Method and device for connecting the connector of an electric vehicle charger to the socket of an electric vehicle

Abstract

A method and apparatus for connecting a connector of an electric vehicle charger to a socket of an electric vehicle, comprising: A. determining a assumed position and orientation of the socket; B. moving the connector in the direction of the assumed position of the socket; C. positioning a connector adjacent to the assumed socket position of the connector by at least one angular rotation around an axis not parallel to the direction of unique movement for the mutual orientation of the connector and the socket, wherein the respective centerlines of at least two pin-hole connecting pins coincide; D. eliminating the angular difference between the assumed position and orientation and the actual position and orientation; E. connecting the connector and the socket by performing unique movements toward each other.

Description

Technology Field

[0001] The present invention relates to a method and apparatus for connecting a connector of an electric vehicle charger to a socket of an electric vehicle. Apparatuses for this purpose are known in the art, for example, from the international patent application PCT / NL2020 / 050266 of the same applicant. Background Technology

[0002] The charging cable of a charger for charging an electric vehicle is typically equipped with a connector (also called a plug or coupler) for plugging into a socket provided in the electric vehicle. Such a connector may be of a multi-pole type, meaning it may be designed to establish multiple connections when connected to the socket. These connections may be provided for AC or DC power connections for charging (discharging) the vehicle battery and / or for data exchange between the charger and the vehicle, particularly the vehicle's battery management system. The connector and the socket may include pin-and-hole connections, wherein both the connector and the socket may have a combination of both pins and holes.

[0003] Connectors and sockets for charging electric vehicles are standardized. Currently commonly used types are described in standards such as IEC 62196 and SAE J1772. Connector and socket types in these standards are also referred to as CCS-1, CCS-2, Type-1, Type-2, Type-3, CHAdeMO, and GB / T (also described in GB / T 20234.3). Other standardized EV charging connectors include, for example, the newly defined ChaoJi connector for use in China and Asia, Euro-Din according to DIN VDE 0623-589 used for low-voltage vehicles such as forklifts, and the Future HPCCV connector for use in heavy electric vehicles such as trucks and buses. In particular, CCS-2 type connectors and sockets are gaining popularity in Europe. In addition to multi-pole electrical connections, connectors and sockets establish mechanical connections, which ensure the correct poles are paired and maintain the engaged electrical connection during charging. To maintain a mechanical connection, the connectors feature a tight fit that secures the connector to the socket. The aforementioned standards, connectors, and sockets are intended specifically for placement inside or on top of the vehicle body or carrosserie, and are generally positioned on the side of the vehicle or, if possible, on the top.

[0004] These connectors are not specifically intended for use under the vehicle, i.e., in contact with or integrated under the vehicle floor, or inside or opposite to the chassis. Accordingly, the invention (and the method according to it) may not be explicitly intended for connections under the vehicle and / or to the floor or chassis of the vehicle.

[0005] Standard connectors may have chamfers for guidance and may have a "loose" fit during the initial stage of insertion into the socket. Nevertheless, inserting a standard electric vehicle connector into a socket is generally a high-precision task requiring accurate positioning of the connector to be inserted. Furthermore, in real-world situations, unexpected changes in the position (position / rotation) of the vehicle socket may occur during the insertion process (such as passenger boarding, cargo loading and unloading, wind loads, etc.).

[0006] The object of the present invention is to reduce the requirements for highly accurate pose estimation methods, which are complex and consequently costly, despite uncertainties in the position and orientation of sockets and connectors, and / or to reduce the requirements for highly accurate robots that have the same complex and costly disadvantages. The present invention also aims to provide a more adaptive solution for unexpected movements during the insertion process, more specifically during the final stage of the insertion process (after the last pose estimation). In general, it is the object of the present invention to provide a useful alternative to the latest technology.

[0007] The present invention relates to connecting a connector of an electric vehicle charger to a socket of an electric vehicle in a supposed position and orientation, wherein the connector and the socket each have a plurality of poles electrically interconnectable by establishing pairs of electrically conductive pin-and-hole connections, wherein the connector includes a pin and the socket includes an associated hole, and / or the connector includes a hole and the socket includes an associated pin, wherein each pin-and-hole has a centerline extending axially from the center of the associated pin or hole, and these centerlines are parallel, wherein the connector and the socket can be connected by a single unique movement toward each other.

[0008] This unique movement has a direction parallel to the centerline direction of the pins and holes, and a mutual orientation of the connector and socket, wherein the respective centerlines of the pins and holes of at least two pin-hole connection pairs coincide, wherein each connector and socket includes a housing, wherein the connector and socket housings can be connected by the same unique movement toward each other, wherein the connector and / or socket include mechanical guide portions that protrude beyond the ends of the pins in a direction parallel to the direction of the centerlines.

[0009] The above directions and orientations are applied to the final part of the physical connection setup, where at least a portion of the connector and socket housing are in contact with each other.

[0010] Although the aforementioned standards satisfy the above limitations, the present invention is not limited to these standards.

[0011] The method according to the present invention comprises the following steps:

[0012] A. A step of determining the assumed position and orientation of the socket;

[0013] B. A step of moving the connector toward the assumed position of the socket with the help of an automatic actuator and / or manipulator;

[0014] C. A step of positioning a connector adjacent to an assumed socket position of a connector by at least one angular rotation around an axis not parallel to the direction of movement inherent to the mutual orientation of the connector and the socket, with the help of the above-described automatic actuator and / or manipulator—wherein the respective centerlines of the pins and holes of at least two pin-hole connection pairs coincide—;

[0015] D. A step to eliminate the angular difference between the assumed position and orientation and the actual position and orientation;

[0016] E. A step of connecting the connector and the socket by performing unique movements toward each other with the help of an automatic actuator and / or manipulator.

[0017] Steps A through E may also be referred to as a plug-in sequence.

[0018] In the present application, as in other fields, an axis being not parallel to a direction means that there is an angle between the axis and the direction with an absolute value greater than zero. Consequently, not being parallel is not a negative definition but excludes a series of directions that are parallel (including coincident directions).

[0019] The method according to the present invention provides the advantage that the alignment of 6 degrees of freedom (6DOF) required prior to performing a unique movement to connect a connector and a socket is no longer required simultaneously but can be satisfied in stages. The coupling procedure is performed in such a way that the shape of the connector guides the alignment, regardless of whether it is specifically designed for that purpose.

[0020] In the latest technology methods, since many locations must be aimed precisely and simultaneously between specific boundaries of a connector or socket, an attempt is made to align and plug the entire connector at once, which requires the simultaneous alignment of larger surfaces within specific boundaries of the connector or socket, rather than small surfaces or even lines or points.

[0021] The procedure may begin by applying intentional rotational misalignment, for example, by first aiming a protruding part, such as the edge of the connector, at a predetermined location on the socket, which may be an edge, or between the slits or gaps of the socket. That is, the present method may include the step of positioning a portion of the connector between the geometric boundaries of the vehicle socket. Since such slits or gaps may be relatively wide relative to the protruding part of the connector, and the first part of the positioning is possible because there are fewer constraints and the remaining constraints allow for a larger error, as it does not attempt to accurately aim at the gaps at other locations (i.e., parts of the socket). Alternatively, the present method is considered to partially mat the connector and the socket so that they come into partial contact, where the convex hull is superimposed, and then the centerlines of the pin-hole pairs are aligned, thus employing an intentional misalignment method. Misalignment or bias can be designed based on the connector and socket geometry and angle of attack, which means that, apart from intentional rotational misalignment, there may also be intentional displacement misalignment applied in one direction to facilitate plug-in sequences with rotational misalignment.

[0022] When a portion of the connector enters a slit or gap, the connector's free movement is restricted by the shape of the automotive connector and the shape of the connector. This simplifies the alignment of the remaining degrees of freedom, which can be aided by mechanically guiding the surfaces of the connector and socket.

[0023] In the sense of the present invention, adjacent should be understood as being in mechanical contact at a mutual distance of less than 10 cm, preferably and / or generally less than 5 mm.

[0024] In the first embodiment of the present invention, steps D and E may occur sequentially. That is, by performing unique movements toward each other before connecting the connector and the socket, the angular difference between the assumed position and orientation and the actual position and orientation can be eliminated. In this embodiment, step D may be performed by an automatic actuator and / or manipulator.

[0025] Step D can be triggered by the detection of a connector in contact with a socket, or by a determination or detection that the minimum distance between parts of the connector has reached a predetermined threshold, such as less than 5 mm, particularly less than 1 mm.

[0026] This can be done, for example, when information about mechanical contact is obtained, or when (updated) camera information indicates that alignment is within a specific boundary, or when the connector is positioned, for example, in a slit or gap of the socket, or subsequently positioned in a known or determined part of the socket that can serve as a reference.

[0027] After that, if the connector is partially positioned in the socket, it can be rotated to the aligned orientation. Due to intentional misalignment, full positioning (and connection) in the socket is not yet possible at this stage, but this can occur after the aligned orientation is reached.

[0028] In an alternative embodiment, steps D and E occur at least partially simultaneously, particularly while applying force and / or torque with at least a directional component in the direction of inherent movement toward each other.

[0029] This is preferably performed while applying force and / or torque with a directional component corresponding to the inherent movement, but is not essential.

[0030] The method according to the present invention may or may not include actively rotating the connector by performing an operation to rotate the connector. While this may be a preferred embodiment, such rotation may be the result of movement in the direction of inherent movement toward each other and / or movement following the shape.

[0031] In another preferred embodiment of the method according to the present invention, the angular rotation occurs around an axis perpendicular to the direction of the inherent movement toward each other, and when it is found that such rotation results in a suitable part of the connector protruding toward the socket, it first engages with the socket and forms a reference for additional connection movement.

[0032] Subsequently, step D may occur, for example, while the connector rotates relative to the socket and one or more contacts or lines. These one or more contacts may be (virtually connected) lines and may change—particularly gradually—during steps D and E.

[0033] Step D may be caused by active rotational manipulation of the connector, for example, by an actuator or a robot (part). For example, this may be performed where suitable guide surfaces are absent or non-existent on the connector and / or socket, where increased speed is required or necessary, or where the permissible force applied by the connector to the socket is limited. Active rotational manipulation should be understood as applying a torque or force that directly induces rotation.

[0034] Alternatively, step D occurs as a result of step E by manual operation, particularly when manipulating the connector, for example by using compliance, particularly mechanical compliance. In this embodiment, a force is applied only or not entirely in the resulting rotational direction, but while the rotation is caused by the guidance of the connector and / or socket housing, the device for manipulating the connector allows certain degrees of freedom in at least directions different from the directions in which the force or torque is applied. The compliance of the manipulator may be adjusted or provided for this purpose. Generally, the term manual operation is used herein to indicate that there is no directly controlled rotation.

[0035] In another embodiment of the present invention, the connector is positioned adjacent to the location of the assumed socket and is also positioned under movement in addition to the intended rotation. Depending on the shape of the connector and / or socket, intentional movement in a predetermined direction and over a predetermined distance may aid in further alignment and positioning of the connector and socket.

[0036] The assumed position and orientation may be determined based on data derived from a fixed parking position, the vehicle's known geometry, and repeatable and sufficiently accurate parking, for example, where there is a predetermined charging position where the vehicle is parked, or particularly, for example, where parking is performed automatically because the vehicle is equipped with an automatic parking function. Alternatively, data may be provided by the vehicle, and this may be data from parking sensors that can also be used for automatic parking purposes. The sensors may further include cameras on the vehicle or on the manipulator for the charging facility and / or connector, and / or contact sensors may be used on or coupled to the connector and / or socket.

[0037] In another embodiment, the assumed position and orientation of the socket are recursively determined or recalculated during the plug-in sequence, and the movement can be adjusted based on updated information of the assumed position.

[0038] The present invention may be applied in combination with a CCS connector, wherein the angular rotation is 0 to 20 degrees, particularly 1 to 5 degrees, more specifically about 3 degrees, or particularly 12 to 18 degrees, more specifically about 15 degrees with respect to a rotation axis parallel to the connection line between the ends of the DC charging pins of the CCS connector.

[0039] This may also apply if the connector is a Type 1 connector, Type 2 connector, CHAdeMO connector, GB / T connector, Euro DIN connector, or if the connector is a ChaoJi connector or HPCCV connector.

[0040] Generally, a portion of the connector body may protrude into or up the convex hull (boundary-box) of the socket by rotation before reaching final alignment. This protrusion restricts at least one degree of freedom of movement while at least partially constraining the movement of the connector.

[0041] The present invention also relates to an apparatus for performing the method described above, comprising a manipulator for moving a connector of an electric vehicle charger having a socket on an electric vehicle to a assumed position and orientation, wherein the manipulator is configured to move the connector. Such a manipulator may be, but is not limited to, the apparatus described in the international patent application PCT / NL2020 / 050266 of the same applicant, which is incorporated herein by reference.

[0042] The manipulator may be configured to move the connector by at least 3, preferably 4, more preferably at least 5 degrees of movement, and compliance may be provided in at least all degrees of freedom in which the manipulator is not configured to move the connector. This compliance may be of the type disclosed in the same applicant's international patent application PCT / NL2020 / 050266, but is not limited thereto.

[0043] A manipulator for moving a connector may be configured to perform a shape-following movement that brings the connector in the insertion direction. This may be passive or active. In a passive embodiment, the manipulator may be equipped with a passive compliance assembly (e.g., a spring assembly) designed to appropriately correct intentional misalignment or, in particular, intentional incorrect rotation. This embodiment may be applied to relatively small misalignments of a few degrees, e.g., up to 5 degrees, where the compliance passively corrects them. Brief explanation of the drawing

[0044] Now, the present invention will be described in detail with reference to the following drawings. - Figures 1a and 1b show a front view and a cross-sectional view of a method for connecting a connector to a socket according to the latest technology. - FIGS. 2a and 2b show a front view and a cross-sectional view of a method for connecting a connector according to the present invention to a socket. - FIGS. 3a and 3b show a front view and a cross-sectional view of a method for connecting a connector according to the present invention to a socket. - FIGS. 4a to 4d show cross-sectional views of a method for connecting a connector according to the present invention to a socket. Specific details for implementing the invention

[0045] FIGS. 1A and FIGS. 1B illustrate a connector (1) of an electric vehicle charger that can be connected to a socket (2) of an electric vehicle (not shown) in a hypothetical position and orientation (as shown), wherein the connector (1) and the socket (2) are electrically interconnected in a multi-pole manner by establishing pairs of electrically conductive pins (3) and holes (4), wherein in the illustrated case, the connector is of the CCS 2 standard type including holes (4) and the socket includes associated pins (3), wherein each pin has a centerline (6) extending axially from the center of the pin, and each hole has a centerline (5) from the associated hole, and the centerlines (6) (of all pins (3)) are parallel and the centerlines (5) (of all holes (4)) are parallel, wherein the connector (1) and the socket (2) can be connected by a single unique movement toward each other, and this movement is the centerline (5) of the pins (3) and holes (4), 6) has a direction (7) parallel to the direction of the connector (1) and socket (2), and the centerlines (5, 6) of the pins (3) and holes (4) of at least two pin-hole connection pairs coincide. The connector (1) and socket (2) each include a housing (8, 9), wherein the connector and socket housings (8, 9) can be connected by the same intrinsic movement (7) toward each other and include mechanical guide parts (10, 12) that protrude (11) in a direction parallel to the direction of the centerlines (5, 6) beyond the ends of the pins.

[0046] The mutual orientation of the connector (1) and the socket (2) is "aligned," which means that when the connector moves in the direction (7), the connector and the socket are connected, in other words, the connector is plugged in.

[0047] FIG. 1b shows a cross-sectional view corresponding to line A-A' of FIG. 1a, taken precisely from the front plane of the socket (2), which is part of the socket surrounding the DC pins. The DC pins are slightly deeper than the AC pins, and are ultimately deeper than the front plane. The connector is in the position of FIG. 1a, which means that the protrusion (10) extends from the slit or gap (12) of the socket. The protrusion (10) and the slits or gaps (12) work together to form mechanical guide parts for mutually positioning the connector (1) and the socket (2) in this case.

[0048] In FIG. 1b, it is clearly visible that in order to connect the connector (1) and the plug (2), the protrusion (10) of the connector must fit within the geometric boundary of the socket, which is formed by the edge of the slit or gap (12). Detail B indicates that the tolerances (13, 14) for establishing the connection are very small and can be seen in the overall shape of the corresponding elliptical portions of the connector (1) and the socket surrounding the DC charging pins (15, 16). In the case of automated connection, coupling, or plugging of the connector (1) and the socket (2), these small tolerances and complex positioning requirements form an obstacle that sets limits on the techniques that can be applied and the speeds at which they can be operated.

[0049] The method according to the present invention eliminates these disadvantages, as can be seen from FIGS. 2a, b and FIGS. 3a, b, which consider step C of the present invention, even though the same CCS 2 connector and socket are connected.

[0050] FIG. 2a shows the connector (1) and socket (2) from FIG. 1a and FIG. 1b, but now misaligned by an angle rotation (α) of 3 degrees with respect to the axis (15) perpendicular to the direction of movement (7) of the mutual orientation of the connector (1) and socket (2), where the respective centerlines of the pins and holes of at least two pin-hole connection pairs coincide.

[0051] FIG. 2b again shows a cross-section of line A-A' with a small portion of the protrusion (10) within the geometric boundary of the socket (2). This effect is achieved by the misalignment of the connector (1) over an angle (α) of 3 degrees. As can be seen in FIG. 2b, there is a relatively much larger receiving space with a larger tolerance around the protrusion (10) of the connector (10). This makes it easier to place the connector (1) against the socket (2), thus setting less strict requirements and enabling work automation.

[0052] FIGS. 3a and 3b show another configuration of the same connector (1) and socket (2), now having a misalignment (β) of 15 degrees. As can be seen in the drawings, the tolerances (18 and 19) are much larger than the tolerances (12, 13) of FIG. 1b.

[0053] The examples provided above indicate the operating angles for the CCS2 connector. For other connector and socket combinations, the optimal angles may differ. However, in practice, this is not an issue because the connector is coupled to the charger, and the charger may be equipped with a connector manipulator tailored to the specific connector. The operating range for any type of connector and socket can be predetermined by one or more optimal misalignment angles from the front.

[0054] In all embodiments within the scope of the present invention, uncertainty regarding the position and orientation (or vice versa) of the socket relative to the assumed (which may be synonymous with "assumed") connector forms the reason for adding intentional misalignment. The uncertainty and angle at which the misalignment has an advantageous effect may all have a certain range, and such misalignment may be selected considering the uncertainty and direction of the assumed position. That is, despite the worst-case estimate of the socket position, the misalignment is still within a range that facilitates the connection between the connector and the socket.

[0055] FIG. 4a shows a cross-section of a situation in which the connector (1) undergoes unintended rotation around an axis (20) that is parallel to the centerlines of the pins and holes. This direction of rotation is called roll, and the illustrated misalignment is 3 degrees. In Section D, it can be seen that the connector (1) and the socket (10) come into contact due to the misalignment. In this orientation, it may be impossible to connect the connector and the socket because the rest of the connector may come into contact with the socket and the contours of the pins and holes are not correctly outlined.

[0056] FIG. 4b shows the situation of FIG. 4a again, with an unintended roll of 5 degrees and an intentional rotation of 3 degrees around the axis (25) from left to right in the drawing, called pitch. As shown in the drawing, the connector no longer comes into contact with the socket, and the connector and the socket can be connected by moving the connector in the direction (20) indicated in FIG. 4a.

[0057] FIG. 4c shows an unintended rotational misalignment of 3 degrees of the axis center in the direction from top to bottom (21) of the drawing, called yaw, for the mutual orientation of the connector (1) and the socket (2), where the respective centerlines of the pins and holes of at least two pin-hole connection pairs coincide. A gap (23, 24) is shown that sets a constraint on the positioning of the connector (1) in the socket.

[0058] FIG. 4d is a re-illustration of the situation in FIG. 4c, with 3 degrees of unintended yaw and 3 degrees of added intentional pitch, setting less strict constraints on the positioning of the connector (1) in the socket as can be seen in the smaller part (10) of the connector (1) in the socket, thus adding more tolerance and making the connection easier. Compared to FIG. 4c, the effect of adding intentional pitch to the unintended yaw can be seen.

[0059] The given examples are merely examples and do not limit the scope of protection defined by the following claims.

Claims

Claim 1 A method for connecting a connector of an electric vehicle charger to a socket of an electric vehicle in a assumed position and orientation, wherein: o the connector and the socket each have a plurality of poles electrically interconnectable by establishing electrically conductive pin-and-hole connection pairs, the connector includes a hole and the socket includes an associated pin, wherein: o each pin-and-hole pair of the connector and the socket has a centerline extending axially from the center of the corresponding pin or hole, and these centerlines are parallel to each other; and - the connector and the socket can be connected by a single unique movement toward each other, wherein the movement has a mutual orientation of the connector and the socket such that o a direction parallel to the direction of the centerlines of the pins and holes, and o the respective centerlines of the pins and holes of at least two pin-and-hole connection pairs coincide; and - each of the connector and the socket includes a housing, wherein the housings of the connector and the socket can be connected by the same unique movement toward each other; o comprising mechanical guiding portions protruding beyond the ends of the pins in a direction parallel to the direction of the centerlines; the method comprises: A. determining the assumed position and orientation of the socket; B. moving the connector in the direction of the assumed position of the socket with the help of an automatic actuator or manipulator; C. performing active manipulation with the help of the automatic actuator or manipulator to position the connector in a position adjacent to the assumed position of the socket by at least an intentional angular rotation about an axis perpendicular to the direction of the inherent movement—the direction of the inherent movement is for the mutual orientation of the connector and socket where the respective centerlines of the pins and holes of the at least two pin-hole connection pairs coincide—; D.A method comprising: a step of eliminating the angular difference between the assumed position and the adjacent position by performing an active rotational operation on the connector by means of the automatic actuator or the manipulator; E. a step of connecting the connector and the socket by performing a unique movement toward each other with the help of the automatic actuator or the manipulator. Claim 2 A method according to claim 1, wherein steps D and E are performed sequentially. Claim 3 A method according to claim 2, wherein step D can be triggered by detection of the connector in contact with the socket, or by determination or detection that the distance between the part of the connector and the part of the socket has reached a predetermined threshold value, such as less than 5 mm. Claim 4 A method according to claim 1, wherein steps D and E are performed at least partially simultaneously while applying a force and / or torque having at least a directional component in the direction of the inherent movement toward each other. Claim 5 A method according to claim 1, wherein step D is performed while the connector rotates around one or more contacts or lines with the socket. Claim 6 A method according to claim 1, wherein step C comprises partially mating the connector and the socket to partially contact them. Claim 7 In claim 1, the method wherein rotation in step D is caused by the guidance of the connector and / or socket housing. Claim 8 A method according to claim 1, comprising the step of positioning the connector adjacent to an assumed position of the socket under at least one rotational misalignment, in addition to translational misalignment. Claim 9 A method according to claim 1, wherein the assumed position and orientation are determined based on: - a fixed parking position for charging and a known geometric structure of the vehicle; - data provided by the vehicle; and - data derived from one or more sensors and / or cameras. Claim 10 A method according to claim 1, wherein the assumed position and orientation of the socket are recrystallized or recalculated during step AE, and the movement is adjusted. Claim 11 A method according to claim 1, wherein the connector is a CCS connector, and the angle rotation is 0 to 20 degrees with respect to a rotation axis parallel to the connection line between the ends of the DC charging pins of the CCS connector. Claim 12 A device for performing the method according to claim 1, - a manipulator for moving a connector of an electric vehicle charger having a socket in an electric vehicle to a assumed position and orientation, wherein the manipulator is configured to move the connector. Claim 13 In claim 12, the device wherein the manipulator is configured to move the connector to at least one degree of freedom. Claim 14 In claim 12, the connector is a device suspended from the manipulator by compliance in at least one degree of freedom. Claim 15 In claim 12, the device comprises a compliance including a spring assembly. Claim 16 delete

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