Device for reducing the force required to automatically insert / extract a connector attached to a charger of an electric vehicle into / from a socket of the electric vehicle

Abstract

The present invention relates to a device for separating a connector of an electric vehicle charger from a socket of an electric vehicle at a predetermined position and orientation. The device comprises a connector operating mechanism, the connector operating mechanism comprising an actuating positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference coordinate system, and at least one compliant assembly configured to move the connector adaptively with at least two degrees of freedom relative to the fixed reference coordinate system. The at least one compliant assembly is kinematically connected in series with the positioning mechanism between the fixed reference coordinate system and the connector, and has a compliant stroke defined as an effective displacement between the actual position and orientation of the connector and the current / temporary virtual position and orientation of the connector. To separate the connector, the connector operating mechanism is configured to apply to the connector a first moment and / or force in the direction of movement for moving the connector in the direction of movement, and at least a second moment and / or force superimposed on the first moment and / or force and having a direction component or a direction not equal to the direction of the only movement, the second moment and / or force being directed towards the unconstrained position and orientation of the connector.

Description

Detailed Description of the Invention

[0001] [Background of the Invention] The present invention relates to a device for reducing the force required to automatically insert / extract a connector attached to a charger of an electric vehicle into / from a socket of the electric vehicle. Throughout this specification, the terms "insert" and "extract" may be replaced with "connect", "disconnect", or "plug in", "plug out", respectively.

[0002] Automatically inserting or extracting a charging connector into / from a socket of an electric vehicle has become a new goal for owners of large fleet vehicles in recent years. Many electric vehicles have vehicle sockets intended for manual plugging in, such as vehicle sockets compliant with IEC62196. The combination of the connector and the vehicle socket usually has a shape that fits precisely. Therefore, a certain degree of accuracy is required in terms of positioning, orienting, and inserting or extracting the connector for automatic plugging in. This combination will always experience friction during insertion or extraction, where the contact force between the connector and the conductors in the socket is the main factor. Many factors can affect the friction, such as designed intersections and manufacturing intersections, weather conditions, wear and damage, and other designed characteristics of the connector and the socket. Another major factor can be misalignment between the connector and the socket during insertion or extraction, for example, due to past or current vehicle movements, misidentification of the socket position, and inaccuracies in the control of automatic mechanisms (such as charging robots) for insertion / extraction.

[0003] When such misalignment occurs, the charger of the electric vehicle may require additional force (beyond the specifications) to insert or extract the connector into / from the socket of the electric vehicle, and accordingly, there is a risk of damage to the vehicle, the charging robot, and unexpected objects or people present between or around the charging robot and the electric vehicle.

[0004] It is difficult to extract a significantly misaligned connector (imagine pulling a mass out of a narrow hole using a string with a pulling direction and angle). A misalignment between the connector and the robot can occur only if the system can tolerate a significant compliance stroke. The compliance stroke in the context of the present disclosure means the distance by which a system or its component can move in response to an external force. This can occur, for example, when the suspension of a vehicle is compressed or released due to added weight for loading / unloading the vehicle. This can also be the result of working with a dedicated device. This is because the dedicated device plugs in and holds the connector, while a human does so to plug in and release the connector. However, this can also occur when the device mimics human operation (subsequently plugging in the connector, releasing the connector, waiting for charging to complete, reconnecting to the connector, and finally pulling out the connector). All instances in an automated charging process where a mechanism holds a connector (partially) inserted into a vehicle socket can experience the problems described above.

[0005] [Brief Description of the Prior Art] So far, several solutions have been proposed in this technical field. WO2019166234A1 discloses a method for automatically inserting or withdrawing a connector into or from a socket of a vehicle by using a vibration unit that prompts the charging connector to vibrate. The vibration helps to reduce the required insertion or withdrawal force, while also complicating the design requirements for both the manipulator that operates the connector and the vehicle with the socket. In both cases, the vibration should be damped to avoid unwanted effects. The above-mentioned document mentions damping on the connector side, but does not mention damping on the socket side. Furthermore, the above-mentioned document mentions a dedicated actuator on the connector side for generating vibration. It is not desirable to add components to the end effector of the manipulator, that is, to add weight, complexity, and cost. Finally, the vibration does not solve the significant misalignment, that is, the clamping problem.

[0006] CN108790916A discloses an electric vehicle charging system that includes a square airbag that inflates when the charging head approaches the socket in order to overcome the problem of position changes due to fluctuations in the vehicle during charging.

[0007] DE102012014936A1 discloses a system for correcting position and orientation offsets when positioning a connector. Finally, paper DOI 10.1109 / SSD.2015.7348200 discloses a strategy for reducing the force required for insertion. The document describes the use of an industrial robot with a six-degree-of-freedom force sensor to facilitate the combined control of position and force during connector insertion. This solution may enable force reduction but is associated with many disadvantages. Force control requires a sufficiently high control frequency, a deterministic control loop, and sufficient computing power to enable a fast and accurate response from the motor controller and motors. These requirements are accompanied by increasing weight and cost and are difficult (if not impossible) to certify for use in public environments. Furthermore, to implement a manipulator using force control, which is in contrast to significant physical compliance, the manipulator needs to be continuously controlled throughout the charging process. Apart from wasting energy, if the controller stops for any reason, the electric vehicle may still move passively due to its suspension, but brakes will be applied to parts of the system (manipulator, connector, socket).

[0008] [Summary of the Invention] Generally, systems according to the prior art have one or more of the following disadvantages. Such systems are only for correcting misalignment of orientation or position and do not solve potential clamping due to misalignment during withdrawal. Generally, the systems include extra devices (sensors or actuators) to operate. Such devices are also only suitable for connector insertion and do not solve potential clamping due to misalignment during withdrawal. Generally, they may not be effective in reducing at least the average force required to plug a connector into a socket.

[0009] A method and system for reducing the force required to insert or withdraw a socket attached to a charger of an electric vehicle into or from a socket of the electric vehicle, which eliminates the disadvantages of the prior art or at least forms a useful alternative thereto, is an object of the present invention.

[0010] Also, in an electric vehicle, a method for controlling an automatic charging device (ACD) for automatic connection to or automatic separation from a socket of a connector is also an object of the present invention. The ACD comprises a connector operating mechanism including an operative connector positioning mechanism and a compliance assembly that enables compliant connection / separation of the connector by movement in the connection / separation direction. Also, introducing a reliable and safe solution is an object of the present invention. A further object is to reduce the force in the insertion direction for safety purposes. Yet another object is to reduce costs, maintain maintainability, implement a less complex system, and enhance the robustness of the system.

[0011] Therefore, the present invention presents an apparatus and method according to independent claims.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2A

Figure 2B

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Figure 4B

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] [DETAILED DESCRIPTION OF THE INVENTION] During the insertion or extraction phase, there is physical contact between the connector and the socket. As a result of this physical contact, at least friction occurs. Friction, along with other effects such as clamping by pressing against intentional or non-intentional features (ridges, scratches, etc.), is caused by misalignment or generally and, respectively, requires a higher pressing force or tensile force in the direction of the centerline of the socket than the nominal pressing force or tensile force (as described in the reference) in order to successfully complete the insertion or extraction.

[0014] In other words, in a perfectly matching shape of the combination of the connector and the socket, as a result, clamping or increasing friction (static and dynamic) often occurs. It may be the result of misalignment between the connector and the socket, but it can also occur even if the connector and the socket are not misaligned. This increases the force required to insert or extract the connector, and as a result, there are safety issues or risks of damaging the socket, connector, or robot. There is also a risk that the connection between the socket and the connector may not be made properly or not at all.

[0015] One aspect of the present invention is to apply a moment and / or a force to the connector in addition to those in the insertion or extraction direction to generate a camming operation of the connector in the socket.

[0016] The compatibility between the socket and the connector, and thus the friction therebetween, depends on several factors. Among them are the design and structure of the connector and the socket (e.g., manufacturing tolerances), the contact pressure of the electrical contacts, the geometric design adapted to human insertion and / or extraction such as a self-searching function, and the material properties (rigidity, roughness, etc.). Other factors include general wear and tear, misuse, as well as exposure to weather conditions or other conditions in which the socket and the connector were used (dirt or elements that got into the socket).

[0017] Another factor of friction is the misalignment caused by the movement of the vehicle (and thus the socket) at the moment of insertion / extraction, or the error or inaccuracy in the operation control of the positioning mechanism. Vehicle movement can occur for several reasons such as loading / unloading, wind load, and adjustment of the vehicle suspension. The charging station that facilitates automatic connection must be able to handle such slight vehicle movement in order to avoid damage to either the infrastructure or the vehicle. The present invention uses a device that combines physical compliance in an active positioning mechanism to solve the problem that brings the possibility of misalignment.

[0018] In all cases, the combination of the socket and the connector is designed to fit perfectly, so friction will be felt when inserting or extracting the connector, and clamping may also be experienced.

[0019] To avoid such problems, when an alternating moment and / or an alternating force in a direction different from at least the center line in the socket direction (P) is applied to the socket, a jamming operation of the connector in the socket occurs, leading to a reduction in friction and / or a lever-like operation. In the context of the present invention, the insertion / extraction direction may be referred to as the plug-in direction and may correspond to a direction that is essentially or substantially parallel to the direction of the center line of the pin and the hole. In the context of the present invention, the terms insertion, connection, and plug-in may be used interchangeably. Similarly, the terms extraction, separation, and plug-out may also be used interchangeably.

[0020] The force or moment applied to reduce the insertion or extraction force is not necessarily in the direction to eliminate misalignment. This is because their purpose is not to directly overcome the misalignment itself or completely overcome the misalignment itself, but to reduce the frictional force that may be indirectly caused by the misalignment. Utilizing the direction of misalignment has the additional advantage that the misalignment is eliminated, even if only temporarily.

[0021] As a result of alternately switching the moment and / or force, a number of jamming operations occur. Thus, such alternating moments or alternating forces can also cause the connector to reach the most advantageous orientation arrangement many times (intentionally or unconsciously), thereby facilitating the reduction of the required force.

[0022] By performing a quasi-static operation controlled using a positioning mechanism simultaneously with the insertion or extraction operation, when the connector is not at least partially inserted into the socket, the connector may move in a direction different from the insertion or extraction with respect to the socket, but an adaptation stroke, an additional adaptation stroke, and a larger adaptation stroke are effectively induced. The second movement may include at least one of a linear movement along the axis of the maximum dimension, a rotational movement about the axis of the maximum dimension and an axis perpendicular to the insertion / extraction direction, and / or a movement about a point where misalignment may be eliminated.

[0023] The device according to the present disclosure comprises a connector operating mechanism with an actuating positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference coordinate system, and at least one compliant assembly configured to move the connector adaptively with at least two degrees of freedom relative to the fixed reference coordinate system. Thus, the at least one compliant assembly can be configured to facilitate correct connection, for example, under misalignment during insertion due to misrecognition of the position and / or orientation of the socket, and / or under misalignment occurring after plugging in due to passive vehicle movements caused, for example, by vehicle loading (settling) during a charging session.

[0024] All of these facilitate a reduction in the force required to connect and / or disconnect the connector and socket, as compared to the force required to connect the connector using only the force in the insertion / extraction direction. For example, this enables the insertion and extraction of the connector towards the center in the socket direction using a force that can be smaller than in the case of no lateral movement.

[0025] Compliance occurs where, as a result of lateral translational and / or rotational movements, a point with significantly less (or no) misalignment is encountered, facilitating extraction.

[0026] Some devices suitable for constructing according to the present invention are described in patent applications of the same applicant (in particular, NL2023019, NL2024952, NL2025959, NL2026365, NL2026710, NL2028169). These applications are incorporated herein by reference. All of the devices described herein can be configured to implement the method according to the present invention.

[0027] In one embodiment, to connect the connector, the connector operating mechanism may be configured to limit the second moment and / or force to an extent that a controlled quasi-static movement of the connector can be obtained.

[0028] According to the present invention, quasi-static motion refers to a slow and controlled motion where the system is either almost stationary or moving very slowly so that it can maintain a stable position. In quasi-static motion, generally, the driving force is applied slowly and continuously to such an extent that dynamic forces such as acceleration and inertia can be ignored.

[0029] When the connector is within the socket, there is little room for movement. Only design tolerances, manufacturing tolerances, and material properties provide that room. It is difficult to achieve dynamic motion within the socket, and in particular, due to vibrations, there is a possibility that unwanted wear and damage may occur unintentionally to the vehicle, as well as to the socket and the connector. In addition, the operation according to the present application is intended to be quasi-static.

[0030] Throughout the present application, the term quasi-static is used for such motions where inertial effects can be ignored. When the operation is performed with the connector not clamped, for example, by the socket, the compliance-induced adaptive stroke due to the inertial effects of the mass supported by the compliance can be ignored. Considering one-directional motion as a simplified spring-mass system, quasi-static behavior is considered to be motion that satisfies the following conditions.

[0031] m*omg^2 / k < sqrt(2)-1 Here, m = mass supported by the adaptive effector k = stiffness of the adaptive assembly omg = operating frequency Transfer function = 1 / (1 + m*omg^2 / k) = 1 / sqrt(2) The cut-off point / breakpoint of the dominant behavior in the frequency response is as follows.

[0032] ―3dB = 20log(1 / sqrt(2)) This simplification applies to devices where the adaptive assembly is placed only after the final actuator (end effector compliance) and damping is omitted.

[0033] In a further embodiment, the connector operating mechanism is configured to superimpose a second moment and / or force along a single axis or around a single axis. Typically, the most beneficial second moment and / or force depends on the particular combination of connector and socket under consideration and may also depend on the specific situation in which that combination is used.

[0034] For example, a connector having a maximum (facing the plane orthogonal to the insertion direction) lateral dimension on a vertical axis may benefit most from a moment about the horizontal axis in the lateral direction and the resulting controlled rotation, so the dimensions of the connector are utilized such that the connector is jammed into or out of the socket.

[0035] In another example, a moment or force only in the direction of a possible / occurred misalignment has the additional advantage of temporarily eliminating the misalignment in addition to the jamming operation.

[0036] In a further embodiment, the connector operating mechanism is configured to switch at least once, in a particularly controlled manner, the direction of the superimposed second moment or force.

[0037] Typically, it may not be sufficient to apply an additional moment or force in one direction along an axis. By an alternating switch along one axis or a general alternating switch that produces other patterns (e.g., circular or something more complex), the overall success rate of the invention is improved.

[0038] In a further embodiment, the connector operating mechanism is configured to set a second moment and / or a force to an amount greater than 0.03 m, preferably, for translation, and / or to an amount greater than 3 degrees for rotation, more preferably, to an amount greater than 0.01 m for translation, and / or to an amount greater than 2 degrees for rotation, most preferably, to an amount greater than 0.005 m for translation, and / or to an amount greater than 1 degree for rotation. Such values have been experimentally found to be beneficial for the present invention.

[0039] In a further embodiment, the second moment and / or the force are applied only when it is determined that the connector has become non - removable. If the second moment and / or the force are applied when they are incorrect, there is a risk of adverse effects. For example, the compliant stroke can be realized by operating the positioning mechanism only when the connector is within the socket or otherwise constrained. Adverse effects can be avoided only by implementing this method when noticing the above - mentioned nominal forces for insertion or extraction.

[0040] In a yet further embodiment, the second moment and / or the force are based on inputs from sensors such as force sensors or cameras, or measured misalignments. Different strategies may be required depending on the use case. By adapting the second moment and / or the force to a particular use case, the controller can select the correct strategy to solve a particular example.

[0041] Insertion or extraction may be hindered by various effects. For example, due to a horizontal ridge in the socket, the edge of the connector may not be able to pass due to a slight unintentional misalignment. As a result, the connector may rotate slightly within the socket. Controlled movement of the connector within the tolerance of the socket may resolve this as the edge moves over the ridge, but it may not help in movement along the ridge.

[0042] In a further embodiment, the second moment and / or force is applied in a direction in which the principal component of the measured misalignment decreases. The force required to insert or extract is likely to be minimized at the point of minimum misalignment. Thus, by selecting a direction likely to resolve a part of the measured misalignment, the controller minimizes the insertion force or extraction force by both resolving the misalignment and the crosstalk operation.

[0043] More particularly, the present invention relates to an apparatus for connecting a connector of a charger of an electric vehicle to a socket of the electric vehicle at a predetermined position and orientation, - The connector and the socket each have a plurality of poles that are electrically interconnected by establishing a connection pair of electrically conductive pins and holes, the connector having pins and the socket having associated holes, and / or the connector having holes and the socket having associated pins, Each pair of pins and holes has a center line extending axially from the center of the associated pin or hole, the center lines being parallel, - Connectable by movement directed towards each other, the movement being A direction substantially parallel to the direction of the center lines of the pins and holes, And at least two, the center lines of the pins and holes of each connection pair of pins and holes coincide, the relative orientation of the connector and the socket, And having, - Each having a housing, the housings of the connector and the socket are Connectable by movement directed towards each other, Comprising a mechanical guide portion protruding in a direction parallel to the direction of the center line beyond the end of the pin, The housings of the connector and the socket have manufacturing tolerances and / or operating tolerances that facilitate restricted movement in at least one degree of freedom, The apparatus is - Comprising a connector operating mechanism, the connector operating mechanism being ​An actuating positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference coordinate system, At least one compliant assembly configured to adaptively move the connector with at least two degrees of freedom relative to a fixed reference coordinate system, Comprising, At least one compliant assembly is Kinematically connected in series with the positioning mechanism between the fixed reference coordinate system and the connector, Has a compliant stroke defined as an effective displacement between the actual position and orientation of the connector and the neutral position and orientation of the connector, defined at least by a connector operating mechanism that holds the connector in a state where the connector is not restricted by the socket. To connect the connector, the connector operating mechanism applies to the connector - A first moment and / or force in the direction of movement for moving the connector in the direction of movement, and - At least a second moment and / or force that is superimposed on the first moment and / or force and has a direction component or a direction different from the direction of movement, and is directed towards the neutral position and orientation, the second moment and / or force and Is configured to apply, The connector operating mechanism is configured to apply at least the second moment and / or force to the connector when and only when the connector is at least partially inserted into the socket, and the second moment and / or force is added by generating or expanding a compliant stroke by the actuation of the positioning mechanism.

[0044] More particularly, the present invention also relates to an apparatus for separating a connector of an electric vehicle charger from a socket of an electric vehicle at a predetermined position and orientation, - The connector and the socket are Each having a plurality of poles that can be electrically interconnected by establishing an electrically conductive pin-and-hole connection pair, the connector having pins, the socket having associated holes, and / or the connector having holes and the socket having associated pins, Each pair of pin and hole has a center line extending axially from the center of the associated pin or hole, and the center lines are parallel, - Capable of being separated by a movement directed away from each other, the movement being A direction substantially parallel to the direction of the center lines of the pin and the hole, At least two, the mutual orientation of the connector and the socket where the center lines of the pin and the hole of each connection pair of the pin and the hole coincide, And having, - Each having a housing, and the housings of the connector and the socket are Capable of being separated by the same movement directed away from each other, Having a mechanical guide portion that projects in a direction parallel to the direction of the center line beyond the end of the pin, The housings of the connector and the socket have manufacturing tolerances and / or operating tolerances that facilitate limited movement in at least one degree of freedom, The device is - Equipped with a connector operating mechanism, and the connector operating mechanism is An actuating positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference coordinate system, At least one compliant assembly configured to move the connector adaptively with at least two degrees of freedom relative to a fixed reference coordinate system, And having, At least one compliant assembly is Kinematically connected in series with the positioning mechanism between the fixed reference coordinate system and the connector, Having a compliance stroke defined as the effective displacement between the actual position and orientation of the connector and the neutral position and orientation of the connector defined at least by the connector operating mechanism that holds the connector in a state not restricted by the socket, To separate the connector, the connector operating mechanism applies to the connector: - a first moment and / or force in the movement direction for moving the connector in the movement direction, and - at least a second moment and / or force that is superimposed on the first moment and / or force and has a direction component or a direction that is not equal to the movement direction, the second moment and / or force being directed towards the neutral position and orientation, and is configured to apply: The connector operating mechanism is configured to apply at least the second moment and / or force to the connector when, and only when, the connector is at least partially inserted into the socket, the second moment and / or force being applied by generating or augmenting an adaptation stroke by the operation of the positioning mechanism.

[0045] In one embodiment, to connect or disconnect the connector, the connector operating mechanism is configured to limit the second moment and / or force to an extent that a controlled quasi-static movement of the connector is obtained.

[0046] In one embodiment, the connector operating mechanism is configured to superimpose the second moment and / or force along a single axis or around a single axis. In one embodiment, the connector operating mechanism is configured to switch the direction of the superimposed second moment or force at least once, particularly in a controlled manner.

[0047] In one embodiment, the connector operating mechanism is configured to apply the second moment and / or force by setting an adaptation stroke preferably to an amount greater than 0.02 m for translation and / or greater than 2 degrees for rotation, more preferably to an amount greater than 0.01 m for translation and / or greater than 1 degree for rotation, most preferably to an amount greater than 0.005 m for translation and / or greater than 0.5 degrees for rotation.

[0048] In some embodiments, the second moment and / or force is applied only if it is determined that the connector has become disengaged. In some embodiments, the present invention comprises controlling the second moment and / or force based on input from a sensor such as a force sensor or a camera, or on a measured misalignment.

[0049] In some embodiments, the second moment and / or force is applied in a direction in which the principal component of the measured misalignment decreases. In some embodiments, the actuator used to apply the second moment and / or force is also used to control at least one degree of freedom of the positioning mechanism.

[0050] In some embodiments, the second movement is · a linear movement along an axis having a maximum dimension orthogonal to the movement direction, · a rotational movement about an axis having the maximum dimension and an axis orthogonal to the movement direction, and / or · a movement centered at a point where the misalignment is eliminated, and comprises at least one of.

[0051] The present invention also relates to a method for controlling an automatic charging device (ACD) for automatically connecting a connector into a socket in an electric vehicle, the ACD comprising a connector operating mechanism having an operative connector positioning mechanism and a compliant assembly enabling a compliant connection of the connector by movement in a connection direction, the method comprising a) applying, by the connector operating mechanism, a first moment and / or force to the connector in a direction substantially parallel to the connection direction; and b) applying, by the connector operating mechanism, a second moment and / or force to the connector in a direction not equal to the direction of the first moment and / or force; and controlling the ACD for. The second moment and / or force is - When the connector is at least partially inserted into the EV socket, it is superimposed on the first moment and / or force, - By generating and / or expanding the compliant stroke of the connector, it is applied.

[0052] By the method of the present invention, the force required to connect the connector and the EV socket can be reduced. The present invention also relates to a method for controlling an automatic charging device (ACD) for automatically separating a connector from a socket in an electric vehicle, the ACD comprising a connector operating mechanism having an operative connector positioning mechanism and a compliant assembly enabling a compliant separation of the connector by movement in a separation direction, the method comprising c) applying, by the connector operating mechanism, a first moment and / or force to the connector in a direction substantially parallel to the separation direction, d) applying, by the connector operating mechanism, a second moment and / or force to the connector in a direction not equal to the direction of the first moment and / or force, comprising controlling the ACD for The second moment and / or force is - When the connector is at least partially inserted into the EV socket, it is superimposed on the first moment and / or force, - By generating and / or expanding the compliant stroke of the connector, applied.

[0053] By the method of the present invention, the force required to separate the connector from the EV socket can be reduced. In one embodiment, the method comprises controlling the second moment and / or force such that a controlled quasi-static movement of the connector is obtained.

[0054] In one embodiment, the method includes applying a second moment and / or force to the connector when the interaction force between the partially inserted connector and the socket exceeds a predetermined threshold. In particular, the method enables controlling the application of the second moment and / or force only when the aforementioned interaction force exceeds the threshold, in order to enable the adaptive assembly to counteract such interaction forces without necessarily generating and / or expanding the adaptive stroke of the connector. The interaction force of the present invention means the force exerted by one object on another object as a result of the interaction between the objects. As a non-limiting example, there is the frictional force generated by the action between their surfaces when the socket and the connector come into contact.

[0055] In one embodiment, the method includes applying a second moment and / or force to the connector in a direction substantially opposite to the interaction force between the partially inserted connector and the socket.

[0056] In one embodiment, the method includes applying a second moment and / or force to the connector when the interaction force between the partially inserted connector and the socket in the insertion / extraction direction exceeds a first predetermined threshold.

[0057] In one embodiment, the method includes applying a second moment and / or force to the connector when the interaction force between the partially inserted connector and the socket in a direction other than the insertion / extraction direction exceeds a second predetermined threshold.

[0058] It is important to note that the interaction forces may have different directions (which may affect the thresholds used to control the addition of the second force or moment). Thus, to account for different interaction forces, the method further includes determining appropriate thresholds for different types of interaction forces, such as the interaction force in the plug-in / plug-out direction or the interaction force in a direction other than the plug-in / plug-out direction.

[0059] In one embodiment, the method comprises applying a second moment and / or force while continuing to apply a first moment and / or force to the connector in a direction substantially parallel to the plug-in direction until it is determined that the interaction force between the partially inserted connector and the socket is below a predetermined threshold.

[0060] In one embodiment, the method comprises the following movement of the connector, - linear movement along an axis having a maximum dimension orthogonal to the movement direction, - rotational movement about an axis having a maximum dimension and an axis orthogonal to the movement direction, - movement about a point where misalignment is eliminated, - quasi-static square diamond movement, - sine wave movement, comprising applying a second moment and / or force such that at least one of the above is obtained.

[0061] In one embodiment, the method comprises that applying a second moment and / or force includes switching alternately between operations when it is determined that the interaction force between the partially inserted connector and the socket is not reduced.

[0062] In one embodiment, the method comprises applying a first moment and / or a second moment and / or force until an electrical connection between the socket and the connector is determined.

[0063] In one embodiment, the method comprises receiving a signal that the connector and the socket are clamped before applying the second moment and / or force. The invention will be described in more detail with reference to the following drawings.

[0064] Figure 1 shows a connector (1) properly inserted into a socket (6), together with the insertion direction (P), the vertical axis (C) fixed to the connector, the vertical axis (S) fixed to the socket, and the slight tolerance (11) that exists when the connector is properly inserted. Usually, an electrical contact (not shown) enables the symmetric (or at least constant) use of the tolerance by a (passive) mechanism (e.g., a leaf spring mechanism for one side of a pin-and-hole pair) that provides sufficient contact pressure between conductors.

[0065] Figures 2A and 2B illustrate two implementation forms of a connector operating mechanism. The figures show a connector (1) positioned by a positioning mechanism composed of an actuator (2), together with an adaptive assembly (3) that is kinematically in series with the actuator (2) between a fixed reference coordinate system (5) and the connector (1). The adaptive assembly is distributed throughout the mechanism in Figure 2A and concentrated near the connector (1) in Figure 2B. The figures also show the position and orientation of the connector (1) and the adaptive position (4) of the adaptive assembly (3) when the connector is not constrained by the socket, i.e., in the neutral position and orientation of the connector (1).

[0066] Figures 3A and 3B illustrate the result of applying the invention to a connector operating mechanism by a translation orthogonal to the insertion direction (Figure 3A) and the result of magnifying the interaction between the connector and the socket (Figure 3B).

[0067] Figure 3A shows a connector operating mechanism having an adaptive stroke (7) with respect to the normal adaptive position (4) of the adaptive assembly (3) when the connector (1) is not constrained by the socket (6), i.e., in the neutral position and orientation of the connector (1).

[0068] Figure 3B shows the connector (1) partially inserted into the socket (6). Also shown are the forces (F) and (I) applied to the connector (1) by the compliant assembly (3) due to the compliant stroke (7) (shown in Figure 3A), where the force (I) in the insertion direction is intended to effect the insertion operation, and the force (F) orthogonal to the insertion direction is intended to alleviate the requirements of (I). The force (F) orthogonal to the insertion direction causes a slight displacement (12) of the connector (1) within the tolerance of the socket (6) for symmetric use of the tolerance (11). This effectively shows an example during the camming operation.

[0069] Figures 3A and 3B illustrate the results of insertion, but by using a compliant stroke that results in a force in the opposite direction of I, the same results can be obtained for extraction.

[0070] Figures 4A and 4B illustrate the result of applying the invention within the connector operating mechanism by rotation about an axis orthogonal to the insertion direction (Figure 4A) and the result of magnifying the interaction between the connector and the socket (Figure 4B).

[0071] Figure 4A shows a connector operating mechanism with a compliant stroke (8) of the compliant assembly (3) when the connector (1) is not constrained by the socket (6). Figure 4B shows the connector (1) partially inserted into the socket (6). Figure 4B also shows the moment (M) and the force (I) applied to the connector (1) by the compliant assembly (3) due to the compliant stroke (8), where the force (I) in the insertion direction is intended to effect the insertion operation, and the moment (M) about an axis orthogonal to the insertion direction is intended to relieve the requirement of (I). Due to the moment (M) about an axis orthogonal to the insertion direction, a slight rotation (13) of the connector (1) within the tolerance of the socket (6) occurs with respect to the insertion direction (P). This effectively shows an example during the crosstalk operation. Although Figures 4A and 4B illustrate the result of the insertion, the same effect can also be obtained for extraction by using a compliant stroke that results in a force in the opposite direction of I.

[0072] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of such measures cannot be used to advantage. Reference signs in the claims should not be construed as limiting the scope.

Claims

1. An apparatus for connecting a connector of an electric vehicle charger to a socket of an electric vehicle at a predetermined position and orientation, comprising: The connector and the socket each have: a plurality of poles that can be electrically interconnected by establishing a connection pair of electrically conductive pins and holes, the connector having pins and the socket having associated holes, and / or the connector having holes and the socket having associated pins; each pair of pin and hole has a center line extending axially from the center of the associated pin or hole, and the center lines are parallel; the connector and the socket are connectable by a movement directed towards each other, the movement being: in a direction substantially parallel to the direction of the center lines of the pins and the holes; at least two mutual orientations of the connector and the socket in which the respective center lines of the pins and the holes of the connection pairs of pins and holes coincide; and the connector and the socket each have a housing, and the housings of the connector and the socket are: connectable by a movement directed towards each other; provided with mechanical guide portions protruding in a direction parallel to the direction of the center line beyond the ends of the pins; the housings of the connector and the socket have manufacturing tolerances and / or operating tolerances that facilitate a limited movement in at least one degree of freedom; the apparatus comprises a connector operating mechanism, the connector operating mechanism comprising: an actuating positioning mechanism for moving the connector with at least two degrees of freedom with respect to a fixed reference coordinate system; at least one compliant assembly configured to move the connector adaptively with at least two degrees of freedom with respect to a fixed reference coordinate system; and the at least one compliant assembly: is kinematically connected in series with the positioning mechanism between the fixed reference coordinate system and the connector; has a compliant stroke defined as an effective displacement between the actual position and orientation of the connector and the neutral position and orientation of the connector defined at least by the connector operating mechanism that holds the connector in a state not restricted by the socket; To connect the connector, the connector operating mechanism applies to the connector a first moment and / or force in the direction of movement for moving the connector in the direction of movement, and at least a second moment and / or force having a direction component or a direction not equal to the direction of movement, superimposed on the first moment and / or force, the second moment and / or force being directed towards the neutral position and orientation, and is configured to apply the connector operating mechanism is configured to apply the at least second moment and / or force to the connector when and only when the connector is at least partially inserted into the socket, and the second moment and / or force is applied by generating or expanding the compliant stroke by the operation of the positioning mechanism, characterized in that the device **Claim 2** A device for separating a connector of an electric vehicle charger from a socket on the electric vehicle at a predetermined position and orientation, wherein the connector and the socket each have a plurality of poles that can be electrically interconnected by establishing a connection pair of electrically conductive pins and holes, the connector comprises pins, the socket comprises associated holes, and / or the connector comprises holes and the socket comprises associated pins, each pair of pin and hole has a center line extending axially from the center of the relevant pin or hole, and the center lines are parallel, the connector and the socket can be separated by a movement directed away from each other, the movement being in a direction substantially parallel to the direction of the center lines of the pins and the holes, and at least two mutual orientations of the connector and the socket in which the center lines of the pins and the holes of the connection pairs of pins and holes coincide, and the connector and the socket each comprise a housing, and the housings of the connector and the socket can be separated by the same movement directed away from each other, comprise mechanical guide portions protruding in a direction parallel to the direction of the center lines beyond the ends of the pins, the housings of the connector and the socket have manufacturing tolerances and / or operating tolerances that facilitate restricted movement in at least one degree of freedom, the device comprises a connector operating mechanism, the connector operating mechanism An actuating positioning mechanism for moving the connector with at least two degrees of freedom relative to a fixed reference coordinate system, At least one compliant assembly configured to adaptively move the connector with at least two degrees of freedom relative to a fixed reference coordinate system, Comprising, Said at least one compliant assembly, Is kinematically connected in series with the positioning mechanism between the fixed reference coordinate system and the connector, Has a compliance stroke defined as an effective displacement between the actual position and orientation of the connector and the neutral position and orientation of the connector defined at least by the connector operating mechanism that holds the connector in a state where the connector is not restricted by the socket, To separate the connector, the connector operating mechanism applies to the connector, A first moment and / or force in the direction of movement for moving the connector in the direction of movement, At least a second moment and / or force that is superimposed on the first moment and / or force and has a direction component or a direction that is not equal to the direction of movement, and is directed towards the neutral position and orientation, said second moment and / or force, Is configured to apply, The connector operating mechanism is configured to apply the at least second moment and / or force to the connector only when and especially when the connector is at least partially inserted into the socket, and the second moment and / or force is applied by generating or expanding the compliance stroke by the operation of the positioning mechanism, Device, characterized in that.

3. The device according to claim 1 or 2, The device, wherein the connector operating mechanism is configured to limit the second moment and / or force to such an extent that a controlled quasi-static movement of the connector can be obtained, for connecting or separating the connector.

4. The device according to claim 1, 2, or 3, The device, wherein the connector operating mechanism is configured to superimpose a second moment and / or force along a single axis or around a single axis.

5. The device according to any of the preceding claims, An apparatus, wherein the connector operating mechanism is configured to switch at least once, in a particularly controlled manner, the direction of the superimposed second moment or force alternately. **Claim 6** The apparatus according to any one of the preceding claims, wherein the connector operating mechanism is configured to apply the second moment and / or force by setting an adaptive stroke, preferably to an amount greater than 0.02 m for translation and / or to an amount greater than 2 degrees for rotation, more preferably to an amount greater than 0.01 m for translation and / or to an amount greater than 1 degree for rotation, most preferably to an amount greater than 0.005 m for translation and / or to an amount greater than 0.5 degrees for rotation. **Claim 7** The apparatus according to any one of the preceding claims, wherein the second moment and / or force is applied only when it is determined that the connector cannot be removed. **Claim 8** The apparatus according to any one of the preceding claims, comprising controlling the second moment and / or force based on an input from a sensor such as a force sensor or a camera, or on a measured misalignment. **Claim 9** The apparatus according to any one of the preceding claims, wherein the second moment and / or force is applied in a direction in which the main component of the measured misalignment decreases. **Claim 10** The apparatus according to any one of the preceding claims, wherein the actuator used to apply the second moment and / or force is also used to control at least one degree of freedom of the positioning mechanism. **Claim 11** The apparatus according to any one of the preceding claims, wherein the second movement a. a linear movement along the axis having the maximum dimension perpendicular to the movement direction, b. a rotational movement about the axis having the maximum dimension and the axis perpendicular to the movement direction, and / or c. a movement centered at the point where the misalignment is eliminated, comprises at least one of them. **Claim 12** A method for controlling an automatic charging device (ACD) for automatically connecting a connector into a socket in an electric vehicle, the ACD comprising a connector operating mechanism having an actuating connector positioning mechanism and an adaptive assembly enabling an adaptive connection of the connector by a movement in the connection direction, the method comprising a. applying a first moment and / or a force to the connector by the connector operating mechanism in a direction substantially parallel to the connection direction; b. applying a second moment and / or a force to the connector by the connector operating mechanism in a direction different from the direction of the first moment and / or the force; characterized by comprising: wherein the second moment and / or the force is superimposed on the first moment and / or the force when the connector is at least partially inserted into the EV socket, by generating and / or expanding the compliant stroke of the connector, a method. **Claim 13** A method for controlling an automatic charging device (ACD) for automatically separating a connector from a socket in an electric vehicle, the ACD comprising a connector operating mechanism having an actuable connector positioning mechanism and a compliant assembly enabling compliant separation of the connector by movement in a separation direction, the method comprising: a. applying a first moment and / or a force to the connector by the connector operating mechanism in a direction substantially parallel to the separation direction; b. applying a second moment and / or a force to the connector by the connector operating mechanism in a direction different from the direction of the first moment and / or the force; characterized by comprising: wherein the second moment and / or the force is superimposed on the first moment and / or the force when the connector is at least partially inserted into the EV socket, by generating and / or expanding the compliant stroke of the connector, a method. **Claim 14** The method according to any one of claims 12 or 13, further comprising controlling the second moment and / or the force such that a controlled quasi-static movement of the connector is obtained. **Claim 15** The method according to any one of claims 12 or 13, further comprising applying the second moment and / or the force to the connector when an interaction force between the partially inserted connector and the socket exceeds a predetermined threshold. **Claim 16** The method according to claim 15, A method further comprising applying the second moment and / or force to the connector in a direction substantially opposite to the interaction force between the partially inserted connector and the socket at least.

17. The method according to any one of claims 15 or 16, further comprising applying the second moment and / or force to the connector when the interaction force between the partially inserted connector and the socket in the insertion / extraction direction exceeds a first predetermined threshold value.

18. The method according to any one of claims 15 or 16, further comprising applying the second moment and / or force to the connector when the interaction force between the partially inserted connector and the socket in a direction other than the insertion / extraction direction exceeds a second predetermined threshold value.

19. The method according to claim 15, further comprising applying the second moment and / or force until it is determined that the interaction force between the partially inserted connector and the socket is below the predetermined threshold while continuously applying the first moment and / or force to the connector in a direction substantially parallel to the plug-in direction.

20. The method according to any one of claims 12 to 19, the following movement of the connector, a. Linear movement along the axis having the maximum dimension perpendicular to the movement direction, b. Rotational movement about the axis having the maximum dimension and the axis perpendicular to the movement direction, c. Movement centered at the point where the misalignment is eliminated, d. Quasi-static square diamond movement, e. Sinusoidal movement, further comprising applying the second moment and / or force so that at least one of them is obtained.

21. The method according to any one of claims 12 to 20, wherein applying the second moment and / or force further comprises alternately switching between operations when it is determined that the interaction force between the partially inserted connector and the socket is not reduced.

22. The method according to any one of claims 12 to 21, further comprising applying the first moment and / or the second moment and / or force until the electrical connection between the socket and the connector is determined.

23. The method according to any one of claims 12 to 22, A method further comprising receiving a signal that the connector and the socket are clamped before applying the second moment and / or force.

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