Charging Robot Plug Unit with Bellows Cover for Precise Alignment
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Solution Overview
Problem
Existing charging robots lack robustness, reliability, precision, and cost-effectiveness in establishing a stable electrical connection with vehicles for charging, particularly in aligning and positioning the plug units for efficient energy transfer.
Innovation Solution
A method and design for a charging robot that employs a connector unit with a deformable cover element, guided by electric drives, allowing precise alignment and vertical movement to establish contact with a vehicle's charging socket, while being reinforced for durability and capable of withstanding vehicle parking, ensuring reliable and efficient charging connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the charging robot uses a rigid connector unit, then structural strength is improved, but adaptability to different vehicle positions deteriorates
Solution Approach 1:
The connector unit is equipped with a bellows element that provides flexibility and deformability, allowing the connector to adapt to different vehicle positions while maintaining structural integrity. The bellows element can expand and contract to accommodate positioning variations.
Solution Approach 2:
The connector unit transitions from a static rigid structure to a dynamic system that can change its shape and position. The bellows element enables the connector to deform and adapt dynamically during the charging process.
2Manufacturing precision
If the charging robot uses precise alignment mechanisms, then connection precision is improved, but device complexity increases
Solution Approach 1:
The system uses sensors to detect the vehicle's position and automatically adjusts the connector's position accordingly. The charging robot performs self-alignment without requiring complex manual adjustment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical alignment mechanisms with sensor-based detection and control systems. Sensors detect vehicle position and guide the connector alignment, reducing mechanical complexity.
3Weight of moving object
If the charging robot housing is made lightweight, then ease of movement is improved, but structural strength deteriorates
Solution Approach 1:
The housing is constructed using composite materials that provide high strength-to-weight ratio. This allows the housing to be lightweight for easy movement while maintaining the structural strength needed to support vehicle parking.
Solution Approach 2:
The housing has varying material properties in different regions - thicker and stronger where structural support is needed, and thinner and lighter where weight reduction is prioritized. This local optimization balances strength and weight requirements.
4Productivity
If the charging robot operates quickly, then productivity is improved, but connection reliability deteriorates
Solution Approach 1:
The system performs preliminary alignment and positioning actions before the actual charging connection is established. Sensors detect vehicle position in advance, and the connector is pre-positioned to ensure reliable connection before charging begins.
Data Source
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AI summary
Method for operating a charging robot, wherein the charging robot has a plug unit (1) which is movable at least in substantially horizontal (x) and vertical (z) directions, wherein the charging robot has a cover (2) by which the plug unit (1) is covered in a first movement state, wherein the plug unit (1) and the cover (2) are moved together in the horizontal direction (x) by means of a first drive unit (3), wherein the cover (2) covers the plug unit (1) at least until a second movement state is reached, after which the cover (2) is moved alone in the horizontal direction (x) starting from the second movement state and the plug unit (1) is exposed until a third movement state is reached, after which the plug unit (1) is moved in the vertical direction (z) until a fourth movement state is reached.