Charging Head Mechanism for Self-Aligning Electric Vehicle Battery Connection
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Solution Overview
Problem
Automated charging systems for vehicles face challenges in precisely positioning and connecting charging heads to receiving heads due to varying vehicle designs and heights, requiring complex robotic systems for accurate alignment.
Innovation Solution
A charging device with a lifting mechanism actuated by a single actuator, allowing the charging head to move perpendicular to its surface and then parallel to the vehicle's underbody, guided by mechanical means to ensure contact with the receiving head, regardless of height or lateral offset, using lamellar contacts and springs for stable and flexible alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex robotic systems with target detection and measurement systems are used to guide the charging head to the receiving head, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The charging head automatically finds and connects to the receiving head through its own movement capabilities without requiring complex external detection or measurement systems. The system uses the vehicle's underbody as a guide surface, allowing the charging head to self-position through controlled movement and impact followed by lateral guidance.
Solution Approach 2:
The patent replaces complex robotic mechanical systems with a simpler mechanism that uses a single actuator for vertical movement combined with mechanical guidance along the vehicle's underbody. This substitution eliminates the need for sophisticated target detection, measurement, and image processing systems while achieving reliable positioning.
2Adaptability or versatility
If the receiving head is arranged on the underbody of the vehicle to accommodate different vehicle designs, then adaptability is improved, but positioning difficulty increases due to varying vehicle heights
Solution Approach 1:
The charging head is designed with dynamic movement capabilities in both vertical and lateral directions. A single actuator enables vertical movement to accommodate different vehicle heights, while mechanical guidance structures enable lateral movement to achieve precise positioning. This dynamic design allows the system to adapt to various vehicle configurations without requiring complex detection systems.
3Ease of operation
If vehicles are positioned with an error of around +-10cm by drivers, then ease of operation is improved, but connection precision deteriorates
Solution Approach 1:
The charging head automatically compensates for positioning errors by using its own movement mechanisms to find and connect to the receiving head. The system does not require precise vehicle positioning by the driver, as the charging head self-corrects for lateral and vertical misalignments through its controlled movement and mechanical guidance along the vehicle's underbody.
Data Source
Figure 1A~1B
Figure 2
Figure 3~4A
AI summary
The invention relates to an electric charging device, to a charging system, to a method for charging a battery of a vehicle, and to an electric connection device of a vehicle for charging a battery of the vehicle. The electric charging device comprises the following: a lifting device (11) to which a charging head (12) is coupled, wherein the charging head (12) has a first plurality of first electric contacts (14) on a first surface (13) of the charging head (12), at least some of said contacts being connectable to an energy source in order to charge the battery; and an actuator (16) by means of which the lifting device (11) can be actuated such that the charging head (12) can be at least partly moved in a first direction (R1) that is substantially perpendicular to the first surface (13). The lifting device (11) is further designed such that the charging head (12) can be moved in a second direction (R2) along a stop surface (U, P) by continuing to actuate the lifting device (11) by means of the actuator (16) upon striking the stop surface (U, P) in the first direction (R1).