Ball-Coupling Charging Module for Automated EV Attachment

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Solution Overview

Problem

Existing electric vehicle charging facilities rely on manual operation and pneumatic pressure, making them unsuitable for outdoor use and hindering automation.

Innovation Solution

An attachment/detachment device with a driving part, pressing part, movable part, and elastic member, along with ball members and a coupling mechanism, automates the charging process by rotating and pressing ball members to engage or disengage a charger with the vehicle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If pneumatic pressure is used for the tool changer, then the coupling mechanism can operate, but it becomes unsuitable for outdoor electric vehicle charging stations

Engineering Contradiction:
Improvesuitability for outdoor useVSAvoidoperational reliability
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces the pneumatic pressure system with a mechanical ball member-based coupling mechanism. The ball members are pressed by elastic members (springs) to engage with corresponding holes in the charger, eliminating the need for pneumatic systems that are unsuitable for outdoor environments. This mechanical substitution maintains operational reliability while improving adaptability to outdoor charging stations.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If manual operation is used to couple the charger to the tool changer, then the process can be performed, but complete automation cannot be implemented

Engineering Contradiction:
Improveautomation levelVSAvoidoperational simplicity
Core Design Contradiction:
Extent of automationVSEase of operation

Solution Approach 1:

The patent implements a self-service coupling mechanism where the attachment/detachment device automatically engages and disengages the charger using a driving part that rotates to move the pressing part. The elastic members automatically press the ball members to secure the charger, and the system can release the charger automatically when needed. This eliminates manual operation while maintaining ease of use through automated mechanical actions.

Inventive Principle:
Principle #25Self-service

3Volume of moving object

If the attachment/detachment device uses a compact design, then the size is reduced, but the coupling mechanism must still ensure reliable engagement

Engineering Contradiction:
Improvedevice sizeVSAvoidcoupling reliability
Core Design Contradiction:
Volume of moving objectVSReliability

Solution Approach 1:

The patent divides the coupling mechanism into multiple ball members (typically three) distributed around the coupling interface. Each ball member is independently pressed by elastic members, allowing the system to achieve reliable engagement through distributed contact points. This segmentation enables compact design while maintaining coupling reliability, as the multiple small ball members occupy less space than a single large coupling mechanism.

Inventive Principle:
Principle #1Segmentation

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 automated charging of electric vehicles without manual intervention, suitable for outdoor use and enhancing infrastructure efficiency.

Implementation Method 1

an elastic member provided at one side of the movable part and configured to press the movable part in a second direction D2 that is different from the first direction D1

Methodology Applied
Scientific EffectElastic force: Elasticity

Implementation Method 2

The movable part presses the one or more ball members in an inward direction, which is a direction opposite to an outward direction R

Methodology Applied
Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS20250313107A1Attachment/detachment device and a charging module including the same
Publication Date: 2025.10.09 HYUNDAI MOTOR CO LTD
  • US20250313107A1 patent drawing
  • US20250313107A1 patent drawing
  • US20250313107A1 patent drawing

AI summary

An attachment/detachment device including: a driving part configured to rotate about a driving axis; a pressing part configured to rotate in conjunction with the rotation of the driving axis; a movable part configured to be movable by the rotation of the pressing part; an elastic member configured to press the movable part; a coupling member provided to face the movable part; and one or more ball members accommodated in the coupling member. The one or more ball members are provided to protrude outward from the coupling member.