by a camera located within the system, as outlined in previous embodiments. By examining these images and utilizing its learned algorithms, the neural network can estimate the spatial spacing between the connector assembly and the charging port in real time.

[0124] The proximity sensor may be attached, coupled, and / or mounted on or to a base unit, robot arm, or connector assembly. The proximity sensor can be positioned to provide proximity data, encompassing not only the spatial relationships of system components but also the immediate vicinity of the charging system. Preferably, the proximity sensor can be configured to monitor the presence of objects, individuals, or potential disturbances near the system and generate such proximity sensor data. This data not only aids in coordination cycles but also enhances situational awareness, enabling it to respond effectively to dynamic conditions.

[0125] Force sensors can be attached, coupled, and / or mounted on or to a base unit, robot arm, or connector assembly. Such forces can originate from contact with an object or surface, resistance encountered during movement, or unexpected external disturbances. The output generated by the external force sensor is preferably used as an input to the control system, enabling the autonomous charging system to react quickly to deviations from the intended trajectory, prevent collisions, and ensure the completion of the charging process. Force information can be acquired through the implementation of force / torque sensors connected to any component of the system, such as the robot arm, connector assembly, or vehicle connector. Preferably, the control system can utilize the data from this sensor in conjunction with other sensor inputs to adjust the movement of the robot arm and initiate corrective actions when necessary.

[0126] Computer vision systems using neural networks and camera sensor feedback can acquire information associated with physical deflections in any system component, including robotic arms, connector assemblies, compliance components, and any of their sub-components. This deflection can be used as an indication of external forces acting on any such component. In some embodiments, upon detecting a significant physical deflection exceeding a predetermined threshold, the control system is configured to initiate corrective actions to respond to the external force or disturbance.

[0127] The system may also include means for receiving operational data, such as communication devices. This operational data may also include instructions based on system algorithms. The operational data may be associated with at least one of signals from the vehicle, instructions from the operator, or signals from a remote system. Specifically, i) signals from the electric vehicle may include information about the vehicle's battery status, charging port location, charging status, and any specific requirements or preferences regarding the charging process; ii) instructions provided by the system's operator or user may include specifying charging parameters, overriding automated processes, or requesting specific actions related to the charging cycle; iii) the system may interact with remote systems, such as a central charging station management system or a grid management system. Operational data received from these remote systems may include grid demand information, rates, and scheduling priorities, enabling the autonomous charging system to make informed decisions.

[0128] The system may include a charging port cover handling device, preferably using any suitable means, such as a gripper mechanism, which can be selected from a range of gripper types, including but not limited to parallel jaw grippers, vacuum grippers, finger grippers, magnetic grippers, or combinations thereof. Depending on the gripper type and the configuration of the charging port and the EV, the device can use mechanical jaws, suction, or flexible fingers to grasp and manipulate the charging port cover. Preferably, the charging port cover handling device is configured to apply a controlled force to open or close the cover, exposing the charging port. The gripper's suction cup can be positioned over the charging port cover, thereby creating a vacuum seal that effectively attracts the cover and allows manipulation, i.e., opening and closing the cover.

[0129] The charging port cover handling device can communicate with a control system configured to receive operational data and / or sensor data. Upon receiving a communication from the EV indicating that cover handling is ready, the control system initiates a sequence of cover opening or closing. When the camera sensor detects data regarding the orientation of the charging port, the control system can calculate the optimal motion path for guiding the gripper mechanism during operation to complete the initiation of cover opening or closing.

[0130] The control system is adapted to respond to unexpected or undesirable events during the cover handling process. Such events include various anomalies, including but not limited to situations where the charging port cover is found to be locked, improperly unlocked, or obstructed in any way. The control system is configured to acquire updated input from at least one sensor to identify deviations from the cover handling process. Preferably, data acquired from a camera sensor is relayed to the control system, which then uses this information to determine whether the charging port cover is locked, improperly unlocked, or obstructed in any way. The control system can initiate corrective actions associated with the specific nature of the event. For example, if the charging port cover is detected as locked, the control system can initiate communication with the EV to properly unlock the cover. Similarly, if the cover is found to be obstructed or improperly unlocked, the control system can activate appropriate mechanisms to correct the situation and facilitate the opening or closing of the cover, such as signaling the operator for further correction. Likewise, the control system can acquire and reacquire information from at least one of the EV, camera sensor, or position sensor, and reconfigure instructions for handling the cover should the position of the charging port cover shift during the handling process.

[0131] According to a first embodiment of the present invention, a method for controlling an autonomous charging system for an electric vehicle includes allowing a robotic arm to transition from an unlocked state to a locked state before engaging a connector with a charging port based on received operational data and / or sensor data, wherein in the locked state, at least one arm segment is prevented from moving relative to an adjacent arm segment or relative to a base unit, and wherein such movement is permitted in the unlocked state.

[0132] The robotic arm is configured to switch between an unlocked and locked state before mating the connector with the charging port based on received operational data and / or sensor data. The term "before mating the connector with the charging port" includes any moment before actual mating and does not need to immediately precede it. Various intermediate steps may occur during this period, such as potential repositioning actions to acquire new data. The term "based on received operational data and / or sensor data" indicates that the data obtained is evaluated by the control system to ensure it conforms to predetermined criteria and thresholds that should allow mating operation. When the received data meets predetermined parameters, indicating that conditions are suitable for a reliable mating process, the control system may allow or instruct the robotic arm to transition to the locked state. Conversely, if the received data indicates any deviation or condition that does not meet the predetermined criteria for mating, the control system may keep the robotic arm in the "unlocked" state. In this state, the system remains adapted to make necessary adjustments in response to changes or variations detected in the environment.

[0133] The control system is configured to monitor and / or analyze this operational data and / or sensor data. In this context, "monitoring" requires observing and collecting data from various sources throughout the autonomous charging process, including sensor and operational parameters. Analysis refers to the examination and interpretation of the collected data, which includes activities such as comparing the data with predetermined thresholds and parameters.

[0134] Autonomous charging systems typically undergo a charging cycle that includes several steps. The charging cycle includes, but is not limited to, the following steps: i. Orient the connector assembly toward the vehicle's charging port; and ii. Connect the charging connector to the vehicle's charging port.

[0135] Guiding a connector assembly toward a vehicle's charging port involves the controlled actuation of the robotic arm supporting the connector assembly. Guiding typically requires the use of sensors and / or operational data, algorithms, and control commands to ensure that the connector assembly approaches the vehicle's charging port accurately.

[0136] Matching the charging connector with the vehicle's charging port requires a physical connection between the charging connector and the charging port on the electric vehicle.

[0137] A charging cycle may include at least one of the following: repositioning the robotic arm as needed to optimize alignment; acquiring sensor or operational data for precise positioning; initiating the charging process; monitoring and adjusting charging parameters; completing the charging process; and disengaging the charging connector from the vehicle's charging port. The charging cycle may include intermittent pauses or interruptions for safety and system optimization; and establishing communication with the EV or external remote systems for data exchange and coordination. The charging cycle may include any other necessary steps to enable the autonomous charging system to reliably and autonomously charge the electric vehicle (EV).

[0138] At any step of the charging cycle, the control system can switch the robot arm from an unlocked state to a locked state, and vice versa, depending on the situation and the specific stage of the charging cycle.

[0139] Depending on the specific circumstances, the order of these steps can be adjusted, or some steps can be repeated. At any step of the charging cycle, the control system is configured to monitor and analyze this operational data and / or sensor data.

[0140] The method includes initiating a calibration action if analysis of operational data and / or sensor data indicates the need for a calibration action to allow the system to mate the connector with the charging port. This calibration action becomes necessary in various situations where the operational data and / or sensor data exhibit deviations exceeding or falling outside predetermined thresholds or ranges, or where specific predetermined conditions are met or not met, wherein these predetermined thresholds or ranges are pre-set to enable the system to mate the connector with the charging port.

[0141] The term "initiate" encompasses a broad range of actions, including any relevant actions necessary to instruct, continue, stop, interrupt, or perform analysis of operational and / or sensor data. The term "complete engagement" covers more than just the simple physical connection between the charging connector and the charging port. It includes any and all necessary processes, including but not limited to steps facilitating proper connection, charging, and disconnection, enabling the autonomous charging system to efficiently charge electric vehicles (EVs).

[0142] Other corrective actions may include: restarting a new charging cycle; adjusting the mating angle or orientation of the charging connector; initiating a diagnostic self-test to identify any system anomalies; activating an emergency stop to halt the mating process in the event of a critical problem, or when triggered by an operator or remote system; and notifying an external control system or operator for manual intervention.

[0143] At any stage of the charging / coordination cycle, the control system can respond to receiving information from one or more sensors that detects that the sensor information exceeds a predetermined threshold, and output a control command to change the robot arm from a locked state to an unlocked state, and vice versa.

[0144] Allowing the robotic arm to transition from an unlocked state to a locked state and vice versa allows the system to make necessary adjustments when determining the orientation of the charging port or charging port cover. This can be advantageous when the camera sensor is mechanically coupled to the robotic arm and the orientation of the charging port or charging port cover needs to be determined from different locations. This is further advantageous when the camera sensor is not mechanically coupled to the robotic arm but a moving part of the robotic arm obstructs the camera view used for orientation determination (which would require repositioning this moving part). Similarly, if sensor data indicates a change in the position of the charging port after initial alignment or initial orientation determination, if the orientation of the charging port exceeds a confidence level, or if the orientation of the charging port or charging port cover cannot be determined using the current input from the camera sensor, the control system can switch the robotic arm to an unlocked state, allowing the system to collect new orientation estimation data, guide and / or align the connector assembly based on this new data, and switch the arm to a locked state to initiate or continue this mating. The control system can allow the robotic arm to transition from an unlocked state to a locked state when such orientation data is within a predetermined threshold for mating, such orientation data being at least one of the charging port orientation and the connector assembly orientation. Similarly, when the connector assembly is within a predetermined range for mating, the control system can allow the robotic arm to transition from an unlocked to a locked state. This range may include specific distance thresholds, such as within 1-10 mm, to ensure close proximity. Angular alignment within a certain tolerance (e.g., 5 degrees) may be required for proper insertion.

[0145] If sensor data indicates that the distance between the connector assembly and the vehicle charging port exceeds a predetermined threshold or falls outside a predefined confidence level during any step of the mating / charging cycle, the control system can initiate specific corrective actions to optimize the mating process. Such actions may include, but are not limited to: switching the robotic arm to an unlocked state, enabling it to adjust its position and orientation; repositioning the robotic arm to bring the connector assembly closer to the vehicle charging port, thereby reducing the detected distance; initiating a data refresh operation to obtain new sensor data, which may include updated distance measurements; and retrying the mating process by guiding the connector assembly toward the vehicle charging port using adjusted parameters to improve alignment.

[0146] If sensor data indicates a physical or electrical connection between the electric vehicle connector and the vehicle inlet / charging port during the mating process, the control is configured to detect and evaluate such a connection. If the sensor data indicates a problem or anomaly in the connection, the control system initiates specific corrective actions to optimize the mating process, such as those mentioned herein. For example, once such an electrical connection is detected, the control system may allow the robotic arm to transition to a locked state to complete the mating.

[0147] The control system is configured to monitor parameters, such as any forces acting on the robot arm, connector assembly, or any other component of the system. If any of these parameters exceeds a predetermined range or falls outside a confidence level, the control system can be configured to transition the robot arm from a locked state to an unlocked state, and vice versa. For example, when the robot arm is in the locked state, the control system monitors the force applied to the connector assembly, ensuring it remains within a predetermined range and confidence level. If this force parameter deviates significantly, indicating the possibility of excessive stress or misalignment, the control system can initiate a transition to the unlocked state to facilitate repositioning of the robot arm or acquisition of new sensor data. Once the data acquired by the control system indicates that the force acting on the connector assembly is within the predetermined range, it can restart the guidance of the connector assembly toward the charging port, and subsequently transition the arm to the locked state when sensor data or operational data indicates that the connector assembly's position is within the predetermined range. In some cases, this predetermined range depends on the connector's position relative to the charging port.

[0148] The control system allows the robot arm to transition from a locked state to an unlocked state and vice versa, based on specific input parameters related to connector attitude estimation. When the robot arm remains locked, such as during connector mating, the control system continuously monitors attitude estimation data to ensure that parameters remain within predefined confidence levels and thresholds. If significant parameter deviations occur, indicating potential inaccuracies in the attitude estimation, the control system can acquire new attitude data, briefly reposition the arm to obtain the new data, or transition the arm to an unlocked state for repositioning and / or acquiring new sensor data from the new location. This transition allows the robot arm to reposition while triggering the acquisition of attitude estimation data. Once the control system verifies that the attitude estimation data is within a predefined confidence interval, it can resume connector guidance or mating.

[0149] If operational data associated with any step of the charging cycle is received, the control system can evaluate the operational data and respond appropriately to allow the system to complete the mating of the connector and the charging port. This covers scenarios related to operational data from the vehicle, which may include, but are not limited to: receiving data indicating changes in the vehicle's state, such as power on or off, which may require adjusting the charging cycle to suit the vehicle's power requirements and safety considerations; receiving data related to the vehicle's battery state, charging level, or charging preferences, allowing the control system to adjust the charging cycle to meet the vehicle's specific needs; receiving data indicating vehicle movement, such as repositioning or shifting, and taking corrective actions to achieve a proper connection between the connector assembly and the vehicle's inlet / charging port; monitoring signals of emergency or safety issues, triggering the robot arm to transition to an unlocked state or initiating an emergency stop procedure if necessary to ensure the safety of the charging process, or combinations thereof.

[0150] At any stage of the charging / mating cycle, the control system can receive socket attitude parameters and, when the socket attitude parameters are within a predetermined acceptable mating range, switch the robot arm from an unlocked state to a locked state. In some cases, the control system is configured to receive socket attitude parameters and, when the socket attitude parameters are outside the predetermined acceptable mating range, switch the robot arm from a locked state to an unlocked state.

[0151] The predetermined acceptable range or threshold of the socket attitude parameters can be adjusted according to the specific circumstances and can include, for example, the range of X, Y and Z coordinates, thresholds for pitch, yaw and roll angles, and distance thresholds, so that if the socket attitude parameters indicate that the connector is within an acceptable distance range, the control system can lock the arm for mating.

[0152] In the context of the described embodiment, during the locked state, the control system (directly or indirectly by activating system components) is configured to prevent at least one arm segment from undergoing at least one of joint motion, rotation, translation, actuation, displacement, or combinations thereof relative to any other non-moving system component or relative to the stationary world. In the locked state, as previously described, the control system is configured to limit the range of motion and functionality of the robotic arm.

[0153] This limitation can occur in both the stowed and unfolded positions, but it is primarily advantageous and preferred in the unfolded position.

[0154] In certain situations, such as when a robotic arm is retracted, it may be beneficial to impose limited restrictions on the arm's movement. For example, when the arm retracts to its retracted position, the control system can impose certain restrictions on joint movement, rotation, translation, actuation, or displacement to ensure a safe and controlled retraction process and retracted position. With this implementation, the robotic arm can transition to a locked state during the retracted position, and therefore, this prevents any further movement of the arm, protecting it from unauthorized access, tampering, or damage.

[0155] Preferably, during the stowed position, and for example, referring to Figure 12 The connector housing is configured to at least partially accommodate the connector assembly 30, preferably accommodating the connector charging interface. By allowing this engagement, unwanted arm movements can be restricted without having to lock the robotic arm.

[0156] The advantages of a locked state are realized during the deployed position of the robotic arm operation. In this case, the control system is configured to more significantly limit at least one arm segment from undergoing joint movements, rotations, translations, actuations, displacements, or combinations thereof. This limitation is particularly valuable during mating cycles where precision and stability are required. Specifically, by transitioning to the locked state and thus limiting arm movement during the deployed position (e.g., before the charging connector mates with the charging port), the control system can ensure that the arm remains in a predetermined configuration. Such a locking phase prevents any unintended displacement or adjustment that could lead to misalignment with the charging port of the electric vehicle.

[0157] Furthermore, locking the arm segments in the proper position during the deployment phase ensures they maintain the desired orientation and position for controlled mating and charging. In some cases, the arm segments transition to the unlocked state once mating is complete. Additionally, activation of the locked state allows for a reduction in the total force exerted by system components to complete the mating process. Specifically, when the robotic arm is in the locked position, the actuators at the distal end of the robotic arm can be primarily actuated for the mating step. Thus, during the mating or dismounting phases, the control system can selectively activate the actuators located at the distal end of the robotic arm. These actuators are responsible for the final alignment and mating of the charging connector with the charging port of the electric vehicle. In parallel, the control system can control the remaining joints and segments of the arm to remain locked, thereby preventing any unintended movement or joint activity. This selective locking significantly reduces any potential resistance or force required during the mating process.

[0158] Unless otherwise stated, terms such as “configured as” cover components in various states. Conditional terms (“capable,” “may,” etc.) indicate that some embodiments include certain features that others may not. Words such as “including” and “or” are inclusive, allowing for additional elements or options. The term “allows” covers actions such as permitting and enabling. Method steps do not need to follow a specific order to achieve the desired result.

Claims

1. A method for controlling a system for autonomous charging of an electric vehicle, the system comprising: A connector assembly that supports a connector for mating with a vehicle charging port; Base unit; A robotic arm, comprising multiple arm segments; and a control system configured to receive operational data and / or sensor data, wherein the method includes: The connector assembly is guided toward the vehicle's charging port by actuating the robotic arm; Before engaging the connector with the charging port based on received operational data and / or sensor data, the robot arm is allowed to transition from an unlocked state to a locked state, wherein in the locked state, at least one arm segment is prevented from moving relative to an adjacent arm segment or the base unit; and wherein in the unlocked state, such movement is permitted. The connector is engaged with the charging port by moving the connector assembly while monitoring and analyzing operational or sensor data; and If analysis of the operational data and / or sensor data indicates that a calibration action is required to allow the system to complete the mating of the connector with the charging port, then the calibration action is initiated.

2. The method of claim 1, further comprising comparing the operational data and / or sensor data with at least one predetermined operational data and / or sensor data, and using the result of the comparison to determine whether a correction action is required.

3. The method according to any one of claims 1 or 2, comprising: When such operational data or sensor data is within a predetermined range, the robotic arm is allowed to switch between the unlocked state and the locked state.

4. The method according to any one of the preceding claims, comprising performing at least one of the following actions to enable the system to engage the connector with the charging port: i) switching the robot arm to the unlocking phase; ii) switching the robot arm to the locking phase; iii) repositioning the robot arm; or iv) obtaining new or updated operational data or sensor data; or v) retrying the engagement.

5. The method according to any one of the preceding claims, comprising receiving: Sensor data associated with at least one of the following: the orientation of the charging port, the orientation of the connector assembly, the distance between the connector and the charging port, the physical or electrical connection between the electric vehicle connector and the charging port, the external force applied to the robot arm, and the physical deflection of the components of the system; and / or Operational data associated with at least one of the signals from the vehicle, instructions from the operator, or signals from a remote system.

6. The method according to any one of the preceding claims, comprising receiving attitude data of the connector assembly, and allowing the robotic arm to transition from the unlocked state to the locked state when such attitude data is within a predetermined threshold for mating.

7. The method according to any one of the preceding claims, wherein, During the locked state, movement of at least two arm segments is prevented and movement of at least one arm segment is permitted, in each case, the movement being relative to an adjacent arm segment or the base unit.

8. The method according to any one of the preceding claims, comprising allowing the robotic arm to undergo more than one transition between a locked state and an unlocked state prior to the engagement.

9. The method according to any one of the preceding claims, comprising receiving sensor data associated with an external force acting on the connector, and initiating a correction action when such sensor data deviates from a predetermined range, wherein such threshold depends on the position of the connector relative to the charging port.

10. The method according to any one of the preceding claims, comprising: The robotic arm is allowed to switch between a retracted position and an extended position; wherein, during the retracted position, the connector assembly, and preferably the charging connector, is at least partially engaged by the connector housing, and during the extended position, the connector or the connector assembly is not engaged by the connector housing.

11. The method according to any one of the preceding claims, comprising: During the locked state, the connector mates with the charging port by allowing the robotic arm to apply a temporarily higher force than when the robotic arm is in the unlocked state.

12. The method according to any of the preceding claims, comprising allowing the robotic arm to transition from a locked state to an unlocked state at any time after the charging connector engages with the charging port.

13. The method according to any one of the preceding claims, comprising allowing the robotic arm to transition to a locked state before disengagement.

14. A system for autonomously charging an electric vehicle, comprising: Base unit; A connector assembly that supports a connector for mating with a vehicle charging port; A robotic arm, positioned between the base unit and the connector assembly, and comprising multiple arm segments; A control system configured to receive operational data and / or sensor data and to guide the robotic arm and connector assembly toward the vehicle's charging port; The robotic arm is configured to switch between an unlocked state and a locked state before engaging the connector with the charging port based on received operational data and / or sensor data. In the locked state, movement of at least one arm segment relative to an adjacent arm segment or base unit is prevented; and in the unlocked state, such movement is permitted. The control system is configured to monitor and analyze such operational data and / or sensor data, and to initiate the correction action if the analysis of the operational data and / or sensor data indicates that a correction action is needed to allow the system to complete the mating of the connector with the charging port.

15. The system of claim 14, wherein the robotic arm is configured to switch between a retracted position and an extended position, wherein in the retracted position the connector assembly is at least partially engaged by the connector housing, and in the extended position the connector assembly is disengaged from the connector housing.

16. The system according to any one of claims 14 or 15, wherein, At least one joint assembly includes a joint member and a braking member, and the control system is configured to activate and deactivate such braking member to cause the robotic arm to switch between the locked state and the unlocked state, and vice versa.

17. The system according to any one of claims 14 to 16, wherein, The control system is configured to receive attitude data of the connector assembly and, when such attitude data is within a predetermined threshold for mating, allow the robotic arm to transition from the unlocked state to the locked state.

18. The system according to any one of claims 14 to 17, wherein, The control system is configured to trigger a short-term partial lock of the joint assembly to effectively reduce any momentum that the robotic arm may experience.

19. The system according to any one of claims 14 to 18, wherein, The control system is configured to engage the connector with the charging port when the distance between the connector and the charging port is less than or equal to a predetermined threshold.

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