Charging Head Linkage Alignment for Automated Vehicle Contacting
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Solution Overview
Problem
Current vehicle charging methods, such as plug-in connections, are time-consuming and require manual alignment, which is not conducive to in-route charging, especially when multiple vehicles need to be charged simultaneously, and often necessitate complex and costly mechanisms for vertical and lateral adjustments of charging heads.
Innovation Solution
A charging assembly that uses an actuator to drive an upper arm, which moves a passive linkage to extend or retract, allowing the charging head to move vertically and horizontally to align with vehicle charging contacts, with sensors to control the movement based on electrical characteristics, enabling efficient and cost-effective alignment and charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual plug-in connection method is used, then charging can be performed, but the process is time-consuming and requires manual alignment
Solution Approach 1:
The charging head automatically aligns with the vehicle charging contact through sensor detection and actuator-driven movement, eliminating the need for manual alignment by operators. The system performs self-service alignment by detecting electrical characteristics and autonomously adjusting its position.
Solution Approach 2:
The patent replaces manual mechanical alignment with an automated system combining sensors (electrical field detection) and actuators (mechanical movement). This substitution of manual operation with sensor-actuator systems resolves the contradiction between ease of operation and time consumption.
2Manufacturing precision
If charging head is moved vertically and laterally to align with vehicle, then alignment precision is improved, but the mechanism becomes more complex and expensive
Solution Approach 1:
A single actuator system performs both vertical and lateral movement functions of the charging head. The actuator is driven to extend or retract, causing the charging head to move in multiple directions (vertically and horizontally) through a linkage mechanism, eliminating the need for separate actuators for each direction and reducing overall system complexity.
Solution Approach 2:
The patent combines multiple movement functions (vertical and lateral adjustment) into a single integrated actuator-driven mechanism. By merging the alignment functions into one actuator system with passive linkage, the design achieves complex positioning capability without proportionally increasing system complexity or cost.
3Reliability
If operator exits vehicle to secure connectors, then connection can be made, but operational efficiency decreases
Solution Approach 1:
The charging system performs automatic alignment and connection without requiring the operator to exit the vehicle. The sensor detects electrical characteristics and the actuator automatically positions the charging head, making the system self-sufficient and eliminating manual intervention, thereby maintaining reliability while improving productivity.
Solution Approach 2:
The sensor continuously monitors electrical characteristics (such as resistance or voltage) to detect when proper alignment and connection are achieved. This feedback mechanism ensures reliable connection by confirming electrical contact, while the automated nature of the process maintains high operational efficiency without requiring manual verification.
Data Source
AI summary
A method of moving a charging assembly to engage a vehicle is provided. The method may include driving an upper arm of the charging assembly with an actuator, moving a lower arm and a passive linkage using a force from the upper arm and the actuator, and extending or retracting the passive linkage using the force from the upper arm and the actuator. The method may include sensing one or more electrical characteristics of the charging assembly. The method may include engaging a stop of the passive linkage to allow a substantially vertical movement of a charging head of the charging assembly responsive to the electrical characteristics being below a threshold. The method may include moving the passive linkage away from the stop to allow a substantially horizontal movement of the charging head responsive to the electrical characteristics being at or above the threshold.