A docking device, charging system and method of use

Abstract

The present application relates to the technical field of charging system, especially refers to a docking device, a charging system and a use method. The docking device is mainly composed of three mechanisms of supporting, adjusting and charging. The supporting mechanism includes a base, a first sliding guide module and a first rack arranged on the base along a first horizontal direction. The adjusting mechanism includes a mounting frame, an extension frame, multiple driving sources, a rotating module and a first driving module, which can respectively control the transverse movement of the mounting frame, the extension and rotation of the extension frame, and the lifting of the charging rack. The charging mechanism is composed of a charging rack, two movable seats, a floating plate and multiple charging heads. The movable seats are slidingly connected, and the floating plate is elastically connected to the second movable seat. The second and third driving modules are matched to adjust the angle and horizontal displacement of the first movable seat, respectively. The multiple driving structures work cooperatively to realize multi-dimensional position and attitude adjustment of the docking device. The present application has the advantages of improving the positioning accuracy of the charging plug and the reliability of the docking.

Description

Technical Field

[0001] This invention relates to the field of charging system technology, and in particular to a docking device, a charging system, and a method of using it. Background Technology

[0002] With the development of automated production technology and intelligent equipment, automatic mating technology for charging plugs, industrial connectors and other similar electrical connection devices has been increasingly widely used in automated production lines, intelligent charging stations and other scenarios.

[0003] In existing technologies, the automatic mating function of the aforementioned connectors mainly employs the following technical solutions: a rigid mating scheme based on a fixed mechanical structure. This scheme achieves mechanical positioning and insertion of the plug through preset guide rails, clamps, or positioning pins. However, due to factors such as accumulated manufacturing tolerances, thermal deformation, and mechanical wear, there is a deviation between the actual and theoretical positions of the plug. This scheme is difficult to adapt to multi-degree-of-freedom attitude deviations, and the positioning accuracy can typically only be controlled within the range of ±1 mm to ±3 mm. When there is a small angular deviation, the rigid mating mechanism is prone to mechanical interference, leading to pin bending, insulator damage, or connector housing deformation. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is to overcome the problems in the prior art, thereby providing a docking device, a charging system and a method of use.

[0005] In a first aspect, a docking device is provided, comprising:

[0006] The support mechanism includes a base and a first sliding guide module and a first rack disposed on the base along a first horizontal direction;

[0007] The adjustment mechanism includes a mounting frame fixed to the base, a telescopic frame slidably mounted on the mounting frame, a first drive source connected to the first rack and pinion, a second drive source connected to the telescopic frame, a rotary module located at the bottom of the mounting frame, and a first drive module located on one side of the mounting frame.

[0008] The charging mechanism includes a charging frame slidably connected to the telescopic frame, a first movable seat slidably connected to the charging frame, a second movable seat slidably connected to the first movable seat, a floating plate elastically connected to the second movable seat, and a plurality of charging heads disposed on the floating plate; second drive modules are provided on both sides of the first movable seat, and third drive modules are provided on the top and bottom of the first movable seat.

[0009] Wherein, the first drive source drives the mounting frame to move along a first horizontal direction, the second drive source drives the telescopic frame to move along a second horizontal direction, the rotary module drives the telescopic frame to rotate, and the first drive module drives the charging rack to lift and lower; the second drive module and the third drive module drive the first movable seat to move along the second horizontal direction.

[0010] In one embodiment of the present invention, the adjusting mechanism further includes a first gear connected to the output end of the first drive source; the first gear meshes with the first rack.

[0011] In one embodiment of the present invention, the adjustment mechanism further includes a second gear connected to the output end of the second drive source and a second rack disposed on the telescopic frame along the second horizontal direction and meshing with the second gear.

[0012] In one embodiment of the present invention, the slewing module includes a third drive source, a third gear connected to the output end of the third drive source, and a slewing bearing meshing with the third gear; the telescopic frame is mounted on the slewing bearing.

[0013] In one embodiment of the present invention, the charging mechanism further includes a fourth sliding guide module disposed between the charging frame and the first movable seat, and a fifth sliding guide module disposed between the first movable seat and the second movable seat.

[0014] In one embodiment of the present invention, the fourth sliding guide module includes a support member fixed to the top and bottom of the charging rack along a second horizontal direction, a fourth guide rail fixed to the support member, and a fourth slider sliding along the fourth guide rail; the fourth slider and the first movable seat are fixedly connected.

[0015] In one embodiment of the present invention, the fifth sliding guide module includes a fifth guide rail fixed to the inner wall of the first movable seat along a second horizontal direction and a fifth slider sliding along the fifth guide rail; the fifth slider and the second movable seat are fixedly connected.

[0016] In one embodiment of the present invention, the support mechanism further includes a bellows cover covering the first sliding guide module; the first sliding guide module includes a first guide rail fixed to the base along a first horizontal direction and a first slider sliding along the first guide rail; the first slider and the mounting frame are fixedly connected.

[0017] In one embodiment of the present invention, the adjustment mechanism further includes a first protective housing covering the telescopic frame.

[0018] In one embodiment of the present invention, the charging mechanism further includes a roller shutter module disposed on one side of the charging rack.

[0019] In one embodiment of the present invention, the charging mechanism further includes a second protective housing covering the charging frame and the roller shutter module; the second protective housing has a channel opening on the side facing the charging head.

[0020] Secondly, a charging system is provided, including the docking device described above.

[0021] Thirdly, a method of use is provided, which utilizes the aforementioned docking device and includes the following steps:

[0022] In the initial state, the base of the support mechanism is fixed to the ground, and the first sliding guide module and the first rack provide a first horizontal moving foundation for the docking device.

[0023] After the vehicle is parked, the adjustment mechanism is activated, and the first drive source drives the mounting frame to move along the first horizontal direction to complete the initial positioning of the charging mechanism.

[0024] The second drive source drives the telescopic frame to slide along the second horizontal direction to calibrate the lateral position; at the same time, the rotation module drives the telescopic frame to rotate around the vertical axis to correct the horizontal yaw angle of the charging mechanism and adapt to the angle deviation of the vehicle's charging interface.

[0025] The first drive module is used to control the raising and lowering of the charging rack, thereby adjusting the vertical height of the electric mechanism to match the vertical position of the vehicle's charging interface.

[0026] The second drive module drives the first movable seat to make fine adjustments in the first horizontal direction. The second drive module adjusts the roll angle of the first movable seat to achieve multi-directional fine position correction.

[0027] The charging head flexibly docks with the vehicle's charging port along with the floating plate, relying on the elastic floating to adaptively compensate for residual position and angle deviations, thus flexibly completing the charging docking.

[0028] Compared with the prior art, the above-described technical solution of the present invention has the following advantages:

[0029] The docking device described in this invention achieves multi-degree-of-freedom dynamic adjustment of the charging head in the horizontal, vertical, and rotational directions through the coordinated work of the support mechanism, adjustment mechanism, and charging mechanism. This solves the problems of low positioning accuracy and mechanical interference caused by manufacturing tolerances, thermal deformation, or mechanical wear in the prior art. It has the advantages of improving the positioning accuracy and docking reliability of the charging plug and reducing mechanical interference and failure risks. Attached Figure Description

[0030] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0031] Figure 1 This is a first-view structural schematic diagram of the docking device in this invention;

[0032] Figure 2 This is a second-view structural schematic diagram of the docking device in this invention;

[0033] Figure 3 This is a schematic diagram of the support mechanism in this invention;

[0034] Figure 4 This is a first-view structural schematic diagram of the adjustment mechanism in this invention;

[0035] Figure 5 This is a schematic diagram of the adjustment mechanism from a second perspective in this invention;

[0036] Figure 6 This is a first-view structural schematic diagram of the adjustment mechanism (the first protective housing is not shown) in this invention;

[0037] Figure 7 This is a second-view structural schematic diagram of the adjustment mechanism (the first protective housing is not shown) in this invention;

[0038] Figure 8 This is a first-view structural schematic diagram of the charging mechanism in this invention;

[0039] Figure 9 This is a second-view structural schematic diagram of the charging mechanism in this invention;

[0040] Figure 10 This is a first-view structural schematic diagram of the charging mechanism (the second protective housing is not shown) in this invention;

[0041] Figure 11 This is a second-view structural schematic diagram of the charging mechanism (the second protective housing is not shown) in this invention;

[0042] Figure 12 This is a first-view structural schematic diagram of the charging mechanism (the second protective housing and the roller shutter module are not shown) in this invention;

[0043] Figure 13 This is a second-view structural schematic diagram of the charging mechanism (the second protective housing and the roller shutter module are not shown) in this invention.

[0044] Explanation of reference numerals in the instruction manual:

[0045] 10. Support mechanism; 101. Base; 102. First guide rail; 103. First slider; 104. First rack; 105. Bellows cover;

[0046] 20. Adjustment mechanism; 201. First protective housing; 202. Telescopic frame; 203. First drive source; 204. First gear; 205. Second drive source; 206. Second rack; 207. Second gear; 208. Second guide rail; 209. Second slider; 210. Third drive source; 211. Slewing bearing; 212. Third gear; 213. Mounting frame; 214. Fixing plate; 215. First drive module; 216. Third guide rail; 217. Third slider;

[0047] 30. Charging mechanism; 301. Charging frame; 302. First movable seat; 303. Second movable seat; 304. Support component; 305. Fourth guide rail; 306. Fourth slider; 307. Floating plate; 308. Charging head; 309. Second drive module; 310. Third drive module; 311. Elastic element; 312. Fifth guide rail; 313. Fifth slider; 314. Roller blind module;

[0048] 40. Second protective casing. Detailed Implementation

[0049] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0050] Traditional automatic mating technology mainly uses a rigid mating scheme with a fixed mechanical structure. In practical applications, due to factors such as manufacturing tolerances, thermal deformation, and mechanical wear, the actual position of the plug deviates from the theoretical position. This scheme is difficult to adapt to multi-degree-of-freedom attitude deviations, has limited positioning accuracy, and is prone to mechanical interference when there are small angular deviations, leading to pin bending, insulator damage, or connector housing deformation.

[0051] In this regard, combined with Figures 1 to 13 This embodiment proposes a docking device, including:

[0052] The support mechanism 10 includes a base 101 and a first sliding guide module and a first rack 104 disposed on the base 101 along a first horizontal direction;

[0053] The adjustment mechanism 20 includes a mounting frame 213 fixed to the base 101, a telescopic frame 202 slidably mounted on the mounting frame 213, a first drive source 203 that is drivenly connected to the first rack 104, a second drive source 205 that is drivenly connected to the telescopic frame 202, a rotary module located at the bottom of the mounting frame 213, and a first drive module 215 located on one side of the mounting frame 213.

[0054] The charging mechanism 30 includes a charging frame 301 slidably connected to the telescopic frame 202, a first movable seat 302 slidably connected to the charging frame 301, a second movable seat 303 slidably connected to the first movable seat 302, a floating plate 307 elastically connected to the second movable seat 303, and a plurality of charging heads 308 disposed on the floating plate 307; second drive modules 309 are provided on both sides of the first movable seat 302, and third drive modules 310 are provided on the top and bottom of the first movable seat 302;

[0055] The first drive source 203 drives the mounting frame 213 to move along the first horizontal direction, the second drive source 205 drives the telescopic frame 202 to move along the second horizontal direction, the rotary module drives the telescopic frame 202 to rotate, the first drive module 215 drives the charging rack 301 to rise and fall, the second drive module 309 and the third drive module 310 drive the first movable seat 302 to move along the second horizontal direction.

[0056] For ease of understanding, the following explains some key terms in this embodiment:

[0057] The support mechanism 10 is configured to provide stable foundation support for the docking device, bear the weight of the upper mechanism, and ensure the stability of the overall structure.

[0058] The adjustment mechanism 20 is configured to achieve a wide range of coarse positioning and attitude adjustment of the docking device, including horizontal movement, extension and retraction, and rotation, providing a basis for subsequent precise positioning.

[0059] The charging mechanism 30 is configured to achieve precise positioning, flexible docking, and actual charging function between the charging head 308 and the target interface.

[0060] The first drive source 203 is configured to provide power to drive the adjustment mechanism 20 to move as a whole along the first horizontal direction, thereby achieving lateral coarse positioning of the docking device.

[0061] The second drive source 205 is configured to provide power to drive the telescopic frame 202 to telescopically move along the second horizontal direction, thereby achieving longitudinal coarse positioning of the docking device.

[0062] The slewing module is configured to provide rotational power to drive the telescopic frame 202 to rotate around the vertical axis, thereby adjusting the rotational attitude of the docking device.

[0063] The first drive module 215 is configured to provide lifting power to drive the charging frame 301 to move vertically, thereby achieving vertical coarse positioning of the docking device.

[0064] The second drive module 309 and the third drive module 310 are configured to provide power to drive the first movable seat 302 to move precisely along the second horizontal direction, thereby achieving precise lateral movement of the charging mechanism 30.

[0065] The floating plate 307 is configured to absorb residual minor deviations and reduce rigid impacts when the charging head 308 mates with the target interface via a flexible connection, thus protecting the connector.

[0066] Specifically, the docking device provided in this embodiment includes a support mechanism 10, an adjustment mechanism 20, and a charging mechanism 30.

[0067] The support mechanism 10 is configured to provide a stable foundation for the docking device. The support mechanism 10 includes a base 101 to ensure overall rigidity and stability. Along a first horizontal direction, the base 101 is provided with a first sliding guide module and a first rack 104. The first sliding guide module may consist of a set of rollers and rails, used to guide the upper mechanism to move smoothly along the first horizontal direction. The first rack 104 may be a straight rack fixed to the inner wall of the base 101, used to cooperate with the first drive source 203 to achieve lateral displacement in the first horizontal direction.

[0068] The adjustment mechanism 20 is configured to achieve coarse positioning and attitude adjustment of the docking device. The adjustment mechanism 20 includes a mounting frame 213 fixed to the base 101, with a telescopic frame 202 slidably mounted on the mounting frame 213. A first drive source 203 is driven by a first rack 104, thereby driving the mounting frame 213 to move along a first horizontal direction, achieving lateral coarse positioning of the docking device. A second drive source 205 is driven by the telescopic frame 202, achieving longitudinal coarse positioning of the docking device. A rotation module is provided at the bottom of the mounting frame 213, which can drive the telescopic frame 202 to rotate, achieving rotational attitude adjustment of the docking device. A first drive module 215 is provided on one side of the mounting frame 213, which realizes the lifting movement of the charging rack 301, achieving vertical coarse positioning of the docking device.

[0069] The charging mechanism 30 is configured to achieve precise positioning and flexible docking of the charging heads 308. The charging mechanism 30 includes a charging frame 301 slidably connected to the telescopic frame 202. A first movable seat 302 is slidably connected to the charging frame 301. A second movable seat 303 is slidably connected to the first movable seat 302. A floating plate 307 is elastically connected to the second movable seat 303, and the floating plate 307 can be connected to the second movable seat 303 by a set of elastic elements 311, such as springs, to provide a certain floating space. Multiple charging heads 308 are provided on the floating plate 307, and these charging heads 308 are configured to electrically connect to a target interface. Second drive modules 309 are provided on both sides of the first movable seat 302, which enable precise movement of the charging mechanism 30 along a second horizontal direction. The top and bottom of the first movable seat 302 are provided with a third drive module 310, which drives the first movable seat 302 to move precisely along the second horizontal direction. The second drive module 309 and the third drive module 310 realize the precise lateral alignment of the charging mechanism 30.

[0070] This docking device provides a stable foundation through the support mechanism 10, and the adjustment mechanism 20 achieves coarse positioning with a wide range and multiple degrees of freedom, including horizontal movement, extension, and rotation. Based on this, the charging mechanism 30 performs fine horizontal adjustment of the first movable seat 302 through the second drive module 309 and the third drive module 310, and utilizes the elastic connection of the floating plate 307 to absorb minor deviations. This effectively solves the problems of mechanical interference, pin bending, and connector damage caused by tolerance accumulation and posture deviation in traditional rigid mating schemes, improving the accuracy and reliability of automatic mating. It is suitable for scenarios such as automated production lines and intelligent charging stations.

[0071] Combination Figure 3 and Figure 5 In this embodiment, the adjustment mechanism 20 further includes a first gear 204 connected to the output end of the first drive source 203, and the first gear 204 meshes with the first rack 104 for transmission.

[0072] Specifically, the first gear 204, as a mechanical transmission element, has teeth that precisely mesh with the teeth of the first rack 104 to convert the rotational motion of the first drive source 203 into linear motion. The tooth profile design (e.g., involute tooth profile) and module of the first gear 204 are strictly matched with those of the first rack 104 to achieve smooth and efficient power transmission. The diameter and number of teeth of the first gear 204 can be optimized according to the required transmission ratio and motion accuracy.

[0073] The first rack 104 is a straight component with toothed teeth, which is fixedly mounted on the base 101 along the first horizontal direction. The first rack 104 typically uses a material and tooth profile that match the first gear 204 to ensure good meshing characteristics between the two. Its installation accuracy is crucial to the motion accuracy of the entire adjusting mechanism 20, and its straightness and flatness are usually ensured through precision machining and calibration. The length of the first rack 104 determines the travel range of the mounting frame 213 along the first horizontal direction.

[0074] The meshing transmission between the first gear 204 and the first rack 104 refers to the interlocking of the teeth of the first gear 204 and the teeth of the first rack 104, through which motion and power are transmitted by contact and rolling between the tooth surfaces.

[0075] Combination Figures 4 to 7 In this embodiment, the adjustment mechanism 20 further includes a second gear 207 connected to the output end of the second drive source 205 and a second rack 206 disposed on the telescopic frame 202 along the second horizontal direction and meshing with the second gear 207.

[0076] The second gear 207 is a rotating mechanical component with toothed teeth. Its main function is to convert the rotational motion of the second drive source 205 into linear motion. Specifically, the second gear 207 can be a standard spur gear, whose tooth profile and module match the second rack 206 to ensure smooth transmission and low noise. The second gear 207 is typically securely mounted on the output shaft of the second drive source 205 via keyed connection, splined connection, or interference fit to reliably transmit torque. Meanwhile, the second rack 206 is a mechanical component with linear toothed teeth, which, together with the second gear 207, forms a rack and pinion transmission pair. The second rack 206 is fixed along the direction of movement of the telescopic frame 202, and its tooth profile and module precisely match the second gear 207. When the second gear 207 rotates, the rotational motion is converted into linear motion of the second rack 206 (and the telescopic frame 202 fixed thereon) through the meshing of the teeth. The second rack 206 can be securely installed at a suitable position on the telescopic frame 202 by means of bolting, welding or riveting. Its length design should cover the entire telescopic stroke required by the telescopic frame 202 to ensure reliable transmission throughout the entire range of motion.

[0077] Combination Figures 4 to 7 This embodiment further proposes that the rotary module of the adjustment mechanism 20 includes a third drive source 210, a third gear 212 connected to the output end of the third drive source 210, and a rotary bearing 211 meshing with the third gear 212; the telescopic frame 202 is disposed on the rotary bearing 211.

[0078] Specifically, the third drive source 210, as the power source for the slewing module, is responsible for providing the torque required to drive the telescopic frame 202 to rotate. It can take various forms; for example, a servo motor can be used to achieve high-precision positioning and speed control; a stepper motor can also be used if cost and control complexity requirements are high. The third gear 212 is a key transmission component connecting the third drive source 210 and the slewing bearing 211. It is connected to the output shaft of the third drive source 210 and transmits the rotational motion and torque of the drive source to the slewing bearing 211. The tooth profile, module, and number of teeth of the third gear 212 can be designed according to the required transmission ratio, load capacity, and space constraints; for example, spur gears, helical gears, or bevel gears can be used. The slewing bearing 211 is a special bearing capable of withstanding various loads such as axial force, radial force, and overturning moment, while allowing relative rotation between its inner and outer rings.

[0079] In this embodiment, the slewing bearing 211 typically has an external gear ring for meshing with the third gear 212, thereby enabling power input. The telescopic frame 202 is securely mounted on the rotating portion of the slewing bearing 211, ensuring that the rotation of the slewing bearing 211 directly drives the telescopic frame 202 to perform precise angular adjustments. The slewing bearing 211 can have various structural forms, such as single-row ball bearing, double-row ball bearing, or crossed roller bearing, to adapt to different load-bearing requirements and precision requirements.

[0080] Combination Figures 4 to 7 This embodiment further proposes that the adjustment mechanism 20 also includes a second guide module disposed between the bottom of the telescopic frame 202 and the mounting frame 213. The second sliding guide module is specifically configured to include a second guide rail 208 and a second slider 209.

[0081] Combination Figures 6 to 9 This embodiment further proposes that the adjustment mechanism 20 also includes a third sliding guide module disposed between the telescopic frame 202 and the charging frame 301. The third sliding guide module is specifically configured to include a fixing plate 214 fixed to one side of the mounting frame 213, a third slider 217 fixed to the fixing plate 214, and a third guide rail 216 sliding along the third slider 217. The third guide rail 216 is fixedly connected to the charging frame 301.

[0082] The second sliding guide module is disposed between the telescopic frame 202 and the mounting frame 213. Its main function is to provide precise guidance and stable support for the sliding of the telescopic frame 202 relative to the mounting frame 213. This module can ensure that the telescopic frame 202 maintains the straightness and stability of its movement trajectory when moving in a preset direction, effectively reducing frictional resistance during movement and preventing swaying or jamming caused by uneven force or external interference.

[0083] Meanwhile, a third sliding guide module is disposed between the telescopic frame 202 and the charging rack 301. Its function is to provide reliable guidance and support for the sliding of the charging rack 301 relative to the telescopic frame 202. This module aims to ensure the movement accuracy and smoothness of the charging rack 301 during the sliding process, and avoid shaking or positioning errors caused by excessive freedom or improper fit clearance.

[0084] Combination Figures 9 to 13 This embodiment further proposes that the charging mechanism 30 also includes a third sliding guide module disposed between the charging frame 301 and the first movable seat 302, and a fourth sliding guide module disposed between the first movable seat 302 and the second movable seat 303.

[0085] The third sliding guide module is disposed between the charging frame 301 and the first movable seat 302. Its main function is to provide precise guidance and stable support for the sliding of the first movable seat 302 relative to the charging frame 301. This module can ensure that the first movable seat 302 maintains the straightness and stability of its movement trajectory when moving in a preset direction, effectively reducing frictional resistance during movement and preventing swaying or jamming caused by uneven force or external interference.

[0086] Meanwhile, a fourth sliding guide module is disposed between the first movable seat 302 and the second movable seat 303. Its function is to provide reliable guidance and support for the sliding of the second movable seat 303 relative to the first movable seat 302. This module aims to ensure the movement accuracy and smoothness of the second movable seat 303 during the sliding process, and to avoid shaking or positioning errors caused by excessive freedom or improper fit clearance.

[0087] Combination Figures 9 to 13 This embodiment further proposes a fourth sliding guide module including a support member 304 fixed to the top and bottom of the charging frame 301 along the second horizontal direction, a fourth guide rail 305 fixed to the support member 304, and a fourth slider 306 sliding along the fourth guide rail 305; the fourth slider 306 and the first movable seat 302 are fixedly connected.

[0088] Specifically, the support member 304 is a structural component used to fix the fourth guide rail 305. It is fixed to the top and bottom of the charging rack 301 along the second horizontal direction. This arrangement ensures that the guide rail system can be securely mounted on the charging rack 301 and provides a solid support base for the horizontal sliding of the first movable seat 302. The support member 304 is typically reliably connected to the charging rack 301 by bolts, welding, or other fixing methods. The fourth guide rail 305 is the core component providing the sliding path and is fixed to the support member 304. The length and cross-sectional shape of the fourth guide rail 305 are designed according to the actual application requirements and load-bearing capacity. Common guide rail types include ball bearing guides, roller bearing guides, or sliding guides, the selection of which depends on the required accuracy, speed, and load-bearing capacity. The fourth slider 306 is a component that cooperates with the fourth guide rail 305 to achieve relative sliding. The fourth slider 306 slides along the fourth guide rail 305 and is fixedly connected to the first movable seat 302. The slider typically contains rolling elements (such as balls or rollers) or sliding bushings to reduce frictional resistance and achieve smooth movement under light or heavy loads. The fixed connection between the fourth slider 306 and the first movable seat 302 ensures that the first movable seat 302 can move precisely along the second horizontal direction as the slider moves. This fixed connection method ensures that the movement of the fourth slider 306 can be directly and stably transmitted to the first movable seat 302. The fixed connection can be achieved through bolt connections, pin connections, or an integrated design to ensure that the first movable seat 302 does not loosen or shift relative to the first horizontal direction, thereby maintaining the positioning accuracy and stability of the entire charging mechanism 30.

[0089] Combination Figures 9 to 13 This embodiment further proposes that the fifth sliding guide module is specifically configured to include a fifth guide rail 312 and a fifth slider 313.

[0090] The fifth guide rail 312, as the core component of the fifth sliding guide module, provides a precise linear motion trajectory for the second movable seat 303. The fifth guide rail 312 is fixed to the inner wall of the first movable seat 302 along the second horizontal direction, ensuring that the sliding direction of the second movable seat 303 is strictly limited, thereby avoiding unnecessary lateral displacement.

[0091] The fifth slider 313 is a component used in conjunction with the fifth guide rail 312. It slides along the fifth guide rail 312 and is fixedly connected to the second movable seat 303. The main function of the fifth slider 313 is to precisely constrain the movement of the second movable seat 303 along the path defined by the fifth guide rail 312, while effectively transmitting and bearing the loads of the second movable seat 303 and the floating plate 307 and charging head 308 it supports. The implementation of the fifth slider 313 is usually matched with the fifth guide rail 312. For example, when the fifth guide rail 312 is a linear rolling guide rail, the fifth slider 313 is a corresponding linear bearing slider, containing precision balls or rollers to ensure smooth and backlash-free sliding; when the fifth guide rail 312 is a sliding guide rail, the fifth slider 313 can use a sliding bushing made of polymer material to provide self-lubrication and shock absorption functions. The fixed connection between the fifth slider 313 and the second movable seat 303 ensures that the second movable seat 303 can stably follow the movement of the fifth slider 313, thereby achieving precise positioning and movement.

[0092] By specifically implementing the third sliding guide module as a fifth guide rail 312 fixedly disposed along the inner wall of the first movable seat 302 and a fifth slider 313 sliding along the fifth guide rail 312, and fixing the fifth slider 313 to the second movable seat 303, this embodiment provides a clear and high-precision guiding structure for the relative sliding between the first movable seat 302 and the second movable seat 303. This structure can effectively eliminate the lateral sway and gaps of the second movable seat 303 during the sliding process, ensuring that its movement trajectory along the second horizontal direction is highly accurate and stable. Given that the second movable seat 303 carries the floating plate 307 and the charging head 308, this high-precision guiding mechanism is crucial for ensuring the accurate alignment of the charging head 308 with the target charging interface.

[0093] Therefore, this embodiment significantly improves the accuracy and reliability of charging docking, reduces the risk of docking failure due to mechanical gaps or unstable movement, and thus improves the working efficiency and service life of the entire docking device.

[0094] Combination Figure 3 This embodiment further proposes that the support mechanism 10 also includes a bellows cover 105 covering the first sliding guide module. The first sliding guide module specifically includes a first guide rail 102 fixed to the base 101 along the first horizontal direction and a first slider 103 sliding along the first guide rail 102; the first slider 103 and the mounting frame 213 are fixedly connected.

[0095] Among them, the accordion cover 105 is a retractable protective device with a structure resembling an accordion, which can extend and retract synchronously with the movement of the protected component. Its main function is to isolate the external environment from the internal precision components, preventing impurities such as dust, chips, and coolant from entering the first sliding guide module, thereby protecting the cleanliness and lubrication of the guide rail and slider.

[0096] Combination Figure 1 and Figure 4 This embodiment further proposes that the adjustment mechanism 20 also includes a first protective housing 201 covering the telescopic frame 202.

[0097] The first protective housing 201 provides protection for the telescopic frame 202 and its internal or surrounding transmission components. Its shape and size can be customized according to the structure of the telescopic frame 202 to ensure no interference occurs when the telescopic frame 202 moves along the second horizontal direction. The first protective housing 201 effectively prevents external contaminants such as dust, moisture, and oil from entering the moving mechanism of the telescopic frame 202, reducing wear and corrosion of mechanical parts, thereby extending their service life and reducing maintenance costs. Simultaneously, it prevents operators or external objects from accidentally contacting the moving parts, improving the operational safety of the equipment.

[0098] Combination Figure 1 , Figure 8 and Figure 9 In addition, the charging mechanism 30 also includes a roller shutter module 314 disposed on one side of the charging frame 301, and a second protective housing 40 covering the charging frame 301 and the roller shutter module 314. The second protective housing 40 has a channel opening on the side facing the charging head 308.

[0099] Roller blind module 314 typically consists of a roller, roller blind slats (or flexible material) and a drive mechanism. Its function is to provide shelter or protection when needed and to retract when not needed.

[0100] The second protective housing 40 serves as the external protective structure of the charging mechanism 30, providing comprehensive protection for key components such as the charging frame 301, the roller shutter module 314, and the internal charging head 308. This housing can be made of high-strength metal or engineering plastic, offering excellent impact resistance and sealing. The access opening is the necessary path for the charging head 308 to extend and perform charging operations; its size and shape match the movement trajectory of the charging head 308. When the charging head 308 retracts into the second protective housing 40, the roller shutter module 314 can close, covering the access opening, thus forming a relatively enclosed protective space.

[0101] This embodiment proposes a charging system, which includes the aforementioned docking device.

[0102] Specifically, this charging system refers to a complete solution for providing electrical energy to electric devices (such as electric vehicles, robots, etc.). It typically includes multiple components such as a power supply unit, an energy conversion unit, a charging interface (i.e., the docking device in this embodiment), a communication module, a control and management unit, and a safety protection mechanism.

[0103] A charging system can be an integrated hardware and software platform that communicates with the device being charged via wired or wireless means, and controls the actions of the docking device and the charging process according to preset strategies or real-time needs. For example, it may include a central controller responsible for receiving charging requests from the device being charged, scheduling the docking device for precise docking, monitoring the charging status (such as voltage, current, and temperature), and issuing commands upon completion of charging or in case of abnormalities. A power supply unit can convert AC power from the mains into DC power suitable for charging and connect it to the docking device via a cable.

[0104] The aforementioned docking device, as the core execution unit of the charging system, is responsible for achieving physical connection and power transmission with the device being charged. Through its support mechanism 10, adjustment mechanism 20, and charging mechanism 30, the docking device can precisely adjust the position and angle of the device being charged, and insert or contact the charging head 308, thereby establishing a stable electrical connection. As a key component of the charging system, the docking device provides the physical basis for achieving automated, high-precision charging connections, and the coordinated operation of its various mechanisms ensures the reliability of the charging process.

[0105] It should be noted that the main design features of this invention are improvements to the structure and usage of the docking device. The specific structure of the charging system, such as the electrical connection part and the mechanical structure part, will not be described in detail.

[0106] The working principle of the docking device in this embodiment is as follows:

[0107] In an automated charging station scenario, precise and reliable automatic charging docking is required for parked electric vehicles. Due to factors such as vehicle parking location, ground flatness, and changes in ambient temperature, the actual position and orientation of the charging interface may deviate from its theoretical position by an angle. Traditional rigid mating solutions are difficult to adapt to such multi-degree-of-freedom orientation deviations, easily leading to bending of the charging pins or damage to the connector.

[0108] The docking device in this example is designed to solve the above problems and achieve high-precision, flexible automatic docking.

[0109] First, the support mechanism 10 of the docking device provides a stable foundation and initial horizontal movement capability. The base 101 is fixed to the ground and has a first sliding guide module mounted on it along a first horizontal direction (e.g., the X-axis). This first sliding guide module includes a first guide rail 102 and a first slider 103 that slides along it, ensuring that the mounting frame 213 can move smoothly along the X-axis. A first rack 104 is also mounted on the base 101 along the X-axis, providing a transmission basis for subsequent drive.

[0110] Once the electric vehicle is parked, the adjustment mechanism 20 begins to operate. The mounting frame 213 is fixedly connected to the first sliding guide module via the first slider 103, thereby enabling overall movement along the X-axis. The first drive source 203 (e.g., a servo motor) engages with the first rack 104 on the base 101 via the first gear 204 connected to its output end, driving the mounting frame 213 to perform coarse positioning along the X-axis, moving the entire charging mechanism 30 approximately in front of the electric vehicle's charging interface.

[0111] Next, the telescopic frame 202 slides along a second horizontal direction (e.g., the Y-axis direction) on the mounting frame 213. A second drive source 205 (e.g., a servo motor) drives the telescopic frame 202 along the Y-axis direction via a second gear 207 connected to its output end, meshing with a second rack 206 mounted on the telescopic frame 202. This adjusts the charging mechanism 30 to align with the Y-axis position of the vehicle's charging interface. Simultaneously, a rotation module is located at the bottom of the mounting frame 213. This module includes a third drive source 210, a third gear 212 connected to its output end, and a slewing bearing 211 meshing with the third gear 212. The telescopic frame 202 is mounted on the slewing bearing 211, thus the rotation module can drive the telescopic frame 202 to rotate about a vertical axis, thereby adjusting the horizontal rotation angle (e.g., yaw angle) of the charging mechanism 30 to match the horizontal angular deviation of the vehicle's charging interface.

[0112] After completing the X, Y axis and horizontal rotation adjustments, the charging mechanism 30 undergoes vertical and fine adjustments. The charging frame 301 is slidably connected to the telescopic frame 202, and the first drive module 215 (e.g., a lifting screw mechanism) drives the charging frame 301 to perform lifting movements, thereby positioning the charging mechanism 30 in the vertical direction (Z-axis direction) to match the vertical height of the vehicle's charging interface.

[0113] The charging mechanism 30 also includes multi-level fine adjustment and floating functions. A second sliding guide module is provided between the charging frame 301 and the first movable seat 302. This module includes a support member 304 fixed to the top and bottom of the charging frame 301, a fourth guide rail 305 fixed to the support member 304, and a fourth slider 306 sliding along the fourth guide rail 305. The fourth slider 306 is fixedly connected to the first movable seat 302, allowing the first movable seat 302 to be finely adjusted relative to the charging frame 301 along the second horizontal direction (Y-axis direction). The second drive module 309 and the third drive module 310 (e.g., a micro screw or rack and pinion mechanism) drive the first movable seat 302 to move finely along the Y-axis direction, further correcting minor deviations on the Y-axis.

[0114] A third sliding guide module is provided between the first movable seat 302 and the second movable seat 303. This module includes a fifth guide rail 312 fixed to the inner wall of the first movable seat 302 and a fifth slider 313 sliding along the fifth guide rail 312. The fifth slider 313 is fixedly connected to the second movable seat 303, so that the second movable seat 303 can be further slidably adjusted relative to the first movable seat 302.

[0115] Finally, the floating plate 307 is elastically connected to the second movable seat 303. Multiple charging heads 308 are mounted on the floating plate 307. This elastic connection allows the floating plate 307 to adaptively float within a small range when the charging heads 308 contact the vehicle's charging interface, absorbing any remaining minor positional and angular deviations and avoiding mechanical interference and damage that might occur with rigid mating. Compared to existing rigid mating schemes that struggle to adapt to multi-degree-of-freedom attitude deviations, this device significantly improves the fault tolerance and reliability of the docking process through multi-stage drive and floating design.

[0116] Through the coordinated operation of the aforementioned support mechanism 10, adjustment mechanism 20, and charging mechanism 30, the docking device can achieve precise movement in the X, Y, and Z axes and adjustment of the horizontal rotation angle. Finally, through the elastic connection of the floating plate 307, it effectively compensates for various position and posture deviations of the electric vehicle charging interface, ensuring reliable and damage-free docking between the charging head 308 and the vehicle charging interface. This solves the technical problem in the prior art where rigid mating schemes are prone to mechanical interference, leading to pin bending or connector damage.

[0117] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A docking device, characterized in that include: The support mechanism (10) includes a base (101) and a first sliding guide module and a first rack (104) disposed on the base (101) along a first horizontal direction. The adjustment mechanism (20) includes a mounting frame (213) fixed to the base (101), a telescopic frame (202) slidably mounted on the mounting frame (213), a first drive source (203) and a first rack (104) connected in transmission, a second drive source (205) and a telescopic frame (202) connected in transmission, a rotary module located at the bottom of the mounting frame (213), and a first drive module (215) located on one side of the mounting frame (213). The charging mechanism (30) includes a charging frame (301) slidably connected to the telescopic frame (202), a first movable seat (302) slidably connected to the charging frame (301), a second movable seat (303) slidably connected to the first movable seat (302), a floating plate (307) elastically connected to the second movable seat (303), and a plurality of charging heads (308) disposed on the floating plate (307); a second drive module (309) is provided on both sides of the first movable seat (302), and a third drive module (310) is provided on the top and bottom of the first movable seat (302); The first drive source (203) drives the mounting frame (213) to move along the first horizontal direction, the second drive source (205) drives the telescopic frame (202) to move along the second horizontal direction, the rotary module drives the telescopic frame (202) to rotate, the first drive module (215) drives the charging rack (301) to rise and fall; the second drive module (309) and the third drive module (310) drive the first movable seat (302) to move along the second horizontal direction.

2. The docking device according to claim 1, characterized in that, The adjustment mechanism (20) further includes a first gear (204) connected to the output end of the first drive source (203); the first gear (204) and the first rack (104) mesh and drive each other.

3. The docking device according to claim 1, characterized in that, The adjustment mechanism (20) further includes a second gear (207) connected to the output end of the second drive source (205) and a second rack (206) disposed on the telescopic frame (202) along the second horizontal direction and meshing with the second gear (207).

4. The docking device according to claim 1, characterized in that, The slewing module includes a third drive source (210), a third gear (212) connected to the output end of the third drive source (210), and a slewing bearing (211) meshing with the third gear (212); the telescopic frame (202) is mounted on the slewing bearing (211).

5. The docking device according to claim 1, characterized in that, The charging mechanism (30) further includes a fourth sliding guide module disposed between the charging frame (301) and the first movable seat (302) and a fifth sliding guide module disposed between the first movable seat (302) and the second movable seat (303).

6. The docking device according to claim 5, characterized in that, The fourth sliding guide module includes a support member (304) fixed to the top and bottom of the charging rack (301) along the second horizontal direction, a fourth guide rail (305) fixed to the support member (304), and a fourth slider (306) sliding along the fourth guide rail (305); the fourth slider (306) and the first movable seat (302) are fixedly connected.

7. The docking device according to claim 5, characterized in that, The fifth sliding guide module includes a fifth guide rail (312) fixed to the inner wall of the first movable seat (302) along the second horizontal direction and a fifth slider (313) sliding along the fifth guide rail (312); the fifth slider (313) and the second movable seat (303) are fixedly connected.

8. The docking device according to claim 1, characterized in that, The support mechanism (10) further includes a bellows cover (105) covering the first sliding guide module; the first sliding guide module includes a first guide rail (102) fixed to the base (101) along a first horizontal direction and a first slider (103) sliding along the first guide rail (102); the first slider (103) and the mounting frame (213) are fixedly connected.

9. The docking device according to claim 1, characterized in that, The adjustment mechanism (20) also includes a first protective housing (201) covering the telescopic frame (202).

10. The docking device according to claim 1, characterized in that, The charging mechanism (30) also includes a roller shutter module (314) located on one side of the charging frame (301).

11. The docking device according to claim 10, characterized in that, The charging mechanism (30) further includes a second protective housing (40) covering the charging frame (301) and the roller shutter module (314); the second protective housing (40) has a channel opening on the side facing the charging head (308).

12. A charging system, characterized in that, Includes the docking device as described in any one of claims 1-11.

13. A method of use, characterized in that, Implemented using the docking device as described in any one of claims 1-11, the process includes the following steps: In the initial state, the base (101) of the support mechanism (10) is fixed to the ground, and relies on the first sliding guide module and the first rack (104) to provide a first horizontal moving base for the docking device; After the vehicle is parked, the adjustment mechanism (20) is activated, and the first drive source (203) drives the mounting frame (213) to move along the first horizontal direction to complete the initial positioning of the charging mechanism (30); The second drive source (205) drives the telescopic frame (202) to slide along the second horizontal direction to calibrate the lateral position; at the same time, the rotary module drives the telescopic frame (202) to rotate around the vertical axis to correct the horizontal yaw angle of the charging mechanism (30) and adapt to the angle deviation of the vehicle's charging interface. The first drive module (215) controls the raising and lowering of the charging rack (301) to complete the vertical height adjustment of the electric mechanism (30) and match the vertical position of the vehicle's charging interface; Fine position correction is achieved by driving the first movable seat (302) to make fine adjustments in the first horizontal direction through the second drive module (309) and the second drive module (310); The charging head (308) flexibly docks with the vehicle's charging interface along with the floating plate (307), and flexibly completes the charging docking by adaptively compensating for residual position and angle deviations through elastic floating.

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