Active Alignment Control for Vehicle Charging Contact Element

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Solution Overview

Problem

The alignment of charging units in electric vehicles with static power lines is technically challenging due to relative motion, leading to inefficiencies in battery charging, especially when the side-tracks are not parallel with the vehicle.

Innovation Solution

An active alignment control system for the contact element of a charging device, comprising a base, linkage arm, pivot joint, charging surface detection sensor, angle detection sensor module, and actuator module, which allows horizontal displacement and rotation of the contact element to align with the charging surface trajectory, using sensors and actuators to adjust the contact element's orientation based on vehicle heading and charging surface angle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a pivotally attached arm is used to align contact means with side-tracks, then alignment capability is improved, but alignment accuracy deteriorates when side-tracks are not parallel with the vehicle

Engineering Contradiction:

Improvealignment capabilityVSAvoidalignment accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The charging device employs dynamic alignment control where the contact element can actively adjust its position and orientation in real-time. The system uses sensors to detect the charging surface trajectory and vehicle heading, then continuously adjusts the contact element's position through actuators to maintain accurate alignment with the charging surface, resolving the contradiction between adaptability and precision.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback control by using charging surface detection sensors and angle detection sensors to monitor the relative position and orientation between the vehicle and charging surface. This feedback information is processed by a control unit that activates actuators to adjust the contact element's position, ensuring accurate alignment even when side-tracks are not parallel with the vehicle.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If active alignment control with sensors and actuators is implemented, then alignment accuracy is improved, but device complexity increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The control unit serves multiple functions: it processes data from charging surface detection sensors, processes data from angle detection sensors, calculates the required alignment adjustments, and controls the actuators. This multi-functionality reduces the need for separate dedicated components, improving alignment accuracy while managing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system merges the alignment control functionality directly into the charging device structure. The actuator module is integrated with the linkage arm and contact element assembly, and the control unit consolidates sensor processing and actuator control functions, reducing overall system complexity while maintaining high alignment accuracy.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If mechanical tie rods are used for alignment, then structural stability is improved, but packaging space increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidpackaging space

Core Design Contradiction:

Stability of the object's compositionVSVolume of moving object

Solution Approach 1:

The invention extracts and eliminates the mechanical tie rod component from the alignment system. Instead of using rigid mechanical linkages, the system uses a control unit with sensors and actuators that provide alignment control without requiring large mechanical structures, thereby reducing packaging space while maintaining stability through active control.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system replaces the mechanical tie rod alignment mechanism with an electro-mechanical control system. Sensors detect position and angle, the control unit processes this information, and actuators make precise adjustments to the contact element's position, eliminating the need for large mechanical tie rods and reducing overall device volume.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11541768B2Arrangement and method for active alignment control of a contact element

Publication Date: 2023.01.03 VOLVO TRUCK CORP

AI summary

The invention relates to an arrangement (100) for active alignment control of a contact element (110) of a charging device (104) for a vehicle (1) for driving on an electrical road system (ERS) comprising a charging surface (3) configured to provide electrical power to the vehicle via the charging device. The arrangement comprises the charging device (104) comprising a base (106), a linkage arm (108), and an electrical contact element (110) and a pivot joint (107) arranged for allowing a movement of the contact element around an axis (105). A control unit is configured to activate an actuator module to align said contact element (110) with said trajectory of said charging surface based on trajectory data and an angle between the vehicle heading and the charging surface. The invention further relates to a method and to a vehicle.