AGV Charging Arm With Magnetic Contacts for Autonomous Docking
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Solution Overview
Problem
Existing battery-operated automated guided vehicles (AGVs) in warehouse environments require manual or inefficient automated charging methods, lacking orchestrated and efficient charging solutions without human intervention.
Innovation Solution
A vehicle charging system comprising a charging interface with a magnet and compressible charger contact, controlled by a controller that articulates an arm into charging position, enables autonomous charging by detecting vehicle presence, regulating power delivery based on battery levels, and terminating charging when full or at a predetermined level, with optional AI/ML for scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual charging methods are used for battery-operated AGVs, then human intervention is required, but charging efficiency decreases and operational downtime increases
Solution Approach 1:
The AGV autonomously navigates to the charging station and performs charging operations without human intervention. The vehicle's controller automatically manages the charging process, including connecting to the charging interface, monitoring battery levels, and disconnecting when charging is complete, thereby eliminating manual operations and reducing downtime.
Solution Approach 2:
The system proactively monitors battery charge levels and schedules charging operations before complete depletion occurs. The controller initiates charging sequences in advance based on predicted energy requirements, ensuring the AGV is recharged during optimal time windows and preventing operational interruptions.
2Extent of automation
If automated charging systems are implemented, then human intervention is reduced, but system complexity increases
Solution Approach 1:
The charging interface is designed with universal compatibility to accommodate multiple AGV models and battery configurations through a standardized magnetic connector system. The same charging station infrastructure can serve different vehicle types, reducing the need for multiple specialized charging systems and thereby managing complexity.
Solution Approach 2:
The system replaces complex mechanical coupling mechanisms with magnetic attraction forces for connector engagement. The magnetic interface automatically aligns and secures charging contacts without requiring precise mechanical positioning or manual intervention, simplifying the physical connection process while maintaining high automation.
3Productivity
If multiple AGVs are charged simultaneously, then charging throughput increases, but coordination complexity increases
Solution Approach 1:
The charging station controller continuously monitors the charge status, battery levels, and operational schedules of multiple AGVs. Based on this real-time feedback, the system dynamically adjusts charging sequences, allocates charging resources, and coordinates disconnection timing to maximize throughput while preventing conflicts or overcharging conditions.
Solution Approach 2:
The system implements periodic charging cycles for multiple AGVs, rotating vehicles through charging slots in a scheduled sequence. This rhythmic, time-based coordination approach allows multiple vehicles to be serviced simultaneously without requiring complex real-time negotiation, as each AGV follows a predetermined charging timetable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, autonomous, and orchestrated charging of multiple AGVs, minimizing human intervention and optimizing charging based on vehicle routes and battery levels, thereby enhancing operational efficiency and reducing downtime.
Implementation Method 1
a charging interface with a magnet and compressible charger contact
Implementation Method 2
in response to compression of the charger contact, deliver a current to the coupled charging interface
Data Source
AI summary
A vehicle charging system comprises at least one controller and at least one arm, each arm having a first end coupled an actuator and a second end comprising a charging interface. The actuator is configured to articulate the arm into a charging position. The charging interface comprises at least one charging contact coupled to a power source and configured to engage and deliver power to a vehicle charging interface to charge at least one battery of a vehicle. The charging system can include a plurality of arms, each configured to charge a different vehicle. A method of charging one or more vehicles using the charging system is also provided.