How to control charging infrastructure

Abstract

The present invention relates to a method for controlling a charging infrastructure including a charging station that charges a vehicle having a vehicle-side charging interface, the charging station including a robot carrying a robot-side charging interface for establishing a charging connection with the vehicle-side charging interface, the robot including a main base and a compliance assembly kinematically arranged to realize compliance between the main base and the robot-side charging interface, the method sequentially including a positioning phase in which the robot-side charging interface moves to an initial connection position, and a connection phase in which the robot-side charging interface establishes a charging connection with the vehicle-side charging interface, in which in the positioning phase, the compliance value is compared with a positioning intervention value, and if the compliance value exceeds the positioning intervention value, the positioning command is changed, and in the connection phase, the compliance value is compared with a connection intervention value, and if the compliance value exceeds the connection intervention value, the connection command is changed, and the positioning intervention value is different from the connection intervention value.

Description

[Technical Field]

[0001] The present invention relates to a method for controlling a charging infrastructure comprising a charging station for charging a vehicle having a vehicle-side charging interface and a robot carrying a robot-side charging interface for establishing a charging connection with the vehicle-side charging interface.

[0002] Furthermore, the present invention relates to a charging infrastructure comprising a charging station for charging a vehicle having a vehicle-side charging interface, and a robot carrying a robot-side charging interface for establishing a charging connection with the vehicle-side charging interface. [Background technology]

[0003] Electric vehicles need to be frequently charged by connecting to a charger. In recent years, attempts have been made to automate the connection establishment, for example, by implementing fast, highly accurate robots programmed to bring the robot's charging interface into the vehicle's interface. However, this complex peg-in-hole task requires highly accurate and therefore costly robot implementations for each charging infrastructure, and robots may still not be suited to safely handle irregularities, such as misalignment of the vehicle's charging interface or unexpected physical contact with an object between the robot's interface and the vehicle's interface. Summary of the Invention [Problem to be solved by the invention]

[0004] It is an object of the present invention to provide a charging infrastructure equipped with a robot and a method for controlling said charging infrastructure that is able to safely handle such irregularities. [Means for solving the problem]

[0005] According to a first aspect, the present invention provides a method for controlling a charging infrastructure comprising a charging station for charging a vehicle having a vehicle-side charging interface, the charging station comprising a robot carrying a robot-side charging interface for establishing a charging connection with the vehicle-side charging interface, the robot comprising a main base and a displacement mechanism for moving the robot-side charging interface relative to the main base with at least three degrees of freedom between the main base and the robot-side charging interface, the displacement mechanism comprising at least one actuator configured to apply a displacement between the main base and the robot-side charging interface over a displacement stroke upon actuation, the robot comprising a compliance assembly kinematically arranged in series with the actuator between the main base and the robot-side charging interface, the compliance assembly configured to achieve compliance by elastically absorbing or releasing displacement between the main base and the robot-side charging interface over the compliance stroke, the method in turn comprising: The charging station charging method includes a positioning phase in which the robot-side charging interface moves from a retracted position where the vehicle can enter and exit the charging station to an initial connection position where the robot-side charging interface is in front of, and preferably aligned with, the vehicle-side charging interface; a connection phase in which the robot-side charging interface establishes a charging connection with the vehicle-side charging interface from the initial connection position; a charging phase in which the vehicle is charged with a charging current via the robot-side charging interface; and a disconnection phase in which the robot-side charging interface detaches from the vehicle-side charging interface and is retracted toward the retracted position. In the positioning phase, the actuator is powered according to a positioning command, compliance is monitored, and the compliance value is compared with a positioning intervention value. If the compliance value exceeds the positioning intervention value, the positioning command is changed. In the connection phase, the actuator is powered according to a connection command, compliance is monitored, and the compliance value is compared with a connection intervention value. If the compliance value exceeds the connection intervention value, the connection command is changed.

[0006] The charging infrastructure according to the present invention includes a robot having an actuator that moves the robot-side charging interface, and a compliance assembly kinematically in series with the actuator to absorb a portion of the actuator's movement. The compliance allows the robot-side interface to quickly absorb unexpected physical collisions while the actuator is still powered, giving the control system time to respond and passively compensating for robot errors so that the robot-side charging interface can establish a proper charging connection with the vehicle-side charging interface. The compliance value is compared to a positioning intervention value during the positioning phase, and the compliance value is compared to a connection intervention value, which is different from the positioning intervention value, during the connection phase. Thus, the robot can be highly sensitive to any unexpected collisions during the positioning phase. On the other hand, if there is intentional physical contact during the connection phase, for example, a higher value may be allowed to overcome friction between the robot-side charging interface and the vehicle-side charging interface accompanying connection establishment but prevent damage due to pinching. This allows for a robot that can operate safely in public areas.

[0007] In one embodiment, the positioning intervention value is less than the connection intervention value.

[0008] In a practical embodiment, the positioning intervention value is less than 50% of the connection intervention value.

[0009] In a preferred practical embodiment, the positioning intervention value is less than 25% of the connection intervention value.

[0010] In one embodiment, the positioning command is modified to deactivate the actuator when the compliance value exceeds the positioning intervention value, so that the compressive force exerted by the robot-side charging interface remains limited to the amount absorbed by the compliance assembly.

[0011] In one embodiment, when the compliance value exceeds the positioning intervention value, the positioning command is aborted and the actuator is powered according to the retraction command to retract the robot side charging interface towards the retracted position.

[0012] In one embodiment, the connection command is modified to deactivate the actuator when the compliance value exceeds the connection intervention value, thereby overcoming the friction between the robot-side charging interface and the vehicle-side charging interface that accompanies establishing the connection, but allowing a certain amount of compressive force from the robot-side charging interface to prevent damage from pinching that could occur if the compliance value exceeds the connection intervention value.

[0013] In one embodiment, when the compliance value exceeds the connection intervention value, the connection command is aborted and the actuator is powered according to the retraction command to retract the robot-side charging interface towards the retraction position or back to the initial connection position.

[0014] In one embodiment, during the charging phase, the actuator is powered according to a charging command and compliance is monitored, the charging command defining a compliance value between a first charging intervention value and a second, lower charging intervention value. Specifically, during the charging phase, the actuator is powered according to the charging command at the start of the charging phase, and preferably is idled for the remainder of the charging phase when the compliance value is between the first charging intervention value and the second, lower charging intervention value. In this case, the compliance assembly is balanced so that the compliance value is between the first charging intervention value and the second charging intervention value. In this case, the robot-side charging interface can passively follow unexpected movements of the vehicle-side charging interface without violating the intervention value. Such unexpected movements may be caused, for example, by a person getting off the vehicle.

[0015] In this embodiment, when the compliance value exceeds the first charging intervention value or falls below the second charging intervention value, the actuator is powered according to the charging command to bring the compliance value between the first charging intervention value and the second charging intervention value, thereby allowing charging to continue in a safe manner.

[0016] In one embodiment, during the positioning, connection and charging phases, the actuator may be powered according to an intervention command, the compliance value is monitored, the compliance value is compared with a warning intervention value, and if the warning intervention value is exceeded an intervention command selected from the group comprising: - Cut off the charging current through the robot's charging interface - Triggering an audio alert - Triggering a visual alarm - Notifying the vehicle or higher level management system of an alarm condition - Triggering a mechanical breakout release, and - Pull back the robot charging interface from the vehicle charging interface.

[0017] In one embodiment, in the positioning phase, the warning intervention value is higher than the positioning intervention value, and in the connection phase, the warning intervention value is higher than the connection intervention value, and / or in the charging phase, the warning intervention value is higher than the first charging intervention value or lower than the second charging intervention value, or the warning intervention value has a first warning intervention value higher than the first charging intervention value and a second warning intervention value lower than the second charging intervention value.

[0018] In one embodiment, the positioning step includes determining a position of the vehicle-side charging interface and determining an initial connection position by adding or subtracting a cumulative system error to the determined position of the vehicle-side charging interface. Note that the inventors have discovered that this is beneficial when there is no physical contact between the robot-side charging interface and the vehicle-side charging interface and when the robot-side charging interface is at or approaching the initial connection position. Therefore, damage to the vehicle caused by the robot-side charging interface moving to the initial connection position can be prevented.

[0019] According to a second aspect, the present invention provides a method for controlling a charging infrastructure comprising a charging station for charging a vehicle having a vehicle-side charging interface, the charging station comprising: a robot carrying a robot-side charging interface for establishing a charging connection with the vehicle-side charging interface; the robot comprising: a main base; and a displacement mechanism for moving the robot-side charging interface relative to the main base with at least three degrees of freedom between the main base and the robot-side charging interface, the displacement mechanism comprising at least one actuator configured to apply a displacement over a displacement stroke upon actuation between the main base and the robot-side charging interface; the robot comprising: a compliance assembly kinematically arranged in series with the actuator between the main base and the robot-side charging interface, the compliance assembly adjusting a compliance stroke between the main base and the robot-side charging interface. The method is configured to achieve compliance by elastically absorbing or releasing displacement over a stroke, and the method sequentially includes a positioning phase in which the robot-side charging interface moves from a retracted position where the vehicle can enter and exit the charging station to an initial connection position in which the robot-side charging interface is in front of, and preferably aligned with, the vehicle-side charging interface; a connection phase in which the robot-side charging interface establishes a charging connection with the vehicle-side charging interface from the initial connection position; a charging phase in which the vehicle is charged with a charging current via the robot-side charging interface; and a disconnection phase in which the robot-side charging interface disengages from the vehicle-side charging interface and is retracted toward the retracted position, and in the charging phase, the actuator is powered according to a charging command, compliance is monitored, and the charging command specifies that the compliance value be between a first charging intervention value and a second, lower charging intervention value.

[0020] In this embodiment, during the charging phase, the actuator is powered according to the charging command at the start of the charging phase, and preferably during the remainder of the charging phase, the actuator is in an idle state when the compliance value is between the first charging intervention value and a second, lower charging intervention value.

[0021] In this further embodiment, when the compliance value exceeds the first charging intervention value or falls below the second charging intervention value, the actuator is powered according to a charging command to bring the compliance value between the first charging intervention value and the second charging intervention value.

[0022] In one embodiment, during the positioning, connection and charging phases, the actuator may be powered according to an intervention command, the compliance value is monitored, the compliance value is compared with a warning intervention value, and if the warning intervention value is exceeded an intervention command selected from the group comprising: - Cut off the charging current through the robot's charging interface - Triggering an audio alert - Triggering a visual alarm - Notifying the vehicle or higher level management system of an alarm condition - Triggering a mechanical breakout release, and - Pull back the robot charging interface from the vehicle charging interface.

[0023] In one embodiment, in the positioning phase, the warning intervention value is higher than the positioning intervention value, and in the connection phase, the warning intervention value is higher than the connection intervention value, and / or in the charging phase, the warning intervention value is higher than the first charging intervention value or lower than the second charging intervention value, or the warning intervention value has a first warning intervention value higher than the first charging intervention value and a second warning intervention value lower than the second charging intervention value.

[0024] According to a third aspect, the present invention provides a charging infrastructure comprising a charging station for charging a vehicle having a vehicle-side charging interface, the charging station comprising a robot carrying a robot-side charging interface for establishing a charging connection with the vehicle-side charging interface, the robot comprising a main base and a displacement mechanism for moving the robot-side charging interface relative to the main base with at least three degrees of freedom between the main base and the robot-side charging interface, the displacement mechanism comprising at least one actuator configured to apply a displacement between the main base and the robot-side charging interface over a displacement stroke upon actuation, the robot comprising a compliance assembly arranged kinematically in series with the actuator between the main base and the robot-side charging interface, the compliance assembly configured to achieve compliance by elastically absorbing or releasing displacement between the main base and the robot-side charging interface over the compliance stroke, and the charging infrastructure further comprising a controller operably connected to at least the robot and configured to perform the method according to the first or second aspect of the present invention.

[0025] According to a fourth aspect, the present invention provides a computer readable medium having instructions which, when executed by a controller or processor, cause a charging infrastructure according to the third aspect of the invention to carry out a method according to the first or second aspect of the invention.

[0026] The various aspects and features described and illustrated herein may be applied individually to the extent possible, and such individual aspects, particularly those aspects and features described in the accompanying dependent claims, may be the subject of divisional patent applications.

[0027] The invention will now be described on the basis of exemplary embodiments shown in the accompanying drawings, in which: [Brief explanation of the drawings]

[0028] [Figure 1A] 1 is a side view of a detail of a charging station comprising a robot according to a first embodiment of the present invention having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle; FIG. [Figure 1B] FIG. 1 is an isometric rear view of a detail of a charging station comprising a robot according to a first embodiment of the present invention having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle. [Figure 1C] FIG. 1 is an isometric front view of a detail of a charging station comprising a robot according to a first embodiment of the invention having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle. [Figure 2A] FIG. 10 is a side view of a detail of a charging station comprising a robot according to a second embodiment of the invention, having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle. [Figure 2B] 1 is an isometric view of a detail of a charging station comprising a robot according to a second embodiment of the invention, having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle; FIG. [Figure 3A] FIG. 10 is an isometric side view of a detail of a charging station comprising a robot according to a third embodiment of the invention having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle. [Figure 3B] FIG. 10 is an isometric rear view of a detail of a charging station comprising a robot according to a third embodiment of the present invention having a robot-side charging interface for establishing a charging connection with a vehicle-side charging interface of an electric vehicle. [Figure 4] 1A, 1B, 1C, 2A and 2B, or 3A and 3B. FIG. [Figure 5A]FIG. 3C is a partial longitudinal cross-sectional view of the robot-side charging interface and the vehicle-side charging interface shown in FIGS. 1B, 2B, and 3B properly aligned immediately prior to establishing a charging connection. [Figure 5B] FIG. 5B is a partial longitudinal cross-sectional view of the robot-side charging interface and the vehicle-side charging interface shown in FIG. 5A with the charging connection properly established. [Figure 5C] FIG. 5B is a partial longitudinal cross-sectional view of the robot-side charging interface and the vehicle-side charging interface shown in FIG. 5A while correcting for allowable errors under the control of the robot. [Figure 5D] FIG. 5B is a partial longitudinal cross-sectional view of the robot-side charging interface and the vehicle-side charging interface shown in FIG. 5A while correcting for allowable errors under the control of the robot. [Figure 6A] 5 is a graph illustrating monitoring the establishment of a charging connection and various possible responses to the establishment of a charging connection using the compliance assembly shown in FIG. 4. [Figure 6B] 5 is a graph illustrating monitoring the establishment of a charging connection and various possible responses to the establishment of a charging connection using the compliance assembly shown in FIG. 4. [Figure 6C] 5 is a graph illustrating monitoring the establishment of a charging connection and various possible responses to the establishment of a charging connection using the compliance assembly shown in FIG. 4. [Figure 6D] 5 is a graph illustrating monitoring the establishment of a charging connection and various possible responses to the establishment of a charging connection using the compliance assembly shown in FIG. 4. [Figure 6E] 5 is a graph illustrating monitoring the establishment of a charging connection and various possible responses to the establishment of a charging connection using the compliance assembly shown in FIG. 4. [Figure 6F] 5 is a graph illustrating monitoring the establishment of a charging connection and various possible responses to the establishment of a charging connection using the compliance assembly shown in FIG. 4. [Figure 7] 1 is a flow diagram of the steps performed during operation of a robot according to the previous figures. DETAILED DESCRIPTION OF THE INVENTION

[0029] 1A, 1B, and 1C show a charging station 1 according to a first embodiment of the present invention. The charging station 1 has a vehicle area 2 for charging an electric vehicle 10, in this example a passenger car. The vehicle 10 may be fully electric or may have a hybrid drive system in which electric drive is combined with fuel combustion. The vehicle 10 has a vehicle body 11 on wheels 12 and a vehicle-side charging interface 20 carried by the vehicle body 11, in this example on the right side of the vehicle body 11, above one of the rear wheels 12.

[0030] 1A, 1B, and 1C, charging station 1 includes a robot 50 having a robot-side charging interface 100 for establishing a charging connection with vehicle-side charging interface 20. Robot-side charging interface 100 is electrically connected to a charger (not shown).

[0031] The specific pin arrangements of the robot-side charging interface 100 and the vehicle-side charging interface 20 may be of any known type, such as those described in official standards such as the IEC / SAE standards. The robot-side charging interface 100 and the vehicle-side charging interface 20 may be so-called Mennekes, Yazaki, Schuko, or Combo types, or any other connectors dedicated to electric vehicle charging. As shown in FIGS. 1B and 5A , the vehicle-side charging interface 20 is a Combo CCS-2 inlet that supports both standard charging and fast charging. The vehicle-side charging interface 20 has a front surface 21 inwardly coupled to a circumferential inner surface 22. The inner surface 22 is coupled to a bottom surface 23 from which a first socket 24 and a second socket 31 protrude. The first socket 24 has a socket body 25 made of an electrically insulating material, having five first channels 26 through which five recessed standard charging connectors 27 extend and two second channels 28 through which two control connectors 29 extend. The second socket 31 includes a socket body 32 of electrically insulating material having two third channels 33 through which two fast charging connectors 34 extend. The inner surface 22 and the socket bodies 25, 32 together define a groove 30 around the periphery of the socket 24, 31. The groove 30, the first channel 26, the second channel 28, and the third channel 33, by design, have a receiving direction R that is parallel to the first channel 26, the second channel 28, and the third channel 33.

[0032] 1C and 5A, the robot-side charging interface 100 in this example is a so-called Mennekes type connector (a Type 2 connector based on IEC 62196) for normal charging. The robot-side charging interface 100 includes a shield 101 that mates with and fits snugly inside the groove 30 of the vehicle-side charging interface 20, and a plurality of first bushings 102 and second bushings 103 that mate with and fit snugly inside the first channel 26 and second channel 28 of the vehicle-side charging interface 20, respectively. The robot-side charging interface 100 includes charging connectors that are recessed inside the bushings 102 and 103 and electrically connect with the connectors 27 and 29 of the vehicle-side charging interface 20 when a charging connection is established. By design, the shield 101, the first bushings 102, and the second bushings 103 have an insertion direction P that is parallel to the charging connector. The insertion direction P is perfectly parallel to and aligned with the receiving direction R of the vehicle-side charging interface 20 by design.

[0033] The vehicle-side charging interface 20 and the robot-side charging interface 100 typically have very precise mating geometries that allow only slight misalignment of up to approximately 0.1 to 0.3 millimeters diagonally across the receiving direction R at initial contact, or up to 1 to 2 degrees of misalignment when manually plugged together. Such minimal misalignment is automatically corrected thanks to the self-seeking shape characteristics of the charging interfaces 20, 100, allowing the charging interfaces 20, 100 to properly engage with each other. The connectors 27, 29, 34 of the vehicle-side charging interface 20 and the connectors 102, 103 of the robot-side charging interface 100 may have different lengths or positions in the insertion direction P and receiving direction R to enforce a default mating sequence even with the aforementioned slight misalignment between the contacting connectors. This ensures, for example, that a ground or control connection is established before a power connection is made. The vehicle-side charging interface 20 is inserted in an insertion direction P into the vehicle-side charging interface 100 over an insertion stroke that ends when the design depth for proper insertion is reached. The vehicle-side charging interface 20 and the robot-side charging interface 100 are provided with remote-controlled locking features for locking the vehicle-side charging interface 20 at the design depth of the vehicle-side charging interface. This physically prevents the properly connected charging interfaces 20, 100 from coming loose during application of a high charging current.

[0034] 1A , the robot 50 of the charging station 1 comprises a pedestal or main base 51, shown schematically in this example with a main frame 52 located on the ground, beside the vehicle area 2, on the side near the vehicle-side charging interface 20. The robot 50 can be located on either side of the vehicle 10, or on the front or rear, depending on the location of the vehicle-side charging interface 20. The robot 50 can alternatively be located on or under the floor of the vehicle 10 to reach a vehicle-side charging interface 20 on the bottom side of the vehicle 10, or the robot 50 can be suspended above the vehicle 10 to reach a vehicle-side charging interface 20 on the top or roof of the vehicle 10.

[0035] As shown in FIGS. 1A-1C, the robot 50 includes a movable carrier 60 having a carrier frame 61 that carries the robot-side charging interface 100. The robot 50 can be of any configuration that allows the movable carrier 60, and thus the robot-side charging interface 100, to move relative to the main base 51. Mathematically, a Cartesian coordinate system O is defined that is coupled to the main base 51 and to which the position of the robot-side charging interface 100 is related. The robot-side charging interface 100 can translate in any of three orthogonal directions X, Y, and Z (lateral, longitudinal, and vertical) and can rotate about these axes (pitch, roll, and yaw) relative to the main base 51, resulting in a total of up to six degrees of freedom (6-DOF), depending on the robot's particular drive chain configuration.

[0036] The robot 50 includes a robot base 54 connected to a main frame 52 via a first rotary actuator 53 for rotation about a vertical first axis D, which in this example corresponds to the Z axis of a Cartesian coordinate system O. The robot 50 includes a first robot arm 56 connected at one end to the robot base 54 via a second rotary actuator 55 for rotation about a horizontal second axis E relative to the main frame 52. The first robot arm 56 is connected at its opposite end to one end of a second robot arm 58 via a third rotary actuator 57 for rotating the second arm 58 about a third horizontal axis F relative to the first arm 56. The opposite end of the second robot arm 58 is connected to the movable carrier 60 via a fourth rotational actuator 59 so as to rotate the movable carrier 60 relative to the second arm 58 about a horizontal fourth axis G and about mutually perpendicular fifth and sixth axes H and J.

[0037] The robot 50 includes a first compliance assembly 90a in series between the movable carrier 60 and the robot side charging interface 100, and thus in kinematic series with the robot side charging interface 100 and at least one of the drive chain rotational actuators 53, 55, 57, 59, as best shown in FIG. 4 . Mathematically, a Cartesian coordinate system C is defined that is coupled to the robot side charging interface 100 and to which compliance is related, with the Y axis preferably parallel to the insertion direction P. The compliance assembly 90a provides mechanical compliance between the drive chain and the robot side charging interface 100.

[0038] The compliance assembly 90a, in this example, comprises an outer tube 91 mounted on the carrier frame 61 and a connecting rod 92 linearly guided inside the outer tube 91, in this example by means of a plain bearing 93. The connecting rod 92 partially protrudes from the outer tube 91, and the first compliance assembly 90a, in this example, comprises an end stop 94 at the end of the connecting rod 92, which rests behind the plain bearing 93 to determine a predetermined outermost position of the connecting rod 92 relative to the carrier frame 61, as well as a reversible flexible element, in this example a spring, specifically a coil spring 95, biased between the end stop 94 and the carrier frame 61 to keep the end stop 94 abutting the plain bearing 93. The connecting rod 92 can resiliently and reversibly slide back over a compliance stroke in direction L by means of the coil spring 95, in this example, when a predetermined threshold force is exceeded, which overcomes the bias of the coil spring 95. Therefore, first compliance assembly 90a provides a first compliance in direction L. Rotational actuators 53, 55, 57, 59 apply a displacement to robot-side charging interface 100, causing robot-side charging interface 100 to follow the rotational actuators unless the displacement exceeds the threshold force of compliance assembly 90a.

[0039] In the illustrated embodiment, the first compliance assembly 90a is biased towards and against the plain bearing 93. Alternatively, a coil spring 95 or any other resilient element may provide resilience in the opposite direction, with or without meeting a threshold force, such that the connecting rod 92 can be resiliently and reversibly pushed towards and pulled away from the movable carrier 60. Both embodiments provide a one-degree-of-freedom compliance stroke.

[0040] 4, first compliance assembly 90a includes a distance sensor 110, shown schematically, positioned and configured to provide an electrical signal via a first electrical cable 111. This electrical signal is indicative of the distance of end stop 94 relative to movable carrier frame 61, and thus the length of first compliance in direction L, and the external force applied in direction L. First compliance assembly 90a includes an end switch 115 positioned and configured to detect abutment of end stop 94, indicating when the length of first compliance has reached its maximum. End switch 115 then provides a corresponding signal via a second electrical cable 116.

[0041] 2A and 2B show a charging station 201 equipped with a robot 250 according to a second embodiment of the present invention. Parts corresponding to those in the first embodiment are given the same reference numerals. Only the differences will be discussed hereinafter.

[0042] The robot 250 includes multiple compliance assemblies 90a-90f, six in this embodiment, between the movable carrier 60 and the robot-side charging interface 100. Only three of the six compliance assemblies are shown in detail. The movable carrier 60 includes six leg supports 97a-97f, which are coplanar and paired in a triangular configuration on the carrier frame 61. The robot 250 includes six leg supports 96a-96f, which are coplanar and paired in a triangular configuration on the robot-side charging interface 100. The outer tubes 91 of the compliance assemblies 90a-90f include first coupling portions 98, embodied as universal rotary joints with two degrees of freedom, that connect to the leg supports 97a-97f of the movable carrier 60. The connecting rods 92 of the compliance assemblies 90a-90f include second couplings 99, embodied as universal rotary joints with three degrees of freedom, that connect to leg supports 96a-96f of the charging interface 100. The six compliance assemblies 90a-90f form a hexapod mechanism, in this example, providing six degrees of freedom of compliance between the robot-side charging interface 100 and the movable carrier 60. Alternatively, the assembled six compliance assemblies 90a-90f form a Stewart platform between the robot-side charging interface 100 and the movable carrier 60. The compliance assemblies 90a-90f are therefore configured parallel to one another and in series with at least one of the rotational actuators 53, 55, 57, and 59 of the robot-side charging interface 100 and the drive chain. The coil springs 95 in each compliance assembly 90a-90f may have different impedances, in this example different stiffnesses, to ensure a default position of the robot side charging interface 100 relative to the moveable carrier 60 without sagging due to uneven weight distribution caused by, for example, the different individual weights of the various components present in the robot side charging interface 100 and compliance assemblies 90a-90f. Each compliance assembly 90a-90f is provided with a distance sensor 110 and an end switch 115.Rotary actuators 53, 55, 57, 59 apply a displacement to vehicle-side charging interface 100, and vehicle-side charging interface 100 follows the rotary actuators as long as a threshold force is not exceeded on any one of compliance assemblies 90a-90f.

[0043] 3A and 3B show a charging station 301 equipped with a robot 350 according to a third embodiment of the present invention. Parts corresponding to those of the first embodiment are given the same reference numerals. Only the differences will be discussed hereinafter.

[0044] The robot 350 includes a main base 51, which in this example is supported by a console 3 located on the side of the vehicle area 2, closer to the vehicle-side charging interface 20. The main base 51 includes a main frame 52 and six leg supports 353a-353f, which are coplanar and paired in a triangular configuration on the main frame 52. The robot 350 includes a movable carrier 60 having a carrier frame 61 and six leg supports 364a-364f, which are coplanar and paired in a triangular configuration on the carrier frame 61, with the distance between pairs of the leg supports 364a-364f being shorter than the distance between pairs of the leg supports 353a-353f on the main base 51. The carrier 60 carries the robot-side charging interface 100.

[0045] The robot 350 comprises a total of six parallel displacement assemblies between the main base 51 and the movable carrier 60, which in this example are embodied as six legs 371a to 371f extending between the leg supports 353a to 353f of the main base 51 and the leg supports 364a to 364f of the movable carrier 60. The legs 371a to 371f are identical in structure and will be described in detail hereinafter with reference to the first leg 371a.

[0046] The first leg 371a includes a linear motion actuator 380 having an outer tube 381 at the bottom end of the first leg, connected to the leg support 353a of the first leg of the main base 51 via a first coupling 388 embodied as a universal rotary joint with two degrees of freedom. The linear motion actuator 380 includes, in this example, an electric motor 383 mounted on the outer tube 381. The linear motion actuator 380 includes a drive rod 382 linearly guided within the outer tube 381 and partially protruding therefrom. The drive rod 382 is operatively connected to the electric motor 383, for example via a spindle. As a result, the drive rod 382 is linearly reciprocable relative to the first coupling 388 in a direction M over a displacement stroke in response to energizing the electric motor 383, as shown in FIG. 3A . The linear motion actuator 380 has an internal sensor, such as a rotation sensor or counter on a spindle, that measures the position of the drive rod 382 relative to the outer tube 381. Thus, each leg 371a-371f has such a sensor.

[0047] Each of legs 371a-371f includes a respective compliance assembly 90a-90f in series with linear motion actuator 380, with outer tube 91 fixed to drive rod 382 and connecting rod 92 including a respective second coupling 396, embodied as a universal rotary joint having three degrees of freedom, connected to leg supports 364a-364f on carrier frame 61. Coil springs 95 of compliance assemblies 90a-90f of each of legs 371a-371f may have different impedances, in this example different stiffnesses, to ensure a default position of robot side charging interface 100 without sagging due to uneven weight distribution, for example, due to different individual weights of various components present in robot 50.

[0048] In this example, six legs 371a-371f form a hexapod mechanism 70 between the main base 51 and the movable carrier 60. Alternatively, the assembled six legs 371a-371f form a Stewart platform. A linear motion actuator 380 applies a displacement between the first coupling 388 and the second coupling 396. As long as the threshold force of the compliance assembly 90 is not exceeded, the movable carrier 60, and therefore the vehicle-side charging interface 100, follows the linear motion actuator. This allows the movable carrier 60 to translate in three orthogonal directions (X, Y, and Z) and rotate about these axes (pitch, roll, and yaw), for a total of six degrees of freedom (6-DOF). A portion of the applied displacement between the first coupling 388 and the second coupling 396 can be reversibly absorbed by the compliance assemblies 90a-90f once the threshold force is exceeded.

[0049] Alternatively, or in addition, the movable carrier 60 includes a sensor 366, such as a pressure sensor matrix, between the carrier frame 61 and the robot side charging interface 100, as shown in FIG. 3A, that acquires or derives compliance data for the six degrees of freedom described above.

[0050] In the above-described embodiments, the rotary actuators 53, 55, 57, 59 or motor 383 form the positioning embodiment. The applied compliance assemblies 90a-90f form the compliance embodiment in series with the rotary actuator or motor.

[0051] The charging station 1, 201, 301 includes an electronic control system that controls the operation of the charging station 1. The electronic control system may include one or more imaging detectors 130, such as a video camera or multiple cameras forming a stereo camera, or distance sensors, such as LIDAR, radar, or LED-based sensors, that detect the position of the vehicle-side charging interface 20 of the vehicle within the charging station 1. The imaging detector 130 thus forms part of a vision system. The imaging detector 130 may be mounted on a base, such as the main base 51, or may be carried by a robot 50, such as the robot-side charging interface 100, as shown.

[0052] The control system includes an electronic controller connected to the rotary actuator 53, 55, 57, 59 or the electric motor 383 to power and control the rotation of the rotary actuator or electric motor. The electronic controller is connected to the detector 130, the distance sensor 110 via a first electrical cable 111, and the end switch 115 via a second electrical cable 116. The charging station 1, 201, 301 may also include a redundant electronic control system connected to the end switch 115, where the aforementioned control system is the primary control system. The redundant control system can ultimately intervene or override the primary control system in certain extreme situations as detected by the end switch 115. The control system is connected to the charger, activates charging via the bushings 102, 103, and can receive feedback from the robot-side charging interface 20 indicating proper insertion of the robot-side charging interface 100 into the vehicle-side charging interface 20, for example, by detecting the mating order of the contacting connectors within the vehicle-side charging interface 20 and the robot-side charging interface 20. The electronic controller communicates with the remote control interlock between the vehicle-side charging interface 100 and the robot-side charging interface 100, and can determine the actual state of the interlock, interlock a properly inserted robot-side charging interface 100, or detect an improper or incomplete insertion while the vehicle 10 is charging.

[0053] The electronic controller is configured to determine the spatial position and orientation of the vehicle-side charging interface 20 within the charging station 1. This can be performed using the vision system described above, or can be derived from a database containing position data of the vehicle-side charging interface 100 of known vehicles, including specific position data of the parked vehicle 10, or can be derived by communication with the vehicle 10 or by an auxiliary control system. Mathematically, a coordinate system S coupled to the vehicle-side charging interface 20 is defined to determine the position of the vehicle-side charging interface in three orthogonal directions X, Y, and Z, as well as any rotational directions about the X, Y, and Z axes, where the Y axis is preferably parallel to the reception direction R.

[0054] The electronic controller is configured to determine the resultant forces and moments acting on the robot side charging interface 100 from the applied compliance strokes of each compliance assembly 90a-90f in direction L. Mathematically, this is expressed using the following stiffness matrix and coordinate system C: │F x │ │k x 0 0 0 0 0 ││Δx│ │F y │ │0 k y 0 0 0 0 ││Δy│ │F z │=│0 0 k z 0 0 0 ││Δz│ │M x │ │0 0 0 k rx 0 0 ││ΔΦ│ │M y │ │0 0 0 0 k ry 0 ││ΔΘ│ │M z │ │0 0 0 0 0 k rz ││ΔΨ│

[0055] In this matrix, F x , F y , F zare the force components along the axes of the coordinate system in Newtons, M x , M y , M z are the moments about the axes of the coordinate system in newton meters, Δx, Δy, Δz are the displacement components in meters, and ΔΦ, ΔΘ, ΔΨ are the rotation components in radians, all expressed in coordinate system C. The stiffness components k of the six degrees of freedom x , k y , k z , k rx , k ry , k rz relates to the stiffness characteristics of the applied coil spring 95 in units of Newtons / meter and Newton meters / radian, and varies depending on the particular configuration and the current value of the compliance stroke. If the compliance is constrained in a particular configuration, thereby having fewer than the maximum six degrees of freedom for which the applied compliance is available, then a substantially higher stiffness component will be applied.

[0056] The force and moment components acting on the robot-side charging interface 100 or applied to the charging interface 100 by the robot 50, 250, 350 are quantitatively related to the stroke of compliance defined by the displacement and rotation directions of the coordinate system C. The following exemplary quantitative relationships apply:

[0057] The following quantification defines the range of possible stiffness and the range of possible compliance strokes within which the stiffness and compliance strokes of embodiments according to the present invention lie for each direction of coordinate system C. Compliance strokes are expressed in meters or degrees, respectively. Stiffness is expressed in kilonewtons / meter and kilonewton meters / radian, respectively. Direction Stiffness Stroke X [0.25,40] [0.005,0.1] Y [0.25,40] [0.005,0.1] Z [0.25,40] [0.005,0.1] RX [0.005,6] [0.5,15] RY [0.005,6] [0.5,15] RZ [0.005,6] [0.5,15]

[0058] The following quantification defines the maximum range of stiffness and maximum range of compliance stroke for each direction of coordinate system C, within which there is a stiffness and compliance stroke of an embodiment according to the present invention. Compliance stroke is expressed in meters or degrees, respectively. Stiffness is expressed in kilonewtons / meter and kilonewton meters / radian, respectively. Direction Stiffness Stroke X [0.1,200] [0.002,0.25] Y [0.1,200] [0.002,0.25] Z [0.1,200] [0.002,0.25] RX [0.001,24] [0.25,30] RY [0.001,24] [0.25,30] RZ [0.001,24] [0.25,30]

[0059] The electronic controller is configured to determine the position and orientation of the robot side charging interface 100 in the coordinate system O from feedback of the rotary actuators 53, 55, 57, 59, or motors 383, compliance assemblies 90a-90f, and by using a vision system.

[0060] The charging station 1 forms part of a charging infrastructure having a remote computer server that communicates with and configures the electronic controller. The electronic control system is loaded with software that is executed by the processor of the electronic controller, causing the charging station 1 to perform the following operations, as described hereinafter:

[0061] The description of the operation of the charging station 1, 201, 301 begins with the robot 50, 250, 350 in a fully retracted position, which retracts the robot-side charging interface 100 from the vehicle area 2 and places it in a standby position to allow the vehicle 10 to enter the charging station 1, 201, 301. As shown schematically in FIG. 1A , the robot-side charging interface 100 is in this fully retracted position at a distance Q, as shown schematically, from the vehicle 10, specifically from the vehicle-side charging interface 20 parked in the vehicle area 2. Hereinafter, the operation will be described with reference to the charging station 1 according to the first embodiment, and differences from the charging stations 201, 301 according to the second and third embodiments will be noted accordingly. FIG. 6A is a diagram showing, along the vertical axis, a first compliance value C1, e.g., in millimeters, realized by the sole first compliance assembly 90a of the charging station 1 according to the first embodiment, or realized by multiple compliance assemblies 90a-90f according to the second and third embodiments. Here, for illustrative purposes, the first compliance C1 and second compliance C2 are plotted for only the first compliance assembly 90a and second compliance assembly 90b, with the horizontal axis representing elapsed time in seconds.

[0062] In the diagram of FIG. 6A, certain compliance reference values ​​are plotted on a graph. In the diagram, a noise threshold C indicates the maximum values ​​of the first compliance C1 and the second compliance C2 that should be ignored because they do not affect the proper functioning of the robot 50, 250, 350. These small values ​​of compliance C1, C2 can typically be caused by vibrations in the drive chain of the robot 50, 250, 350, acting on the robot-side vehicle interface 100 via one or more of the compliance assemblies 90a-90f. The other values ​​C, C, C, C, C, and C indicate maximum or minimum values ​​that, if exceeded, trigger certain interventions, as will be explained hereinafter.

[0063] Hereinafter, an ideal charging cycle will first be described with reference to FIGS. 6A and 7, where the charging cycle is not interrupted by external influences or by obstructions between the mating charging interfaces 20 and 100.

[0064] In a first step 310, the presence of a particular vehicle 10 in the vehicle area 2 is signaled using an imaging detector 130, by any other suitable sensor, by any type of data communication between the vehicle 10 and the charging station 1, by any type of remote trigger system, by registration by the driver of the vehicle 10, or by a human operator on-site at the charging station 1.

[0065] Upon notification of the presence or approach of a vehicle 10, in a second step 320, the spatial position and orientation of the vehicle-side charging interface 20 within the charging station 1 is determined using the imaging sensor 130, or from a database containing position data of the vehicle-side charging interface 20 of known vehicles 20, or derived from communications with the vehicle 20, or obtained from an auxiliary control system. This includes position in three orthogonal directions X, Y, and Z, and any rotational orientations about the X, Y, and Z axes.

[0066] In a third step 330, a corresponding specific initial connection position of the robot-side charging interface 100 relative to the vehicle-side charging interface 20 is determined. The initial connection position is defined as a position where the robot-side charging interface 100 is in front of, but not yet in contact with, the vehicle-side charging interface 20. The initial connection position is determined by determining the position of the vehicle-side charging interface 20 and then subtracting and / or adding the largest accumulated system error, such as sensor and actuator errors, from the determined spatial position and orientation of the vehicle-side charging interface 20. Mathematically, at the initial connection position, the Euclidean distance T between any physical part of the robot-side charging interface 100 and the vehicle-side charging interface 20 is at most 10 millimeters, preferably at most 5 millimeters. At the initial connection position, the robot-side charging interface 100 is aligned with the vehicle-side charging interface 20, and the lateral displacement distance relative to the receiving direction R is at most 5 millimeters, preferably at most 3 millimeters. In the initial connection position, the robot-side charging interface 100 is aligned with the vehicle-side charging interface 20 with an angular offset of up to 3-5 degrees, preferably 2 degrees, and more preferably up to 1 degree. Such offset may be greater than the offset allowed by the self-searching shape characteristics of the charging interfaces 20, 100, which may be compensated for under applicable compliance, as described hereinafter. In the initial connection position, it is practically impossible for there to be any physical obstacles between them, such as a human hand.

[0067] In a fourth step 340, the rotary actuators 53, 55, 57, 59 or motors 383 are individually powered while the rotational position of the rotary actuators or motors is controlled to bring the robot side charging interface 100 to the determined initial connection position, taking into account the maximum cumulative system error in position determination within the drive chain.

[0068] The second step 320, the third step 330, and the fourth step 340 form part of a positioning phase P1, which may be repeated to bring the charging interface 100 to an initial connection position. During this positioning phase P1, the robot-side charging interface 100 undergoes a relatively large movement stroke toward the vehicle 10, ideally without any compliance stroke of the compliance assembly 90a exceeding the noise threshold C. The positioning phase P1 may consist of an imaging-assisted positioning phase P1V followed by a non-visual positioning phase P1B. During the imaging-assisted positioning phase P1V, the robot-side charging interface 100 is moved from the fully retracted position to a position where the imaging detector 130 can no longer clearly determine the position of the vehicle-side charging interface 20 due to the presence of part of the approaching robot 50, 250, 350.

[0069] In a sixth step 360, the rotary actuators 53, 55, 57, 59, or motors 383 are individually powered, while the rotational positions of the rotary actuators or motors are controlled to bring the robot-side charging interface 100 from the initial connection position shown in FIG. 5A to the appropriate final engagement position of the robot-side charging interface 100 with respect to the vehicle-side charging interface 20, shown in FIG. 5B. After the charging interfaces 20, 100 are properly engaged, a remote-controlled locking mechanism is activated to lock the engagement. The sixth step 360 forms part of the connection phase P2. The coordinate system C of the robot-side charging interface 100 is mathematically co-located with the coordinate system S of the vehicle-side charging interface 20.

[0070] During the connection phase P2, a compressive force is required to bring the robot-side charging interface 100 into the vehicle-side charging interface 20, overcoming friction and precisely mating, so some compliance is expected. During the connection phase P2, a slight difference between the value of the first compliance CW1 and the value of the second compliance CW2 may occur, from which a correctable misalignment is derived, and a correction of the misalignment is induced or detected, as determined by the connection command. For example, the first physical contact 200, as shown in FIG. 5C , can force the robot-side charging interface 100 to tilt or slide relative to the vehicle-side charging interface 20, while a pushing force is transmitted from the main base 51 through the biased coil spring 95. The coil spring 95 can compress when a predetermined threshold force of the coil spring is exceeded, which is monitored using sensors 66, 96, and 110. The compliance provided by the individual coil springs 95 can be used to induce sliding of the robot-side charging interface 100 in direction V along the vehicle-side charging interface 20 using the self-seeking shape features of the vehicle-side charging interface, and / or the corrective activation of the electric motor 383 can be determined based on the signals of the sensors 66, 96, and 110. In FIG. 5C, the illustrated misalignment includes translation and rotation in the same plane. It is clear that any misalignment in all six degrees of freedom can occur and can be detected and corrected by corresponding corrective action of the rotational actuators 53, 54, 56, 59, and 383. This is repeated until the appropriate, final engagement position of the robot-side charging interface 100 relative to the vehicle-side charging interface 20 is reached. During this repetition, further physical contact 201 can be detected and corrected by inducing sliding in direction W, as shown in FIG. 5D. Thanks to this repetition, it is possible to compensate for misalignments larger than those permitted by the self-seeking shape features of the charging interfaces 20 and 100. The stroke of the robot 50 is completed so that the first compliance C1 and the second compliance C2 have a value corresponding to approximately half the maximum length of the compliance stroke.This allows the robot-side charging interface 100 to resiliently move towards and away from the movable carrier 60 in the robots 50 and 250 according to the first and second embodiments, and allows the movable carrier 60 to follow the movement of the vehicle-side charging interface 20 in the robot 350 according to the third embodiment.

[0071] In an eighth step 380, charging is initiated. The eighth step 380 forms part of the charging phase P3. The vehicle 10 may move slightly relative to the robot 50 during the charging phase P3, which may result in some change in the compliance value. The slight movement of the vehicle 10 may be caused by passengers getting on or off, or wind acting on the vehicle 10.

[0072] In a tenth step 400, the remote control lock is released, unlocking the engagement of the charging interface 20, 100. The robot-side charging interface 100 is pulled back and disconnected from the vehicle-side charging interface 20 by corresponding actuation of the rotary actuators 53, 54, 56, 59 or motor 383. The tenth step 400 forms part of the disconnection phase P4.

[0073] The first compliance C1 and the second compliance C2 are continuously measured and monitored during the charging phase P3 using the distance sensor 110. During the charging phase P3, any compliance with a value below the noise threshold CN is ignored.

[0074] In the above ideal charging cycle, the first compliance C1 and the second compliance C2 both have values ​​that remain below the positioning intervention value CP during the positioning phase P1. The first compliance C1 and the second compliance C2 both have values ​​that remain below a higher connection intervention value CC during the connection phase P2. The first compliance C1 and the second compliance C2 have values ​​that remain balanced during the charging phase P3 within a range of a first charging intervention value CH1, for example equal to the connection intervention value CC, and a second charging intervention value CH2, for example higher than the positioning intervention value CP and lower than the connection intervention value CC.

[0075] Hereinafter, with reference to FIGS. 6A-6E, several misalignment scenarios will be discussed in which the electronic control system will induce specific interventions to enable safe operation of the charging station 1.

[0076] 6B illustrates a scenario in which, during the positioning phase P1, the first compliance C1 or the second compliance C2 has a value that exceeds the positioning intervention value CP. In this case, it can be concluded that a collision has occurred with an unexpected physical object, such as a person standing between the robot 50, 250, 350 and the vehicle 10. Then, in a fifth step 350, the rotary actuators 53, 54, 56, 59 or the motor 383 are stopped or activated to pull the robot-side charging interface 100 back to its fully retracted position.

[0077] 6C illustrates a scenario in which, at the start of the connection phase P2, the first compliance C1 or the second compliance C2 has a value that exceeds the connection intervention value CC. In this case, it is concluded that the robot-side charging interface 100 is unexpectedly misaligned with the vehicle-side charging interface 20 to the extent that it can no longer properly connect. The applied compressive force exceeds the allowable insertion force. This may be caused, for example, by unexpected movement of the vehicle 10 during the connection phase P2. Then, in a seventh step 370, the rotary actuators 53, 54, 56, 59, or the motor 383 are actuated to retract the robot-side charging interface 100 toward its fully retracted position or to the initial connection position.

[0078] 6D illustrates a scenario in which there is a large mutual difference between the first compliance C1 and the second compliance C2 at the start of the connection phase P2. In this case, it can be concluded that the robot-side charging interface 100 has rotated unexpectedly relative to the vehicle-side charging interface 20. This may be caused, for example, by an unexpected movement of the vehicle 10 during the connection phase P2. Then, in a seventh step 370, the rotation actuators 53, 55, 57, 59, or the motor 383 are actuated to retract the robot-side charging interface 100 toward the fully retracted position of the robot-side charging interface or to the initial connection position.

[0079] 6E illustrates a scenario in which the first compliance C1 or the second compliance C2 has a value that exceeds the connection intervention value CC during the connection phase P2. This may be caused, for example, by an obstruction of the connector while inserting the robot-side charging interface 100 into the vehicle-side 20. Then, in a seventh step 370, the rotary actuators 53, 55, 57, 59, or the motor 383 are actuated to retract the robot-side charging interface 100 toward the fully retracted position of the robot-side charging interface or to the initial connection position.

[0080] 6F illustrates a scenario in which the first compliance C1 or the second compliance C2 has a value that exceeds the first charging intervention value CC1 or has a value that is below the second charging intervention value CC2 during the charging phase P3, which may be caused by, for example, a violent movement of the vehicle 10 due to a large number of passengers boarding the vehicle 10 and pushing the vehicle-side charging interface 20 toward the movable platform 60 to the extent that the limits of safe absorption by the compliance assemblies 90a-90f are reached. Then, in a ninth step 390, the rotary actuators 53, 55, 57, 59 of the robot 50, 250 according to the first or second embodiment are actuated to return the position of the movable platform 60 relative to the vehicle 10 so that the first compliance C1 and the second compliance C2 again have balanced values ​​between the first charging intervention value CC1 and the second charging intervention value CC2, or the motor 383 of the robot 350 according to the third embodiment is actuated so that the compliance assemblies 90a to 90f are again balanced with the same effect.

[0081] In all scenarios, the values ​​of the first compliance C1 and the second compliance C2 are monitored using the distance sensor 110 to see if they exceed the first warning intervention value CW1. The first warning intervention value CW1 is higher than the positioning intervention value CP, the connection intervention value CC, and the first charging intervention value CC1. If the first compliance C1 or the second compliance C2 has a value that exceeds the first intervention value CW1, the rotary actuators 53, 54, 56, 59, or the motor 383 are immediately stopped if activated during the positioning phase P1 or the connection phase P2, and the charging current is interrupted if activated during the charging phase P3. If the first compliance C1 or the second compliance C2 has a value that exceeds the first intervention value CW1, an audio or visual alarm is triggered.

[0082] In all scenarios, the values ​​of the first compliance C1 and the second compliance C2 are monitored using the end switch 115 to see if they exceed the second warning intervention value CW2. The second warning intervention value CW2 is higher than the first warning intervention value CW1. If the first compliance C1 or the second compliance C2 has a value that exceeds the second warning intervention value CW2, the rotary actuators 53, 54, 56, 59 or the motor 383 are immediately stopped if activated during the positioning phase P1 or the connection phase P2, and the charging current is interrupted if activated during the charging phase P3. If the first compliance C1 or the second compliance C2 has a value that exceeds the second warning intervention value CW2, an audio or visual alarm is triggered. If the first compliance C1 or the second compliance C2 has a value that exceeds the second warning intervention value CW2, the remote control locking unit that locks the robot-side charging interface 100 and the vehicle-side charging interface 20 is released, allowing the charging interfaces 20, 100 to passively disengage from each other or to be actively disengaged by appropriately powering the rotary actuators 53, 54, 56, 59 or motors.

[0083] In practice, the first positioning intervention value is equal to or less than 50%, preferably equal to or less than 25% of the first connection intervention value. In the described embodiment, the first charging intervention value CH1 is equal to the charging intervention value CC.

[0084] It should be understood that the above description is included to illustrate the operation of the preferred embodiments and is not intended to limit the scope of the invention. From the above discussion, many variations will be apparent to those skilled in the art that are still encompassed within the scope of the invention.

Claims

1. A method for controlling a charging infrastructure comprising a charging station (1) for charging a vehicle having a vehicle-side charging interface (20), the charging station (1) comprising a robot carrying a robot-side charging interface (100) for establishing a charging connection with the vehicle-side charging interface (20), the robot comprising: main base (51), a displacement mechanism between the main base (51) and the robot-side charging interface (100) for moving the robot-side charging interface (100) with at least three degrees of freedom relative to the main base (51), the displacement mechanism comprising at least one actuator (53, 55, 57, 59, 380) configured to apply a displacement between the main base (51) and the robot-side charging interface (100) over a displacement stroke upon actuation; a compliance assembly disposed kinematically in series with at least one of the actuators (53, 55, 57, 59, 380) between the main base (51) and the robot-side charging interface, the compliance assembly being configured to provide compliance between the main base (51) and the robot-side charging interface (100) by elastically absorbing or releasing displacement over a compliance stroke. said method comprising, in order: a positioning step in which the robot-side charging interface (100) moves from a retracted position, in which the vehicle can enter and exit the charging station, to an initial connection position, in which the robot-side charging interface (100) is positioned in front of the vehicle-side charging interface (20); a connection phase in which the robot-side charging interface (100) establishes a charging connection with the vehicle-side charging interface (20) from the initial connection position; a charging phase in which the vehicle is charged with a charging current via the robot-side charging interface (100); and a disconnection phase in which the robot-side charging interface (100) is detached from the vehicle-side charging interface (20) and pulled back towards the retracted position; Including, During the positioning phase, at least one of the actuators (53, 55, 57, 59, 380) is energized according to a positioning command, the compliance is monitored, the compliance value is compared with a positioning intervention value, and if the compliance value exceeds the positioning intervention value, the positioning command is modified; During the connection phase, at least one of the actuators (53, 55, 57, 59, 380) is powered according to a connection command, the compliance is monitored, the compliance value is compared with a connection intervention value, and if the compliance value exceeds the connection intervention value, the connection command is changed; - the positioning intervention value is different from the connection intervention value, and the positioning intervention value is smaller than the connection intervention value; A method characterized by:

2. 2. The method of claim 1, wherein in the positioning step, the robot-side charging interface (100) moves to the initial connection position where the robot-side charging interface (100) is aligned with the vehicle-side charging interface (20).

3. The method of claim 1 or 2, wherein the positioning intervention value is less than 50% of the connection intervention value.

4. The method of claim 1 , wherein the positioning intervention value is less than 25% of the connection intervention value.

5. 5. The method of claim 1, wherein the positioning command is modified to deactivate at least one of the actuators (53, 55, 57, 59, 380) when the compliance value exceeds the positioning intervention value.

6. 6. The method of claim 1, wherein when the compliance value exceeds the positioning intervention value, the positioning command is aborted and at least one of the actuators is powered according to a retraction command to retract the robot-side charging interface toward the retracted position.

7. 7. The method according to claim 1, wherein the connection command is modified to stop the activation of at least one of the actuators (53, 55, 57, 59, 380) when the compliance value exceeds the connection intervention value.

8. 8. The method of claim 1, wherein when the compliance value exceeds the connection intervention value, the connection command is aborted and at least one of the actuators is powered according to a retraction command to retract the robot side charging interface toward the retracted position or to the initial connection position.

9. 9. The method according to claim 1, wherein during the charging phase at least one of the actuators (53, 55, 57, 59, 380) is powered according to a charging command, the compliance is monitored, and the charging command defines the compliance value to be between a first charging intervention value and a second, lower charging intervention value.

10. 10. The method of claim 9, wherein in the charging phase, at least one of the actuators (53, 55, 57, 59, 380) is powered according to the charging command at the start of the charging phase and is in an idle state if the compliance value is between the first charging intervention value and the second, lower charging intervention value.

11. 11. The method of claim 10, wherein at least one of the actuators (53, 55, 57, 59, 380) is idle for the remainder of the charging phase.

12. 12. The method according to claim 9, wherein when the compliance value exceeds the first charging intervention value or falls below the second charging intervention value, at least one of the actuators (53, 55, 57, 59, 380) is powered in accordance with the charging command to bring the compliance value between the first charging intervention value and the second charging intervention value.

13. During the positioning phase, the connection phase, and the charging phase, at least one of the actuators (53, 55, 57, 59, 380) can be powered according to an intervention command, and the compliance value is monitored, and the compliance value is compared with a warning intervention value, and if the warning intervention value is exceeded, - interrupting the charging current passing through the robot-side charging interface; - triggering an audio alert - triggering a visual alarm - notifying the vehicle or a higher level management system of an alarm condition; - Triggering a mechanical breakout release, and - Pulling back the robot-side charging interface (100) from the vehicle-side charging interface (20).

13. The method of any one of claims 9 to 12, wherein an intervention command selected from the group comprising:

14. - during the positioning step, the warning intervention value is higher than the positioning intervention value, - during the connection phase, the warning intervention value is higher than the connection intervention value, and / or - during the charging phase, the warning intervention value is higher than the first charging intervention value or lower than the second charging intervention value; the warning intervention values ​​have a first warning intervention value higher than the first charging intervention value and a second warning intervention value lower than the second charging intervention value; The method of claim 13.

15. 15. The method according to claim 1, wherein the positioning step includes determining a position of the vehicle-side charging interface (20) and determining the initial connection position by adding or subtracting a cumulative system error to the determined position of the vehicle-side charging interface (20).

16. A charging infrastructure comprising a charging station (1) for charging a vehicle having a vehicle-side charging interface (20), the charging station (1) comprising a robot carrying a robot-side charging interface (100) for establishing a charging connection with the vehicle-side charging interface (20), the robot comprising: main base (51), a displacement mechanism for moving the robot-side charging interface (100) with at least three degrees of freedom relative to the main base (51) between the main base (51) and the robot-side charging interface, the displacement mechanism comprising at least one actuator (53, 55, 57, 59, 380) configured to apply a displacement over a displacement stroke when actuated between the main base (51) and the robot-side charging interface; a compliance assembly disposed kinematically in series with at least one of the actuators (53, 55, 57, 59, 380) between the main base (51) and the robot-side charging interface, the compliance assembly being configured to provide compliance between the main base (51) and the robot-side charging interface (100) by elastically absorbing or releasing displacement over a compliance stroke. The charging infrastructure comprises: A controller operatively connected to at least the robot and configured to perform the method of any one of claims 1 to 13. and charging infrastructure.

17. 17. The charging infrastructure of claim 16, wherein the controller is an electronic controller configured to determine a resultant force and / or moment acting on the robot-side charging interface (100) from the compliance stroke and / or more specifically from the compliance stroke in one direction (L) of the applied individual or coupled compliance assemblies.

18. Charging infrastructure according to claim 16 or 17, comprising a sensor (366) for acquiring or deriving data of compliance in six degrees of freedom between the carrier (60) and the robot-side charging interface (100), in particular a distance sensor for the stroke of the compliance, and / or in particular a force or pressure sensor.

19. Charging infrastructure according to any one of claims 16 to 18, comprising switches (115), in particular end switches, arranged and configured to detect the abutment of the end stops and / or to function as part of a redundant control system for ultimately intervening or overriding the main control system in certain extreme situations.

20. A method for controlling a charging infrastructure comprising a charging station (1) for charging a vehicle having a vehicle-side charging interface (20), the charging station (1) comprising a robot carrying a robot-side charging interface (100) for establishing a charging connection with the vehicle-side charging interface (20), the robot comprising: main base (51), a displacement mechanism between the main base (51) and the robot-side charging interface (100) for moving the robot-side charging interface (100) with at least three degrees of freedom relative to the main base (51), the displacement mechanism comprising at least one actuator (53, 55, 57, 59, 380) configured to apply a displacement between the main base (51) and the robot-side charging interface (100) over a displacement stroke upon actuation; a compliance assembly disposed kinematically in series with at least one of the actuators (53, 55, 57, 59, 380) between the main base (51) and the robot-side charging interface, the compliance assembly being configured to provide compliance between the main base (51) and the robot-side charging interface (100) by elastically absorbing or releasing displacement over a compliance stroke. said method comprising, in order: a positioning step in which the robot-side charging interface (100) moves from a retracted position, in which the vehicle can enter and exit the charging station, to an initial connection position, in which the robot-side charging interface (100) is positioned in front of the vehicle-side charging interface (20); a connection phase in which the robot-side charging interface (100) establishes a charging connection with the vehicle-side charging interface (20) from the initial connection position; a charging phase in which the vehicle is charged with a charging current via the robot-side charging interface; and a disconnection phase in which the robot-side charging interface (100) is detached from the vehicle-side charging interface (20) and pulled back towards the retracted position; Including, During the charging phase, the at least one actuator (53, 55, 57, 59, 380) is powered according to a charging command and the compliance is monitored; The charging command specifies comparing a compliance value with a first charging intervention value and a second, lower charging intervention value, and the charging command is changed when the compliance value moves outside a range defined by the first and second charging intervention values, thereby actively maintaining the compliance value between the first and second, lower charging intervention values ​​using the at least one actuator (53, 55, 57, 59, 380). A method characterized by:

21. 21. The method of claim 20, wherein in the positioning step, the robot-side charging interface (100) moves to the initial connection position where the robot-side charging interface (100) is aligned with the vehicle-side charging interface (20).

22. 22. The method according to claim 20 or 21, wherein in the charging phase at least one of the actuators (53, 55, 57, 59, 380) is powered according to the charging command at the start of the charging phase and is in an idle state when the compliance value is between the first charging intervention value and the second, lower charging intervention value.

23. 23. The method of claim 22, wherein at least one of the actuators (53, 55, 57, 59, 380) is idle for the remainder of the charging phase.

24. 24. The method according to any one of claims 20 to 23, wherein when the compliance value exceeds the first charging intervention value or falls below the second charging intervention value, at least one of the actuators (53, 55, 57, 59, 380) is powered in accordance with the charging command to bring the compliance value between the first charging intervention value and the second charging intervention value.

25. During the positioning phase, the connection phase, and the charging phase, at least one of the actuators (53, 55, 57, 59, 380) is powered according to an intervention command, the compliance value is monitored, the compliance value is compared with a warning intervention value, and if the warning intervention value is exceeded, - interrupting the charging current passing through the robot-side charging interface; - triggering an audio alert - triggering a visual alarm - notifying the vehicle or a higher level management system of an alarm condition; - Triggering a mechanical breakout release, and - Pulling back the robot-side charging interface (100) from the vehicle-side charging interface (20).

25. The method of any one of claims 20 to 24, wherein an intervention command selected from the group comprising:

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