AGV Charging Arm Interface for Autonomous Multi-Vehicle Charging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery-operated automated guided vehicles (AGVs) in warehouse environments require efficient and automated charging systems to manage their battery levels without human intervention, as they operate continuously and need to be charged efficiently to maintain productivity and minimize downtime.
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 a charging position, enables autonomous charging by detecting vehicle presence, regulating power delivery based on battery levels, and terminating the charge cycle when full or at a predetermined level, with optional AI/ML for scheduling and optimizing charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual charging operation is used for battery-operated AGVs, then human intervention is required which increases operational complexity and downtime, but automated charging systems increase device complexity
Solution Approach 1:
The AGV autonomously navigates to charging stations and performs charging operations without human intervention. The vehicle's controller automatically manages battery level monitoring, station selection, and charging execution, enabling the system to service itself and eliminate manual charging operations.
Solution Approach 2:
The AGV proactively monitors its battery charge level and autonomously navigates to charging stations before the battery is depleted. This preliminary action ensures continuous operation by scheduling charging during optimal times and locations, preventing operational interruptions.
2Reliability
If AGVs are charged frequently to maintain battery levels, then operational continuity is improved, but charging time and productivity loss increase
Solution Approach 1:
The AGV's controller continuously monitors battery charge levels and uses this feedback to determine when charging is necessary. The system optimizes charging timing by scheduling charges during low-demand periods or when the AGV is naturally idle, balancing battery maintenance with operational continuity.
Solution Approach 2:
The charging schedule is dynamically adjusted based on real-time operational conditions, battery state, and station availability. The system adapts charging frequency and duration to minimize productivity loss while ensuring reliability, rather than following a fixed charging schedule.
3Productivity
If multiple AGVs are charged simultaneously at centralized stations, then charging efficiency is improved, but station availability and access become bottlenecks
Solution Approach 1:
The charging infrastructure is segmented into multiple distributed charging stations throughout the operational area. This allows multiple AGVs to charge simultaneously at different locations, eliminating the bottleneck of centralized stations and maintaining system adaptability.
Solution Approach 2:
Charging stations are distributed across the spatial dimension of the operational area rather than concentrated at a single location. This spatial distribution enables parallel charging operations and maintains accessibility for all AGVs regardless of their position in the workspace.
4Extent of automation
If AGVs autonomously navigate to charging stations, then human intervention is eliminated, but navigation complexity and sensor requirements increase
Solution Approach 1:
The AGV's navigation system, already required for its primary material handling functions, is leveraged for charging navigation as well. The same sensors, processors, and control mechanisms used for workspace navigation are repurposed to navigate to charging stations, avoiding additional dedicated navigation hardware.
Solution Approach 2:
The charging navigation function is merged with the AGV's existing autonomous navigation capabilities. The controller integrates charging station location data with the vehicle's route planning system, combining these functions into a unified navigation process that eliminates the need for separate charging-specific navigation hardware.
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
The system allows for efficient, automated, and orchestrated charging of multiple AGVs, maximizing their operational efficiency by ensuring they are charged when needed, reducing downtime, and optimizing battery health through intelligent scheduling.
Implementation Method 1
a charging interface (154) of the charging station (150), wherein the charging interface (154) includes at least one magnet (158)
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 to 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.