Charging Robot End Effector for Charge Port Door Opening

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Solution Overview

Problem

Existing automated vehicle charging systems face challenges in efficiently and affordably opening charge port doors and plugging charging cables due to the need for separate robotic arms or active components, which are costly and complex, and often result in collisions with the vehicle body.

Innovation Solution

A single end effector with a passive actuator and electrical connector, designed to be rotated by a robotic arm, that safely opens charge port doors without additional tools, using a transverse actuator and inclined connector body to prevent collisions, and includes magnetic submodules for detachable connection and a camera for accurate alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate robotic arm or active component is used to open the charge port door, then the door opening function is achieved, but the device complexity and cost increase

Engineering Contradiction:

Improvedoor opening functionVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the door opening function and cable plugging function into a single end effector. The actuator integrated in the end effector performs door opening by pressing the door at a certain location, while the electrical connector in the same tool performs cable plugging, eliminating the need for separate robotic arms or active door opening components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The end effector is designed as a multi-functional tool that can both open the charge port door and plug the charging cable. This universal tool replaces multiple specialized tools, reducing system complexity while maintaining both functions reliably

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate tool is used for door opening and cable plugging, then each function can be optimized, but the plugging time and operational efficiency increase

Engineering Contradiction:

Improvefunction optimizationVSAvoidplugging time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By merging door opening and cable plugging into one end effector, the system performs both operations in a single tool engagement, eliminating the time required to switch between tools or coordinate multiple robotic arms, thus reducing overall plugging time

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If the actuator and connector are arranged without inclination, then the structure is simpler, but collisions with the vehicle body occur

Engineering Contradiction:

Improvestructural simplicityVSAvoidcollisions

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The end effector employs an asymmetric design where the connector body is inclined at an angle between 10-30 degrees relative to the actuator axis. This asymmetric arrangement creates clearance between the tool and vehicle body during operation, preventing collisions while maintaining structural efficiency

Inventive Principle:

Principle #4Asymmetry

4Object-affected harmful factors

If the actuator is positioned perpendicular to the connector body extension direction, then the collision safety margin is maximized, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvecollision safetyVSAvoidalignment precision

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent optimizes the inclination angle parameter of the connector body (10-30 degrees) to balance collision safety and manufacturing precision. This parameter change ensures sufficient clearance from the vehicle body while maintaining feasible manufacturing tolerances for the actuator and connector alignment

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260027724A1End effector of automated vehicle charging robot for automatically opening doors of charge ports of electric vehicles and plugging charging cables

Publication Date: 2026.01.29 EMBOTECH AG

AI summary

The invention is notably directed to end effector (10, 10a) for an automated vehicle charging robot (1). The end effector (10, 10a) comprises: a connecting module (100), which is delimited by a reference plane (P) and is designed to enable a connection of the end effector (10, 10a) to a robotic arm (40) of the charging robot (1) on a first side of the reference plane (P); an electrical connector (106, 108) including a body (108) and a plug (106), the plug designed to connect to a charge port (220) and arranged at an end of the body (108), wherein the body (108) extends from the connecting module (100) to the plug (106) on a second side of the reference plane (P), the second side opposite to said first side, along an extension direction (De) that is transverse to the reference plane (P); and an actuator (114, 115) that protrudes from said body (108), transversely to said extension direction (De), the actuator (114, 115) designed to actuate a door (210) of the vehicle charge port (220). The invention is further directed to: a functionalized robotic arm (40), which includes such an end effector; an automated vehicle charging system (1), which includes such a robotic arm; and a method of electrically charging an electrical vehicle using such a functionalized robotic arm.