Method for controlling an autonomous charging system for electric vehicles

Abstract

The present invention relates to a method for controlling an autonomous charging system for electric vehicles. The invention also relates to an autonomous charging system for electric vehicles. The method generally includes guiding a connector assembly toward a vehicle charging port by the operation of a robotic arm; enabling the robotic arm to transition from an unlocked state to a locked state; achieving mating of the connector with the charging port by moving the connector assembly while monitoring and analyzing motion data and / or sensor data; and initiating corrective actions when the analysis of motion data and / or sensor data indicates that corrective actions are required to enable the system to complete mating of the connector with the charging port.

Description

Detailed Description of the Invention

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

[0002] This method generally includes guiding a connector assembly toward a vehicle charging port by actuation of a robotic arm, enabling the robotic arm to transition from an unlocked state to a locked state, achieving mating of the connector with the charging port by moving the connector assembly while monitoring and analyzing motion data and / or sensor data, and initiating a corrective action if analysis of the motion data and / or sensor data indicates that a corrective action is required to enable the system to complete the mating of the connector with the charging port.

[0003] The system of the present invention for autonomously charging an electric motor vehicle comprises a base unit, a connector assembly supporting a connector for mating with a vehicle charging port, a robotic arm disposed between the base unit and the connector assembly and comprising a plurality of arm segments, and a control system configured to receive motion data and / or sensor data, and to guide the robotic arm and the connector assembly toward the vehicle charging port.

[0004] The system further comprises a control system that controls movement and positioning of the robotic arm based on the motion data and / or sensor data.

[0005] [Technical Field] The present invention generally relates to a method for controlling a robotic system for autonomously charging electric motor vehicles, and a related system.

[0006] [Background of the Invention] As the adoption of electric vehicles increases, the demand for autonomous charging solutions, or autonomous charging devices (ACDs), is significantly growing. These systems utilize robotic arms with multiple segments connected by joints, providing flexibility to overcome the spatial complexity of EV charging. The goal of the robotic arms is to position and align charging connectors with EV charging ports, ensuring reliable connections without human intervention.

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

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

[0009] Robotic systems for EV charging can improve charging not only at public stations or for autonomous vehicles, but also at home. However, adapting these systems for home use requires balancing reliability with affordable accessibility. While automated home charging offers convenience and efficiency, being smaller and more cost-conscious, designing a cost-effective solution for a residential environment presents unique challenges.

[0010] Furthermore, the integration of robotic systems to facilitate electric vehicle (EV) charging holds significant potential for large fleets of industrial and transport vehicles. These fleets typically consist of vehicles with similar configurations and charging requirements, creating an ideal scenario for scaling up automated charging systems with standardized needs. Establishing a consistent robotic charging infrastructure becomes more achievable when vehicle fleets share similar charging port locations and connector designs.

[0011] It is desirable to develop a flexible and customizable autonomous charging solution that can function as a platform for implementation in different use cases. For example, some scenarios may require a high degree of automation with minimal human intervention, while others may require more manual control for specialized tasks. The ability to adjust the system's configuration and functions to meet these diverse needs can help improve its versatility and applicability across a wide range of applications.

[0012] It is desirable to provide a cost-effective autonomous charging system that can adapt to the inherent variables of the charging process without relying on sophisticated components. Ideally, such a system should be able to manage differences in EV positioning, charging port placement, and various connector designs. Furthermore, it is desirable to provide a system that can cope with real-time changes, including unexpected EV movement, shifts in environmental conditions, and the potential presence of interference.

[0013] The present invention aims to provide methods and systems that address many of the challenges described herein.

[0014] [Overview of the prefecture] In a first embodiment, a method for controlling a robotic system for autonomously charging an electric vehicle is disclosed, the method comprising: guiding a connector assembly toward a vehicle charging port by the operation of a robotic arm; enabling the robotic arm to transition from an unlocked state to a locked state before mating the connector with the charging port, in which case at least one arm segment is prevented from moving and in which case such movement is enabled; achieving mating of the connector with the charging port by moving the connector assembly while monitoring and analyzing such operation data and / or sensor data; and initiating corrective action when such correction is required.

[0015] According to one exemplary embodiment, the method includes comparing motion data and / or sensor data with at least one predetermined set of motion data and / or sensor data, and using the results of the comparison to determine whether corrective action is required.

[0016] According to one exemplary embodiment, the method includes enabling a robotic arm to transition between an unlocked state and a locked state when such motion data or sensor data are within a predetermined range.

[0017] According to one exemplary embodiment, the method includes taking at least one of the following actions to enable the system to complete mating of the connector with the charging port: i) transitioning the robot arm to the unlocking stage, ii) transitioning the robot arm to the locked stage, iii) repositioning the robot arm, or iv) acquiring new or updated motion data or sensor data, or v) retrying mating.

[0018] According to one exemplary embodiment, the method includes receiving sensor data associated with at least one of the following: the pose of the charging port, the pose of the connector assembly, the distance between the connector and the charging port, the physical or electrical connection between the electric vehicle connector and the charging port, the external force applied to the robotic arm, and the physical deflection of the system components, as well as / or motion data associated with at least one of the following: signals from the vehicle, commands from the operator, or signals from a remote system.

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

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

[0021] According to one exemplary embodiment, the method includes allowing the robot arm to undergo two or more transitions between a locked state and an unlocked state prior to mating.

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

[0023] According to one exemplary embodiment, the method includes enabling a transition of a robot arm between a retracted position and an extended position, wherein while in the retracted position, a connector assembly, and preferably a charging connector, is at least partially engaged by the connector housing, and while in the extended position, the connector or connector assembly is not engaged by the connector housing.

[0024] According to one exemplary embodiment, the method includes mating a connector with a charging port while the robot arm is locked by allowing the robot arm to temporarily apply a force stronger than the force applied while the robot arm is unlocked.

[0025] According to one exemplary embodiment, the method includes enabling the transition of the robot arm from a locked state to an unlocked state at any moment after the charging connector has mated with the charging port. This may be beneficial because it allows the system to adapt to any movement or adjustment made by an electric vehicle (EV) during the charging process, and reduces the need for a constant energy supply to keep the robot arm in the locked position.

[0026] According to one exemplary embodiment, the method includes enabling the robot arm to transition to a locked state prior to dismapping. This can facilitate such a dismapping step. Furthermore, once the connector is dismapping, the robot arm can transition back to an unlocked state. This transition to an unlocked state can serve several purposes as needed, including safely retracting the robot arm or preparing the robot arm to initiate another mating cycle.

[0027] According to the second embodiment, a system for autonomously charging an electric vehicle is disclosed, and the system comprises a base unit, a connector assembly supporting a connector for mating with a vehicle charging port, and a robotic arm disposed between the base unit and the connector assembly and provided with a plurality of arm segments. In particular, based on the received motion data and / or sensor data, before the connector is mated with the charging port, the robotic arm is configured to transition between an unlocked state and a locked state, wherein in the locked state, at least one arm segment is prevented from moving relative to the adjacent arm segment or the base unit, and in the unlocked state, such movement is enabled. Furthermore, the control system is configured to monitor and analyze such motion data and / or sensor data, and to initiate a corrective action if the analysis of the motion data and / or sensor data indicates that a corrective action is required to enable the system to complete the mating of the connector with the charging port.

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

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

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

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

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

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

[0034] In an exemplary embodiment, the robotic arm is configured to transition between a stowed position in which the connector assembly is at least partially engaged by the connector housing, and a deployed position in which the connector assembly is disengaged from the connector housing.

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

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

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

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

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

[0040] In an exemplary embodiment, the control system may selectively lock and unlock individual joint assemblies, and subsequently individual arm segments within the robot arm, to enable, for example, corrections to the position of the robot arm or connector assembly during a charging cycle. Operating in this manner, in certain situations where minor misalignment, shift, or external force is detected, the control system can trigger the locking and unlocking of individual joint assemblies to make small, localized corrections to the arm position or the orientation of the connector assembly.

[0041] In one exemplary embodiment, the control system may activate a lock mechanism in response to an input received from at least one sensor or in response to a predetermined command. In some cases, the control system may use sensors located within or communicating with the system to acquire sensor data or to acquire operating parameters, environmental conditions, or external factors. The control system is configured to process the sensor data and, upon identifying specific conditions or scenarios requiring a particular level of stability, accuracy, or safety, to trigger transitions from one stage to another as appropriate.

[0042] In one exemplary embodiment, the control system may be configured to trigger a short-term partial lock of the joint assembly to effectively reduce any momentum the robot arm may experience, particularly when the robot arm is rapidly rotating or undergoing sudden movement.

[0043] In an exemplary embodiment, the safety system may be integrated to provide an emergency shutdown function and / or to cut off the energy supply to the system or to any system components such as braking components. Activating such a safety system allows the robot arm to be quickly transitioned from a locked state to an unlocked state. [Brief explanation of the drawing]

[0044] [Figure 1] This is a schematic method according to one embodiment of the present invention. [Figure 2] This is a schematic system according to one embodiment of the present invention, including a base unit 20, a robot arm 40, a control system 60, and a connector assembly 30. [Figure 3] This is a schematic system according to one embodiment of the present invention, including a base unit 20, a robot arm 40, a connector housing 70, and a connector assembly. [Figure 4]This is a schematic system according to one embodiment of the present invention, comprising a base unit 20, a robot arm 40, a connector housing 70, and a connector assembly 30. The robot arm 40 is capable of being displaced vertically along the z-axis. [Figure 5a] This illustration depicts an example of the realization of this invention, with the robotic arm in its stowed position. [Figure 5b] This illustration depicts an example of the realization of this invention, with the robotic arm in its deployed position. [Figure 6] This is a schematic system according to one embodiment of the present invention, comprising a base unit 20 and a robot arm 40 having two arm segments 42, 44 coupled to the base unit 20. [Figure 7] This is a schematic system according to one embodiment of the present invention, including a connector changer 90. [Figure 8a] This diagram illustrates an example of this invention in which the system includes cable support means 110, 111. [Figure 8b] This shows an example of a system that includes a support arm 113. [Figure 9a] The diagram illustrates a system according to one embodiment of the present invention, including a base unit 20, a robot arm, a compliance assembly 100, a connector housing 70, and a connector assembly 30. [Figure 9b] The diagram illustrates a system according to one embodiment of the present invention, including a base unit 20, a robot arm, a compliance assembly 100, a connector housing 70, and a connector assembly 30. [Figure 10a] This diagram illustrates a system according to one embodiment of the present invention, including a base unit 20 and a robot arm 40 that can be displaced vertically along the z-axis. [Figure 10b] This diagram illustrates a system according to one embodiment of the present invention, including a base unit 20 and a robot arm 40 that can be displaced vertically along the z-axis. [Figure 11]The diagram illustrates a system according to one embodiment of the present invention, including a base unit 20 and a robot arm 40, wherein the base unit is capable of being displaced horizontally along the x-axis. [Figure 12] This is a schematic system according to one embodiment of the present invention, in which the robot arm 40 is in a stowed position and the connector assembly is engaged by the connector housing 70. [Figure 13a] This diagram shows an enlarged view of a connector housing according to several embodiments of this invention. [Figure 13b] This diagram shows an enlarged view of a connector housing according to several embodiments of this invention. [Figure 14a] An enlarged view of an arm segment according to several embodiments of this invention is shown. [Figure 14b] An enlarged view of an arm segment according to several embodiments of this invention is shown. [Figure 15a] This is a schematic representation of system 10 according to an embodiment of the present invention. [Figure 15b] This is a schematic representation of system 10 according to an embodiment of the present invention. [Modes for carrying out the invention]

[0045] [A brief description of prior art] Some existing systems have various shortcomings for certain applications. Therefore, there remains a need for further contributions in this field of technology.

[0046] WO2019219339A1 describes a charging robot for an automatic vehicle, a method, a device, and a computer-readable storage medium having instructions for controlling the charging robot. The charging robot has a robot structure formed of two or more structural elements and a plug receptacle for a charging plug. An automatic locking drive allows the plug receptacle to move relative to the charging plug socket of the automatic vehicle. A sensor system detects the force exerted on the plug receptacle or the charging plug. In response to the force exerted on the plug receptacle or the charging plug detected by the sensor system, a control device controls the charging robot. This document does not describe a system or method according to embodiments of the present invention, but instead focuses on a non-automatic locking design, so that the robot's drive is powered off after the plug is inserted into the vehicle and the charging robot is connected to the plug. Consequently, when the vehicle is lowered, the charging robot also lowers.

[0047] [Detailed description of the invention] The present invention will now be described more comprehensively below with reference to the accompanying drawings. The drawings show currently preferred embodiments of the invention. However, the invention may be embodied in many different ways and should not be construed as being limited to the embodiments specified herein. Rather, these embodiments are provided for thoroughness and comprehensiveness and fully convey the scope of the invention to those skilled in the art.

[0048] Figure 1 is a flowchart of a method for controlling an autonomous charging system for an electric vehicle according to this disclosure. Among the steps of the method is enabling the robotic arm to transition from an unlocked state to a locked state before mating the connector with the charging port, based on received motion data and / or sensor data. By transitioning to a locked state before connecting the charging connector to the charging port of the electric vehicle, the control system is enabled to maintain a predetermined arm configuration and prevent misalignment. Furthermore, locking the arm segments in place during deployment facilitates orientation for good connection and charging cycles and reduces the overall forces exerted by the system components. This transition from one stage to another can further enable the system to collect pose information of the charging port using camera sensors and thus move throughout the arm's working space. In the locked state, an actuator at the distal end of the arm can be activated for mating, aligning the charging connector with the vehicle's port, while the remaining joints and segments can be kept locked, reducing resistance and force during the mating process.

[0049] Figures 2 to 15 illustrate exemplary embodiments of a system 10 for autonomously charging an electric vehicle according to the present invention, the system 10 comprising a base unit 20, a connector assembly 30 configured to support an electric vehicle connector 31, a robotic arm 40 positioned between the base unit 20 and the connector assembly 30 and comprising a plurality of arm segments 41 and a plurality of joint assemblies 50, and a control system 60 configured to control the motion and positioning of the robotic arm 40, the connector assembly 30, and other components of the system.

[0050] Referring to Figure 2, the robot arm is preferably a multiple-joint controllable arm such that the connector assembly 30 enables the achievement of a desired position and orientation. Suitable robot arms include, but are not limited to, six-axis robot arm systems, horizontal articulated robot arm (SCARA: Selective Compliant Articulated Robot Arm) systems, parallel robot arms, orthogonal robot arms, delta robot arms, articulated robot arms, industrial robot arms, steward platforms, and hexagonal platforms, and the degrees of freedom of the connector assembly may depend on the kinematics of the robot arm, the number of arm links, the number and type of joint assemblies, and combinations thereof.

[0051] Referring to Figure 2, factors that may affect the degrees of freedom of the robot arm 40 and / or connector assembly 30 include combinations of the number of arm segments 41, the number and type of joint assemblies 50 incorporated into such arms, and their spatial arrangement. The arm segments may have any size and shape, but their shape typically depends on factors such as the expected degrees of freedom, use case, vehicle type, connector type, connector cable weight, load-bearing capacity, operability, alignment accuracy, and suitability for the charging environment of the electric vehicle.

[0052] Referring to any of Figures 2 through 15, the system comprises a base unit 20 generally configured to support other components of system 10, the other components including, among other things, at least one of a robot arm 40, a control system 60, a connector housing 70, and a connector cable 80. Figure 2 depicts a base unit 20 configured to directly or indirectly support a robot arm 40 and the movement associated with such a robot arm 40 and connector assembly 30. The base unit 20 may be mechanically structured to support the weight and movement of the robot arm. The base unit 20 may also advantageously include stabilization means configured to immobilize the base relative to the ground and at least partially support the weight of the base and the robot arm (not shown). For example, the base unit 20 may be coupled to a fixed structure such as a wall, floor, or ceiling. Alternatively, the base unit 20 may have a mass and geometric shape such that the base unit supports the robot arm 40 when the base unit 20 is freestanding. In some embodiments, the base unit 20 may further include a movable cart to bring motion to the system, for example, around a vehicle.

[0053] In addition to providing structural support, the base unit 20 can house various other system components, such as mechanical control devices, electrical control devices, or a combination of both. The base unit may also include a display screen (not shown) or other mechanism that can be used by an operator to view information regarding the operation of the system. Electrical or electromagnetic signals can be received from an external input device to control the movement of any component of the system via the control system.

[0054] In exemplary embodiments, such as those depicted in at least one of Figures 2 to 15, the system comprises a plurality of joint assemblies 50. Figure 2 illustrates that the joint assemblies 50 are positioned between adjacent arm segments 41, between an arm segment 41 and a base unit 20, or between an arm segment 41 and a connector assembly 30. The joint assemblies 50 include means configured to move between at least a first position and a second position, thereby adjusting the position of at least one arm segment 41 relative to the base unit 20, or the position of the connector assembly 30 relative to the base unit 20.

[0055] The robot arm may comprise a combination of joint assemblies, including but not limited to linear joint assemblies, rotary joint assemblies, or other suitable joint assemblies. Other suitable joint assemblies include revolute joints, linear joints, ball joints, cylindrical joints, planar joints, continuous joints, flexible joints, hinge joints, slider-crank joints, swivel joints, helical joints, ball joints, flexure joints, sliding contact joints, cam follower joints, and bearing joints. When used in combination, such joint assemblies enable the robot arm, and preferably the connector assembly, to achieve multiple degrees of freedom, facilitating the mating of the charging connector with the EV charging port. In this disclosure, the terms charging port, socket, charging inlet, or simply inlet may be used interchangeably.

[0056] The characteristics and configuration of a joint assembly may vary depending on the specific design and operating requirements of the system. Linear joint assemblies facilitate translational motion, allowing translation of an arm segment relative to another arm segment, connector assembly, base unit, or a combination thereof. Rotary joint assemblies facilitate rotational movement, facilitating the swivel or rotation of one or more robot arm segments relative to another arm segment, connector assembly, base unit, or a combination thereof.

[0057] As shown in Figure 2, the exemplary system 10 includes a connector assembly 30 configured to support an electric vehicle connector 31. The connector assembly 30 is configured to support the electric vehicle connector 31 in either a fixed or releasable manner. The connector assembly may include a release mechanism, which allows for controlled disengagement of the EV connector from such a connector assembly. Such controlled disengagement may allow for rapid release in the event of an operator-triggered event, such as an emergency situation.

[0058] The connector assembly 30 can be implemented as any suitable means of supporting the electric vehicle connector, such as a flange, receptacle, or interface structure, which may be fixed or movable. In a particular embodiment, the connector assembly comprises a flange assembly, which may be fixed or movable. The flange may be designed with a locking mechanism or a set of clamps to reliably hold the electric vehicle connector in place during the charging process. The flange assembly may be oriented vertically or horizontally, depending on the specific requirements of the charging station. The connector assembly may be configured as a receptacle interface with alignment guides, locking pins, or magnetic locks to ensure reliable support and connection between the connector assembly and the connector. In some cases, the connector assembly may utilize an interface structure incorporating geometric shapes, surfaces, or channels that interact with corresponding features on the electric vehicle connector. This implementation allows the connector assembly to support the connector and prevent disengagement during charging. The connector assembly may include a rapid release mechanism that enables rapid and controlled disengagement of the electric vehicle connector 31 from the connector assembly or from at least one section of the connector assembly. The rapid release mechanism can be activated manually or automatically and provides flexibility to disengage the connector in emergency situations or upon completion of the charging process.

[0059] Referring further to Figure 2, the system includes a compliance assembly 100 positioned between the robot arm and the connector assembly 30. This compliance assembly 100 enhances the system's functionality by compensating for unexpected movement during the charging process, thereby ensuring reliable and efficient charging of the electric vehicle. In this example, such a compliance assembly 100 acts as an intermediate component between the robot arm 40 and the connector assembly 30 and is designed to provide controlled flexibility and adaptability to the movement of the connector assembly, allowing the connector assembly to respond to unforeseen variations in the position and orientation of the electric vehicle's charging port.

[0060] A compliance assembly may comprise a compliant element selected from at least one of the following: a spherical mechanism with compliance (flexibility, conformability), a mechanical spring, a pneumatic element, a pneumatic actuator, a rubber / silicone element, a flexure, and a combination thereof.

[0061] The compliance assembly may be distributed throughout the system, between the base unit and the connector assembly. Preferably, the compliance device is configured to allow compliance in different degrees of freedom, such as i) translation along at least one of the X, Y, and Z axes, and ii) rotation around at least one of the X, Y, and Z axes. Such an implementation allows the connector assembly to adjust its orientation to match the angle of the charging port. The compliance assembly may incorporate a Stewart platform configuration with multiple pre-tension springs, such as linear springs. Such springs may be mechanically coupled to the connector assembly on one end and to the robot arm on the other end, thereby providing the connector assembly with controlled compliance in multiple directions. Each spring is mounted on both the robot arm and the connector assembly, forming a hexapod-like structure. Stewart platform configurations with linear springs can provide compliance in at least three degrees of freedom and up to six degrees of freedom, enabling compensation for unexpected movement in any direction, whether it be lateral shift, tilt, or rotation of the connector assembly. Such springs can be individually tensioned at various levels to modify their compliance characteristics and suit specific use cases. For example, in scenarios requiring precise compliance in either translation or rotation, the tension in the corresponding springs can be selectively adjusted. In some embodiments, the compliance assembly includes force sensors selected from at least one of piezoelectric sensors, strain gauges, or load cells, which are configured to provide feedback on compressive and tensile forces.

[0062] Referring further to Figure 2, the system further comprises a control system 60, a connector assembly 30, and a compliance assembly 100. The control system 60 is designed to autonomously manage and supervise various operations and functions involved in charging an electric vehicle (EV). The control system comprises a combination of hardware components, software algorithms, and other components that enable the control system to centrally monitor, analyze, and make decisions based on data received from various sources, including sensors, operating parameters, and external inputs. The control can communicate with external systems or operators as needed, exchange data, and provide status updates, thereby facilitating remote monitoring and management of the charging process.

[0063] Referring to Figure 3, a system is depicted comprising a base unit 20 arranged in a substantially horizontal manner and a plurality of arm segments 41 linked in series through a joint assembly 50. The system further comprises a control system 60 (not shown), a connector assembly 30, and a compliance assembly 100. The base unit 20 further comprises a connector housing 70 which defines a geometric volume for at least partially housing the connector assembly 30, preferably a connector charging interface 31.

[0064] Referring to Figure 4, a system is depicted comprising a substantially elongated base unit 20 arranged vertically and a series of arm segments 41, 42, and 43. The system comprises joint assemblies 50, 51, and 52. In this embodiment, the arm segments 42 and 43 are preferably connected through a linear joint assembly 51 that allows such segments to undergo linear displacement and through a rotary joint assembly 52 that allows pivotal movement. The joint assemblies 51 and 52 are positioned between the base and the arm segments 42 and allow substantially linear displacement of the arm segments 42 along the Z-axis, which can be achieved by various means, including manual or actuated displacement. The rotary joint assembly 52 allows pivoting of the arm segments 42 about the Y-axis. The rotary joint assembly 52 further allows pivoting of the base unit about the Z-axis. In each case, such rotations can be achieved by manual or actuated rotation.

[0065] Figures 5a and 5b show one embodiment of the system in which the robot arm 40 is in the retracted position 5a and the deployed position 5b, respectively. The rotary joint assembly 52 allows the base unit to rotate around the Z axis.

[0066] Referring to Figure 6, the system comprises a plurality of arm segments 41, 42, 43, 44, and 45, a rotary joint assembly 52 and a linear joint assembly 51 located between two arm segments 42, 43 and between arm segments 44, 45, and a linear joint assembly 51 that allows vertical displacement of the base unit 20 and the arm segments 42, 44. The rotary joints 52 between the base unit 20 and the arm segment 42, and between the base unit 20 and the arm segment 44, allow for further pivoting motion of such arm segments.

[0067] Figure 7 illustrates a connector exchange system 90, which includes a connector coupler 91, a connector changer 92, and a connector mounter 93. The connector mounter 93 can be supported by various means, including any type of support 94, or it may be mounted to an external support such as a wall, ceiling, or other suitable structure (not shown).

[0068] A robotic arm and / or connector assembly is designed to operate multiple electric vehicle connectors, facilitating the engagement, disengagement, and positioning of different EV connectors, for example, as depicted in Figure 7. To enable transitions between different EV connectors, the system incorporates a tool exchange system, referred to in this disclosure as a connector exchange system 90. In one embodiment, the connector exchange system 90 comprises three main components: a connector coupler 91, a connector changer 92, and a connector mounter 93.

[0069] The connector coupler 91 is equipped with means for coupling to the charging connector 31 and can be used with various types of charging connectors 31. The connector coupler 91 is designed to selectively and securely fasten to the connector changer 92, which can then be coupled to the connector assembly 30. Additionally, the connector coupler 91 can be mounted onto or removed from the mounter 93. The connector changer 92 is typically mounted on the distal end of the robot arm 40.

[0070] The connector changer 92 is designed to operate the connector coupler 91, which includes tasks such as mounting the coupler 91 onto or off the mounter 93, as needed.

[0071] On the other hand, the mounting device 93 is responsible for securing the couplers 91 and can preferably accommodate multiple connector couplers 91, each of which can be operated by the switcher based on specific charger requirements. In some embodiments (not shown), the mounting device 93 may be attached to a structure such as a wall, a frame, or a shelf. This implementation allows the system to switch between various EV connectors, enhancing the versatility of the system for simultaneously handling multiple EVs.

[0072] As shown in Figure 8a, the base unit 20 may include at least one charging cable mounting means 110, 111 configured to position the end of the charging cable 80 in a position that effectively cancels out any undesirable effects of the charging cable 80 on the movement of the robot arm 40, the movement of the connector assembly 30, or any step in the mating process, such as preventing the cable weight from hindering the movement of the robot arm.

[0073] Mounting means 110, 111 can be configured to position the end of the charging cable at a variable height and variable distance from the robot arm 40 or a portion thereof, and to adapt to different vehicle charging cables and connectors. The mounting means may include a swivel joint that connects itself to the base unit 20. Such a swivel joint facilitates rotational movement, allowing the mounting means 110, 111 to adapt to various charging scenarios and further reducing the influence of the cable's weight or stiffness on the motion of the robot arm or connector assembly. Such a swivel joint ensures that the charging connector 31 can be aligned with the port, regardless of the location or orientation of the charging port of the electric vehicle.

[0074] For example, as shown in Figure 8a, the charging cable 80a can be fully integrated into the robot arm 40. This integration effectively reduces the exposure of the external cable, deprives the cable of potential contact with the operator, and lowers associated safety risks. This implementation further eliminates the need for a liquid cooling system, which was traditionally required to dissipate heat generated during high-power charging. Instead, the robot arm itself acts as a protective barrier, preventing any direct external contact with the hot cable.

[0075] For example, as shown in Figure 8b, a support arm 113 is provided to support the charging cable 80 and to provide such a cable with a greater range of motion. The support arm 113 is mechanically coupled to the base unit 20 and is configured to pivot over a certain range of motion in order to position the charging cable 80 so that the connector 31 can be operated by a robotic arm while minimizing the impact of the weight of the charging cable 32. Preferably, the support arm 113 is coupled to the base unit 20 via a rotary joint 112. The support arm 113 allows the charging cable 80 to be kept in a raised, above-ground position, and protects the cable from the ground, contamination, abrasion / scratches, mud, snow, and ice, preventing the risk of pedestrians tripping, preventing vehicles from driving over the cable 80, and also protects the end connector / fitting from damage and contamination.

[0076] The support arm may be mechanically coupled to a fixed structure such as a wall, floor, or ceiling (not shown), or it may be coupled using similar coupling means such as a rotary joint. The support arm may have one or more joints, such as a rotary joint or a linear joint. In some embodiments, the support arm may be, among other things, an articulated arm, a nesting arm, or a rotary arm. The support arm 113 may further include cable attachment means 114, such as those shown in Figure 8b, which may be configured to rotate or translate along or around such a support arm 113. The support arm 113 may also include biasing means (not shown), such as a spring-loaded mechanism, which takes the support arm 113 into a desired position, such as a retracted or extended position. The biasing means is arranged to exert a force to retract the support arm 113 back to its retracted position when the support arm 113 is not actively holding or operating the charging cable 80. When the support arm 113 is extended or swiveled to position the charging cable 80 for use by the robot arm, the biasing means stores potential energy in the coil spring. Once the robot arm has completed its task and taken in the connector, the energy stored in the spring retracts the support arm back to the take-in position, effectively "winding up" the spring. This retraction minimizes the risk of the charging cable remaining dangling or causing obstruction when not actively in use.

[0077] As depicted in Figure 9a, the exemplary system comprises two arm segments 42 and 43, a rotary joint assembly 52 between such arm segments, and a rotary joint 52 assembly between the base unit 20 and the nearest arm segment 42, thus forming a SCARA-type arm. As depicted in Figure 9a, the exemplary system comprises, at the distal end of the robot arm, two arm segments 44 and 45, and a linear joint assembly 51 between such arm segments, which enables linear displacement of the most distant arm segment 45. Such an assembly, including the two arm segments 44, 45 and the linear joint assembly 51, may be referred to as the fitting section of the robot arm.

[0078] The mating section can be coupled to an adjacent arm segment and / or connector assembly via a linear joint assembly and / or rotary joint assembly, which can provide several degrees of freedom to the aforementioned connector assembly. Depending on the specific use case, such a joint assembly may be fixed (static), actuated, or manually adjustable, and may provide additional pitch, roll, and yaw functions to the connector assembly. In certain configurations, the mating section may be positioned at a pitch angle greater than zero, facilitating the connector assembly to achieve greater vertical displacement along the z-axis. This implementation combines the vertical displacement along the z-axis with the displacement along the x-axis resulting from the movement of the SCARA. This implementation allows the system to compensate for any constraints on the vertical displacement along the z-axis originating from either the base unit or the robot arm.

[0079] Referring to Figures 9a and 9b, an exemplary system is depicted comprising a base unit 20 and a plurality of arm segments 42, 43, 44, 45, 46 linked through joint assemblies 50, 51, 54, forming a SCARA-type robotic arm. The system according to this embodiment further comprises a connector housing 70. The system further comprises a connector assembly 30 and a compliance assembly 100. Figure 9b illustrates the degrees of freedom that the connector assembly 30 can achieve in this configuration. Referring to Figure 9a, the system comprises a rotary joint 52 and a linear joint 51 between the connector assembly 30 and the arm segments 44. In such an embodiment, a combination of different joint assemblies may allow the connector assembly 30 to move with at least 6 degrees of freedom, as depicted in Figure 9b.

[0080] Referring to Figure 10a, a system is depicted comprising a base unit 20 and several arm segments 42, 43, 44, 45, 46, and 47 linked through joint assemblies 50, 51, and 52. The linear joint assembly 51 between the base 20 and the arm segments 42 accommodates the vertical displacement of the robot arm 40 and thus additional degrees of freedom for the motion of the connector assembly 30, as shown in Figure 10b.

[0081] Referring to Figure 11, a system is depicted comprising a base unit 20 supported on a base 21. A linear displacement means 51 enables linear displacement of the base unit 20.

[0082] As depicted in Figure 11, the exemplary robotic arm comprises a shoulder joint assembly 50a, an elbow joint assembly 50b, and a wrist joint assembly 50c. The connector assembly 30 is mechanically coupled to the distal side of the wrist joint assembly 50c.

[0083] A joint assembly may be designed to be fixed or static, acting as a structural connector between two arm segments, between a base and an arm segment, or between a robot arm and a connector assembly, and not allowing movement or articulation between them. Such a static joint assembly may be any linear or rotary joint that is fixed or static by its configuration, or any joint assembly that is static or fixed by its design.

[0084] A joint assembly can be actuated via either active or passive means. Active actuation as used herein involves the intentional application of an external force or energy to initiate or control the motion of the joint assembly. The actuating members include, among other preferred means, electromagnetic actuations, motor-driven actuations (electric motors, stepping motors, or other motor-driven components that actively drive and control the joint assembly), piezoelectric actuations, solenoid actuations (implementation of a solenoid that exerts magnetic force for actuation purposes), hydraulic actuations, and pneumatic actuations.

[0085] Passive action refers to the intrinsic response of a joint assembly to environmental or intrinsic factors such as mechanical forces or temperature gradients, resulting in motion without the explicit application of external forces.

[0086] The actuator member may be any suitable means of operation for driving the aforementioned joint component, preferably an electrically driven device such as a stepping motor, servo motor, hydraulic motor, pneumatic motor, or a combination thereof.

[0087] Referring to Figure 12, the robot arm 40 is in the stowed position, thereby the connector assembly 30 is at least partially engaged by the connector housing 70.

[0088] Figures 13a and 13b illustrate an embodiment of a connector housing including an external enclosure 70a, an internal enclosure 70b, and a power contact compartment 70c. Figure 13b illustrates a section of a connector assembly 30 according to an embodiment of the present invention. The connector assembly supports a charging connector 34.

[0089] As shown in Figures 13a and 13b, the connector housing 70 may comprise at least one of an outer enclosure 70a, an inner enclosure 70b, and a power contact compartment 70c, as shown in Figure 13a. The functions of the inner enclosure include ensuring electrical insulation, ensuring mechanical strength, and / or preventing contamination by water and sludge. The inner enclosure 70b may include protective materials such as soft epoxy and / or silicone-based materials. Such an implementation allows the connector housing to protect the connector assembly when the system is not in operation. Preferably, the inner enclosure 70b allows the connector assembly 30 and / or connector 31 to remain effectively sealed from the ingress of water and dust (preferably in IP rating 24, IP rating 44, or other suitable rating) while the robot arm 40 is in the stowed position.

[0090] The connector housing 70 may be attached to a plate or any similar component coupled to the base unit 20, and the plate or component may be opened or closed via a hinged door assembly or a folding door assembly, depending on the specific design requirements. In this configuration, the plate of the connector housing is attached to the base unit or arm segment and is designed to pivot or fold around a predetermined axis. When the robot arm 40 is in a stowed position or not in use, such a plate can be closed, sealing the connector assembly 30 within the housing 70. In some modifications of this embodiment, the connector assembly 30 can be used to engage in the opening or closing of the plate of the connector housing. As the robot arm moves forward or backward, this movement can trigger the automatic opening or closing of the plate.

[0091] Referring to Figure 14a, the base unit 20, two arm segments 41, and joint assembly 50 are depicted. Figure 14b depicts the joint member 55, actuator member 54, transmission member 56, and braking component 57. The motor section is positioned on the arm segment, and the joint section is connected to the motor section via the transmission assembly.

[0092] Referring to Figure 14b, an enlarged view of an exemplary arm segment 41 and joint assembly 50 is shown. Figure 14b depicts a joint member 55, an actuator member 54, a transmission member 56, and a braking member 57. In this example, the joint member 55 is a rotary joint that allows rotational movement between two adjacent arm segments 41, or between the base unit 20 and an adjacent arm segment, as depicted in Figure 14a. The joint member 55 provides a pivot connection. In this example, the actuator member 54 is mounted on each arm segment and is therefore configured to transmit rotational force to drive the movement of the joint and, preferably, to provide control over the rotational motion of the robot arm. The actuator member is controlled by a control system. The transmission member 56 enables the transmission of torque generated by the actuator 54 to the joint member 55. Depending on the specific design requirements, the transmission member 56 may incorporate various components such as gears, pulleys, belts, or other mechanical elements. The braking member 57 is designed to immobilize or restrict the movement of the joint member 55, thereby restricting the movement of the corresponding arm segment arm relative to any adjacent arm segment or base unit. The braking member 57 can be any type of brake, such as an electromagnetic brake, a spring-loaded brake, or any other type of suitable braking mechanism.

[0093] The braking member 57 may be any suitable braking component that enables the prevention of movement of a joint assembly, arm segment, connector assembly, or any combination thereof, relative to another movable or immovable component of the system, such as a base. The braking member may be at least one of a joint braking type, a motor braking type, or a combination thereof. The braking member may be selected from any one of an electromagnetic brake, a friction brake, a hydraulic brake, a spring-loaded brake, or a combination thereof. A joint assembly, such as those used herein, is locked when the movement of such a joint assembly is restricted, either partially or entirely.

[0094] The robot arm is configured to transition from a locked state to an unlocked state, and vice versa. The lock prevents movement of components, such as movement of adjacent arm segments relative to each other, or movement of arm segments relative to the base unit, or movement of connector assemblies relative to arm segments or the base unit. The lock is achieved by locking one or more joint assemblies that connect such components.

[0095] One or more joint assemblies can be locked and unlocked selectively and independently of other joint assemblies. Alternatively, all joint assemblies in the system can be locked and unlocked simultaneously.

[0096] The joint assembly preferably comprises a locking mechanism in which joint members connecting adjacent arm segments of a robot arm are locked, preferably via a braking member such as an electromechanical brake. In some embodiments, the robot arm comprises a plurality of joint assemblies, such as rotary joint assemblies and linear joint assemblies. In some embodiments, at least two of the plurality of joint assemblies are locked simultaneously. Optionally, all joint assemblies are locked simultaneously. In some embodiments, the locking of the joint assemblies is performed locally at such joints, for example, by mechanical and / or electromechanical components physically positioned at the joint.

[0097] In certain embodiments, the braking member is configured as an electromagnetic brake, which controls motion using the principles of electromagnetism. An electromagnetic brake generally comprises a stationary housing and an electromagnetic coil. The stationary housing is attached to the arm structure and positioned in close proximity to a movable part, such as a joint member, that requires control. When current is applied to the coil, the coil generates a magnetic field. This magnetic field interacts with the joint member to generate either an attractive or repulsive force, restricting the movement of the joint. When the electromagnetic brake is activated, current is supplied to the electromagnetic coil, energizing it and generating a magnetic field. This field interacts with the movable part, allowing the arm segment or joint to remain in a fixed position. When the electromagnetic brake is stopped, the current to the electromagnetic coil is cut off, stopping the generation of its magnetic field. In the absence of electromagnetic force, the brake releases its grip on the movable part, allowing the arm segment or joint to move freely as directed by the control system. This allows the robotic arm to transition between locked and unlocked states, and vice versa, throughout the entire cycle.

[0098] As depicted in Figures 3, 9a, and 12a, at least one of the base unit 20 and the arm segment 41 comprises a connector housing 70, which defines a geometric volume for at least partially housing a connector assembly 30, preferably a connector charging interface 31. The connector housing 70 may have a box-like structure, but preferably it can have any geometric shape that allows for housing, or at least partial housing or support, of the connector charging interface when the robot arm is in the stowed position, as shown in Figure 12. The connector housing 70 may comprise one or more openings and a plate or any suitable structure on which a connector assembly can be placed and mounted. The connector housing 70 may be fixed (i.e., mounted) to the base unit or may be displaceable to accommodate different types, sizes, and positions of the connector assembly.

[0099] Referring to Figures 5a and 12, “storage position” refers to the state of the robot arm when it is not actively engaged in a charging cycle or any operational task. This is a configuration in which the robot arm is in a retracted or tucked position and is typically positioned securely and compactly. In the storage position, the robot arm is fully stowed when not in use and generally awaits deployment for charging, maintenance, or other tasks. In this position, the arm is preferably held securely to prevent unintended movement. This ensures that the robot arm remains securely held in place, preventing any unintended movement that could potentially lead to damage or misalignment, and optimizing the use of available space to ensure that the arm does not unnecessarily protrude when not in use. Preferably, in the storage position, and, referring to Figure 12 for example, the connector housing 70 is configured to at least partially house the connector assembly 30, preferably the connector charging interface.

[0100] In the stowed position, the robotic arm can be held in this position by any mechanism suitable for maintaining the arm in this configuration, such as a pin, latch, or magnetic fastener, which is either actuated or passive. This allows the arm to transition to the unlocked position while remaining stationary, thereby preventing any accidental movement.

[0101] Referring to Figure 12, it is preferable that, in the retracted position, the arm segments are positioned substantially parallel to each other, enabling a particularly compact configuration. Such an arrangement can be achieved, for example, by mounting the actuator member 54, joint member 55, and braking member 57 in a manner that optimizes the distribution of weight and usable space within the robot arm, as shown in Figures 14a and 14b. Such a configuration allows for the construction of compact and short arm segments when retracted, while simultaneously enabling the arm to present a significant reach when extended. This arrangement of joint assembly members significantly contributes to the system's ability to adapt to constrained spaces and reach distant targets while maintaining structural integrity.

[0102] In the context of the embodiments described, “Deployed position” refers to a state in which the robot arm is actively engaged in a charging cycle or any other operational activity, particularly as depicted in, for example, Figures 2, 3, 4, 5b, and 9a. The deployed position encompasses situations in which the robot arm is initiated for a charging cycle and moving toward the charging port of an electric vehicle, or engaging in specific tasks such as connecting or disconnecting a charging connector. In the deployed position, the robot arm is primarily actively performing its intended function, which may involve joint movement, rotation, translation, or other movements necessary for its operation. The term “Deployed position” does not refer to a single, fixed, static position, but rather encompasses a variety of possible positions and orientations that the robot arm may take during various operational scenarios. Preferably, the deployed position includes multiple deployed positions. These variations of the deployed position are characterized by different degrees of extension, rotation, and joint movement, depending on the specific task and requirements at hand.

[0103] The system preferably comprises or communicates with at least one sensor means configured to generate sensor data. The sensor includes, but is not limited to, camera sensors, force sensors, optical sensors, proximity sensors, lidar sensors, ultrasonic sensors, infrared sensors, and magnetic sensors.

[0104] Sensor data may be parameters associated with system components or the environment in which the system operates. Sensor data may include, among other things, at least one of the following: vehicle pose, vehicle charging port pose, distance between connector and charging port, physical or electrical connection between electric vehicle connector and charging port, external force applied to robot arm, and physical deflection of system components. Sensor data may include vehicle or vehicle inlet pose relative to any part of the system. Sensor data may include temperature data indicating the thermal conditions of charging components, voltage and current data reflecting the electrical characteristics of the charging process, battery charge state (SoC) information, environmental data such as ambient temperature, humidity, or air quality, safety interlock status indicating whether safety mechanisms are activated, component wear data, time and timestamp data, communication signal strength, error code or fault data, alignment or calibration data, and combinations thereof.

[0105] The camera sensor may be coupled to a base unit, a robotic arm, or a connector assembly, enabling the sensor to acquire pose information within and around the autonomous charging system of an electric vehicle. Such a camera sensor is positioned to capture pose data, including the positioning of system components and the immediate surroundings of the charging station. Preferably, the camera sensor is directed to collect pose information relating to the electric vehicle and the vehicle's charging port.

[0106] As used herein, the pose of an object describes how the object is positioned within the three-dimensional space in which it is operating. The pose of an object can be determined relative to a viewpoint, such as a camera viewpoint or camera coordinate system. The pose of an electric vehicle charging port can be understood as the position and orientation of the vehicle's charging port, and in some embodiments, is represented by the 3D orthogonal position and yaw (x,y,θ) of the socket. In some embodiments, the pose is a 6D pose, where the position is defined by the 3D Euclidean distance and the orientation is defined by the roll, pitch, and yaw of the socket. Determining the pose of an electric vehicle inlet is useful in describing the pose and orientation of the charging port relative to the camera position of the ACD in order to orient the EV connector, supported by the connector assembly, toward the charging port and complete the mating process.

[0107] The pose of a vehicle charging port may be obtained from a single image, from multiple images possibly from the same pose, from multiple images possibly from different poses, or from using the earliest determined pose. Alternatively or additionally, the pose of an object may be obtained from a multiview image or video. In some embodiments of this disclosure, socket pose determination may be performed by a neural network on which a computer vision unit is based.

[0108] Preferably, a neural network can be trained to determine the pose through the analysis of one or more images. The estimated socket pose may include, among other things, estimates of the socket's dominant axis, roll, elevation angle, angular position, orientation, and azimuth angle. Alternatively, the neural network may be trained to detect the socket's geometric features, which may function as fiducial markers, and based on these fiducial markers, a pose estimation algorithm may determine the socket's pose relative to the camera.

[0109] In addition to determining the pose of the charging port of an electric vehicle, the neural network can provide information about the distance between the connector assembly and the charging port, or between the charger connector and the charging port. Preferably, the neural network is trained to analyze one or more images captured by cameras placed in the system, as outlined in a previous embodiment. By examining these images and utilizing its trained algorithm, the neural network can estimate the spatial separation between the connector assembly and the charging port in real time.

[0110] Proximity sensors may be mounted, coupled, and / or attached to or on the base unit, robot arm, or connector assembly. The proximity sensors can be positioned to provide proximity data encompassing not only the spatial relationships of system components but also the immediate vicinity surrounding the charging system. Preferably, the proximity sensors can be configured to monitor the presence of objects, people, or potential disturbances in the vicinity of the system and generate such proximity sensor data. This data not only assists the mating cycle but also enhances situational awareness, enabling the mating cycle to respond effectively to dynamic conditions.

[0111] Force sensors may be mounted, coupled, and / or attached to or on the base unit, robot arm, or connector assembly. Such forces may include those arising from contact with an object or surface, resistance encountered during movement, or unforeseen disturbances. The output generated by the external force sensor is preferably used as input for a control system, which enables the autonomous charging system to react immediately to deviations from the intended trajectory, prevent collisions, and ensure the completion of the charging process. Force information may be obtained through the implementation of force / torque sensors connected to any component of the system, such as the robot arm, connector assembly, or vehicle connector. Preferably, the control system may use the data from this sensor in conjunction with other sensory inputs to adapt the movement of the robot arm and initiate corrective actions as necessary.

[0112] Computer vision systems can use neural networks and camera sensor feedback to obtain information associated with physical deflection in any system component, including robot arms, connector assemblies, compliance assemblies, and any of their subcomponents. Such deflection can serve as an indicator of external forces acting on any of these components. In some embodiments, the control system is configured to initiate corrective action to address external forces or disturbances when it detects significant physical deflection exceeding a predetermined threshold.

[0113] The system may further include means such as communication means for receiving operational data. Such operational data may also include instructions based on system algorithms. The operational data may be associated with at least one of the following: signals from the vehicle, instructions from the operator, or signals from a remote system. In particular, i) signals from an electric vehicle may include information about the vehicle's battery status, the location of the charging port, the charging status, and any specific requirements or preferences regarding the charging process; ii) instructions provided by the system operator or user may include specifying charging parameters, overriding the automated process, or requesting special measures related to the charging cycle; and iii) the system may interact with remote systems such as a central charging station management system or a grid management system. Operational data received from these remote systems may include grid demand information, fare rates, and scheduling priorities, enabling the autonomous charging system to make informed decisions.

[0114] The system may preferably include a charging port cover handling device using any suitable means, such as a gripper mechanism, which can be selected from a variety of gripper types, including but not limited to parallel jaw grippers, vacuum grippers, finger grippers, magnetic grippers, or combinations thereof. Depending on the gripper type and the configuration of the charging port and EV, the device may use mechanical jaws, suction, or flexible fingers to grip and operate the charging port cover. Preferably, the charging port cover handling device is configured to apply a controlled force to open or close the cover, exposing the charging port. The suction cup of the gripper may be positioned above the charging port cover so that the gripper creates a vacuum seal, effectively holding the cover while allowing operation of such cover, i.e., opening and closing.

[0115] The charging port cover handling device may communicate with a control system configured to receive operational and / or sensor data. When the control system receives a communication from the EV indicating that it is ready to handle the cover, it initiates a sequence for opening or closing the cover. If a camera sensor detects data regarding the charging port's pose, the control system may calculate the optimal motion path to guide the gripper mechanism in motion to complete the initiation of opening or closing the cover.

[0116] The control system is adapted to respond to unexpected or undesirable events during the cover handling process. Such events encompass a variety of anomalies, including, but not limited to, instances in which the charging port cover is found to be locked, improperly unlocked, or otherwise obstructed. The control system is configured to recognize deviations from the cover handling process by acquiring updated input from at least one sensor. Preferably, data acquired from a camera sensor is relayed to the control system, which then uses this information to determine whether the charging port cover is locked, improperly unlocked, or otherwise obstructed. The control system may initiate corrective actions associated with the specific characteristics of the event. For example, if the charging port cover is detected as locked, the control system may initiate communication with the EV to request appropriate cover unlocking. Similarly, if it is found that the cover is obstructed or improperly unlocked, the control system may correct the situation, such as activating an appropriate mechanism and generating a signal to the operator requesting further correction, as well as facilitating the opening or closing of the cover. Likewise, in case the position of the charging port cover has shifted throughout the handling process, the control system may acquire and reacquire information from at least one of the EV, camera sensors, or position sensors to reconfigure instructions for handling the cover.

[0117] According to a first embodiment of the present invention, a method for controlling an autonomous charging system for an electric vehicle includes, based on received motion data and / or sensor data, enabling a robotic arm to transition from an unlocked state to a locked state before mating a connector with a charging port, wherein in the locked state, at least one arm segment is prevented from moving relative to an adjacent arm segment or to a base unit, and in the unlocked state, such movement is permitted.

[0118] The robot arm is configured to transition between an unlocked state and a locked state based on received motion data and / or sensor data before mating the connector with the charging port. The term "before mating the connector with the charging port" encompasses any moment preceding the actual mating, and does not need to be immediately preceding the mating. Various intermediate steps may occur in between, such as potential repositioning measures to acquire new data. The term "based on received motion data and / or sensor data" indicates that the control system evaluates whether the acquired data is consistent with predetermined criteria and thresholds that should allow the mating operation. When the received data satisfies the predetermined parameters and indicates that the conditions are suitable for a reliable mating process, the control system can enable or instruct the robot arm to transition to the locked state. Conversely, if the received data indicates any deviation or condition that does not meet the predetermined criteria for mating, the control system can maintain the robot arm in the "unlocked" state. In this state, the system remains adaptable to make necessary adjustments in response to changes or variations detected in the environment.

[0119] The control system is configured to monitor and / or analyze such operational and / or sensor data. In this context, “monitoring” includes observing and collecting data from various sources, including sensor parameters and operational parameters, throughout the entire autonomous charging process. Analysis refers to examining and interpreting this collected data, which includes activities such as comparing the data with predetermined thresholds and parameters.

[0120] Autonomous charging systems generally go through a charging cycle that involves several steps. The charging cycle is as follows: i. A step of guiding the connector assembly toward the vehicle charging port, ii. The step of mating the charging connector with the vehicle charging port, This includes, but is not limited to, the following:

[0121] Guiding a connector assembly toward a vehicle charging port involves the controlled operation of a robotic arm supporting such a connector assembly. Guiding typically involves using sensor data and / or motion data, algorithms, and control commands to ensure that the connector assembly approaches the vehicle charging port precisely.

[0122] Mating the charging connector with the vehicle's charging port involves making a physical connection between the charging connector and the charging inlet on the electric vehicle.

[0123] The charging cycle may include at least one of the following: repositioning the robotic arm as needed to optimize alignment; acquiring sensor or motion data for precise positioning; initiating the charging process; monitoring and adjusting charging parameters; completing the charging process; and unmating the charging connector from the vehicle charging port. The charging cycle may also include intermittently pausing or interrupting the cycle for safety and system optimization, and establishing communication with the EV or an external remote system for data exchange and coordination. The charging cycle may include any other necessary steps that enable the autonomous charging system to reliably and autonomously charge an electric vehicle (EV).

[0124] Throughout every step of the charging cycle, the control system can perform the transition of the robot arm from unlocked to locked, and vice versa, as many times as required, depending on the case and the specific stage of the charging cycle.

[0125] The sequence of these steps can be adjusted, or some steps can be repeated depending on the specific circumstances. Throughout all steps of the charging cycle, the control system is configured to monitor and analyze such operational data and / or sensor data.

[0126] The method includes initiating corrective action when analysis of operational data and / or sensor data indicates that corrective action is required to enable the system to complete mating of the connector with the charging port. Such corrective action may be required in multiple instances where the operational data and / or sensor data exhibits deviations exceeding or outside predetermined thresholds or ranges, or where specific predetermined conditions are met or not met, and such predetermined thresholds or ranges are predetermined to enable the system to complete mating of the connector with the charging port.

[0127] The term “initiate” encompasses a wide range of actions, including directing, continuing, pausing, interrupting, or starting any relevant actions as determined by the analysis of operational and / or sensor data. The term “complete mating” extends beyond the mere physical connection of the charging connector and the charging port. The term encompasses all essential procedures, including but not limited to the steps that facilitate proper connection, charging, and disconnection, enabling the autonomous charging system to efficiently charge electric vehicles (EVs).

[0128] Other corrective measures may include, among other things, restarting a new charging cycle, adjusting the mating angle or orientation of the charging connector, initiating a self-diagnostic check to identify any system abnormalities, activating an emergency stop to pause the mating process in the event of a critical issue or when triggered by the operator or a remote system, and notifying an external control system or operator to request manual intervention.

[0129] At any stage of the charging / mating cycle, the control system may, in response to receiving information from one or more sensors that detect sensor information outside a predetermined threshold, output a control command to transition the robot arm from a locked state to an unlocked state, and vice versa.

[0130] Enabling transitions of the robot arm from locked to unlocked and vice versa allows the system to determine the pose of the charging port or charging port cover and make necessary adjustments. This can be advantageous when a camera sensor is mechanically coupled to the robot arm and when the pose of the charging port or charging port cover needs to be determined from different positions. This is even more advantageous when the camera sensor is not mechanically coupled to the robot arm, and rather, when the moving parts of the robot arm obstruct the camera view for pose determination, which would require the repositioning of such moving parts. Similarly, if sensor data indicates a change in the position of the charging port after initial alignment or initial pose determination, or if the pose of the charging port is outside the confidence level, or if the pose of the charging port or charging port cover cannot be determined using the current input from the camera sensor, the control system may transition the robot arm to the unlocked state, allowing the system to collect new pose estimation data, guide and / or align the connector assembly based on such new data, and transition the arm to the locked state to initiate or continue such mating. The control system may allow the robot arm to transition from an unlocked state to a locked state when such pose data is within a predetermined threshold for mating, and such pose data is at least one of the poses of the charging port and the connector assembly. Similarly, the control system may allow the robot arm to transition from an unlocked state to a locked state when the connector assembly is within a predetermined position range for mating. This range may include a specific distance threshold, such as within 1 to 10 millimeters, to ensure very close proximity. An angular alignment within a certain tolerance (e.g., 5 degrees) may be required for proper insertion.

[0131] If sensor data indicates that the distance between the connector assembly and the vehicle charging port exceeds a predetermined threshold or falls below a predetermined confidence level at any step of the mating / charging cycle, the control system may initiate specific corrective actions to optimize the mating process. Such actions may include, but are not limited to, transitioning the robotic arm to an unlocked state to allow the robotic arm to adjust its position and orientation; repositioning the robotic arm to bring the connector assembly closer to the vehicle charging port, thereby reducing the detected distance; initiating a data refresh operation to acquire new sensor data, which may include updated distance measurements; or retrying the mating process by guiding the connector assembly toward the vehicle charging port using parameters adjusted to seek improved alignment.

[0132] If sensor data indicates a physical or electrical connection between the electric vehicle connector and the vehicle inlet / charging port during the mating process, the control system is configured to detect and evaluate such connection. If the sensor data indicates a problem or anomaly in the connection, the control system initiates specific corrective actions to optimize the mating process, such as those described herein. For example, once such an electrical connection is detected, the control system may allow the robotic arm to transition to a locked state to complete the mating.

[0133] The control system is configured to monitor parameters such as any forces acting on the robot arm, connector assembly, or any other component of the system. If any of these parameters exceeds a predetermined range or falls outside a confidence level, the control system can be configured to transition the robot arm from a locked state to an unlocked state, or vice versa. For example, while the robot arm is locked, the control system monitors the forces acting on the connector assembly to ensure that the forces remain within a predetermined range and confidence level. If a significant deviation exists in this force parameter, indicating a potential for excessive stress or misalignment, the control system may initiate a transition to an unlocked state to facilitate repositioning of the robot arm or to acquire new sensor data. Once the control system has acquired data indicating that the forces acting on the connector assembly are within a predetermined range, it can resume guiding the connector assembly toward the charging port, and subsequently, once sensor data or motion data indicates that the connector assembly is within a predetermined range, it can resume transitioning the arm to a locked state. In some cases, such a predetermined range depends on the position of the connector relative to the charging port.

[0134] The control system may enable transitions of the robot arm from a locked state to an unlocked state, and vice versa, based on specific input parameters related to socket pose estimation. When the robot arm remains locked, such as when connector mating is occurring, the control system continuously monitors the pose estimation data to ensure that the parameters remain within predetermined confidence levels and thresholds. In the event of a significant parameter deviation, where potential inaccuracies are apparent in the pose estimation, the control system may acquire new pose data, briefly reposition the arm to acquire new data, or transition the arm to an unlocked state, in order to enable repositioning and / or acquisition of new sensor data from the new position. This transition enables repositioning of the robot arm while triggering the acquisition of pose estimation data. Once the control system has verified that the pose estimation data is within a predetermined confidence interval, it can resume guiding or mating the connector.

[0135] If operational data associated with any step of the charging cycle is received, the control system may evaluate this operational data and respond appropriately to enable the system to complete mating of the connector with the charging port. This includes, but is not limited to, scenarios related to operational data from the vehicle, such as receiving data indicating a change in vehicle state, such as turning the power supply on or off, which may require adjustments to the charging cycle to accommodate the vehicle's power requirements and safety considerations; receiving data related to the vehicle's battery status, charge level, or charging preference, enabling the control system to adapt the charging cycle to meet the vehicle's specific needs; receiving data indicating vehicle movement, such as repositioning or shifting, to take corrective action to achieve a proper connection between the connector assembly and the vehicle inlet / charging port; monitoring signals for emergency situations or safety concerns and, if necessary, triggering a transition of the robot arm to an unlocked state or initiating an emergency shutdown procedure to ensure the safety of the charging process, or a combination thereof.

[0136] At any stage of the charging / mating cycle, the control system may receive a socket pause parameter and transition the robot arm from the unlocked state to the locked state if the socket pause parameter is within a predetermined acceptable range for mating. In some cases, the control system is configured to receive a socket pause parameter and transition the robot arm from the locked state to the unlocked state if the socket pause parameter is not within a predetermined acceptable range for mating.

[0137] The predetermined acceptable range or threshold for the socket pose parameter can be adjusted for each case scenario and may include, for example, ranges for the X, Y, and Z coordinates, thresholds for the pitch angle, yaw angle, and roll angle, and distance thresholds. Therefore, if the socket pose parameter indicates that the connector is within an acceptable distance range, the control system can lock the arm in search of mating.

[0138] In the context of the embodiments described, during the locked state, the control system is configured to prevent at least one arm segment from undergoing at least one of the following actions relative to any other non-movable system component or to a fixed world, either directly or indirectly through the activation of system components: joint movement, rotation, translation, actuation, displacement, or a combination thereof. In the locked state, as previously described, the control system is configured to limit the range of motion and functionality of the robot arm.

[0139] This limitation can occur in both the retracted and deployed positions, but is primarily advantageous and preferable when the device is in the deployed position.

[0140] In certain scenarios, such as when a robotic arm is being retracted, it may be beneficial to apply limited restrictions to arm movement. For example, when an arm is being retracted to its retracted position, the control system can impose certain restrictions on joint movement, rotation, translation, actuation, or displacement to ensure a safe and controlled retraction process and position. Such an implementation allows the robotic arm to transition to a locked state while in the retracted position, thus preventing any further movement of the arm and protecting it from unauthorized access, tampering, or vandalism.

[0141] Preferably, while in the stowed position, and, referring to, for example, Figure 12, the connector housing is configured to at least partially house the connector assembly 30, preferably the connector charging interface. By allowing such engagement, undesirable arm movement can be restricted without necessarily placing the robot arm in a locked state.

[0142] The advantages of the locked state are realized during the robot arm's movement in the deployed position. In this context, the control system is configured to more significantly restrict at least one arm segment from undergoing joint movement, rotation, translation, actuation, displacement, or a combination thereof. This restriction is particularly valuable during mating cycles where precision and stability are desired. Specifically, by transitioning to a locked state prior to mating the charging connector with the charging port, and thus restricting the arm's movement while in the deployed position, the control system can ensure that the arm remains in a predetermined configuration. Such a locked phase can prevent any unintended shifts or adjustments that could lead to misalignment with the charging port of an electric vehicle.

[0143] Furthermore, locking the arm segments in place while they are in the deployed position ensures that the arm maintains the desired orientation and position for controlled mating and charging. In some cases, once mating is complete, the arm segments transition to an unlocked state. Moreover, activating the locked state allows for a reduction in the overall force exerted by the system components to complete the mating process. In particular, when the robot arm is in the locked position, the actuator at the distal end of the robot arm can be primarily activated for the mating step. Thus, during the mating or unmating phase, the control system can selectively activate the actuator located at the distal end of the robot arm. Such actuators are responsible for the final alignment and mating of the charging connector with the charging port of the electric vehicle. In parallel, the control system can control keeping the remaining joints and segments of the arm locked, preventing any unintended movement or joint motion. Such selective locking significantly reduces any potential resistance or force required during the mating process.

[0144] Terms such as "configured to" include components in various states unless otherwise specified. Conditional terms ("can," "may," etc.) suggest that one embodiment may include a particular feature while another embodiment may not include that feature. Words such as "comprising" and "or" are inclusive and allow for additional elements or options. The term "allow" deals with measures such as permission and authorization. Method steps do not need to follow a specific order to achieve the desired result.

Claims

1. A method for controlling an autonomous charging system for an electric vehicle, comprising: a connector assembly supporting a connector for mating with a vehicle charging port; a base unit; a robotic arm having a plurality of arm segments; and a control system configured to receive motion data and / or sensor data; - The robot arm is used to guide the connector assembly toward the vehicle charging port, - To enable the robot arm to transition from an unlocked state to a locked state before the connector is mated with the charging port, based on the received motion data and / or sensor data, wherein in the locked state, at least one arm segment is prevented from moving relative to an adjacent arm segment or the base unit, and in the unlocked state, such movement is enabled, thereby enabling the transition. - By moving the connector assembly while monitoring and analyzing such operation data or sensor data, the mating of the connector with the charging port is achieved. - If the analysis of the operation data and / or sensor data indicates that corrective action is required to enable the system to complete the mating of the connector with the charging port, corrective action shall be initiated. Methods that include...

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

3. The method according to any one of claim 1 or 2, comprising enabling the robot arm to transition between the unlocked state and the locked state when such operation data or sensor data is within a predetermined range.

4. The method according to any one of the preceding claims, comprising taking at least one of the following steps to enable the system to complete mating of the connector with the charging port: i) transitioning the robot arm to the unlocking stage; ii) transitioning the robot arm to the locked stage; iii) repositioning the robot arm; or iv) acquiring new or updated motion data or sensor data; or v) retrying the mating.

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

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

7. The method according to any one of the preceding claims, wherein, during the locked state, at least two arm segments are prevented from moving, and at least one arm segment is allowed to move, and in each case, the movement is toward an adjacent arm segment or the base unit.

8. The method according to any one of the preceding claims, comprising enabling the robot arm to undergo two or more transitions between a locked state and an unlocked state prior to the fitting.

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

10. The method according to any one of the preceding claims, comprising enabling a transition of the robot arm between a retracted position and an extended position, wherein while in the retracted position, the connector assembly and preferably the charging connector are at least partially engaged by the connector housing, and while in the extended position, the connector or connector assembly is not engaged by the connector housing.

11. The method according to any one of the preceding claims, comprising enabling the robot arm to temporarily apply a force stronger than the force applied while the robot arm is in the unlocked state, thereby mating the connector with the charging port while the robot arm is in the unlocked state.

12. The method according to any one of the preceding claims, comprising enabling the transition of the robot arm from a locked state to an unlocked state at any moment after the mating of the charging connector with the charging port.

13. The method according to any one of the preceding claims, comprising enabling the transition of the robot arm to a locked state prior to disengaging.

14. - A system for autonomously charging electric vehicles, - Base unit and, - A connector assembly supporting a connector for mating with the vehicle charging port, - A robot arm, positioned between the base unit and the connector assembly, comprising multiple arm segments, - A control system configured to receive motion data and / or sensor data, and to guide the robot arm and connector assembly toward the vehicle charging port, Equipped with, Based on the received motion data and / or sensor data, the robot arm is configured to transition between an unlocked state and a locked state before the connector is mated with the charging port, wherein in the locked state, at least one arm segment is prevented from moving relative to an adjacent arm segment or base unit, and in the unlocked state, such movement is permitted. The control system is configured to monitor and analyze such operational data and / or sensor data, and to initiate corrective action if the analysis of the operational data and / or sensor data indicates that corrective action is required to enable the system to complete the mating of the connector with the charging port. system.

15. The system according to claim 14, wherein the robot arm is configured to transition between a stowed position in which the connector assembly is at least partially engaged by the connector housing and an unstowed position in which the connector assembly is disengaged from the connector housing.

16. The system according to any one of claims 14 or 15, wherein at least one joint assembly comprises a joint member and a braking member, and the control system is configured to activate and deactivate such braking member so as to transition the robot arm between the locked state and the unlocked state and vice versa.

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

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

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

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