Vehicle Charging Connector Alignment for Multi-Standard Automation
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Solution Overview
Problem
Existing vehicle charging systems require significant human intervention, are not adaptable to different vehicles, and fail to accommodate various plugging standards, leading to inefficiencies and high costs.
Innovation Solution
A charging system with a connector on a flexible cable movable along multiple axes, paired with a charging port and adapter that can automatically align and connect with different vehicle charging standards, utilizing a vision system and charging controller to facilitate automated charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated charging systems are implemented, then human intervention is reduced, but device complexity and cost increase
Solution Approach 1:
The charging system employs a universal connector design that can accommodate multiple plugging standards (SAE J1772, CHAdeMO, GB/T, NACS) through a single interface. The connector housing includes adjustable contact plates and alignment features that adapt to different vehicle types, eliminating the need for multiple specialized charging stations and reducing overall system complexity.
Solution Approach 2:
The system incorporates vision systems and sensors that automatically detect vehicle presence, charging port location, and connector alignment requirements. The overhead moving system autonomously positions and mates connectors with vehicle ports without human intervention, while the controller automatically manages charging parameters based on detected vehicle type.
2Adaptability or versatility
If fixed charging port configurations are used, then system cost is reduced, but adaptability to different vehicles deteriorates
Solution Approach 1:
The charging system features dynamically adjustable components including movable contact plates within the connector housing, adjustable alignment pins, and flexible cable management systems. These elements can be repositioned or reconfigured to match different vehicle charging port specifications, allowing a single charging station to serve multiple vehicle types without permanent modifications.
Solution Approach 2:
The system utilizes controllable parameters such as connector position, contact plate configuration, and cable tension that can be adjusted based on detected vehicle type. The vision system identifies vehicle model and charging standard, then the controller modifies these parameters to optimize the charging connection, enabling adaptability without hardware complexity.
3Productivity
If manual charging insertion is required, then system complexity is reduced, but productivity and efficiency deteriorate
Solution Approach 1:
The system replaces manual mechanical insertion operations with automated overhead moving systems that use vision guidance and robotic positioning to mate connectors with vehicle ports. Sensors detect alignment requirements and the system automatically adjusts connector position and orientation, eliminating the need for users to manually insert charging plugs while significantly improving charging throughput.
4Adaptability or versatility
If multiple charging stations are deployed for different vehicle types, then adaptability is improved, but loss of time and resource efficiency worsen
Solution Approach 1:
The charging system consolidates multiple charging station functions into a single universal platform that can serve different vehicle types (electric and plug-in hybrid) with various plugging standards. The overhead moving system can quickly reposition and reconfigure connectors between charges, allowing one station to replace multiple specialized stations and eliminate vehicle waiting time for compatible charging ports.
Data Source
AI summary
A charging system for a vehicle includes a connector suspended on a flexible cable and movable along at least one of a plurality of axes perpendicular to one another and a charging port fixed to the vehicle. The connector is movable into a mated position with the charging port.