Container Vehicle Charging Interface With Flat Contacts and Position Tolerance
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Solution Overview
Problem
The existing automated storage and retrieval systems face challenges with charging systems due to high precision requirements and limited practical charging current, which can lead to wear and reduced efficiency, especially with larger plug/socket interfaces that increase friction and force needed for connection/disconnection.
Innovation Solution
The system employs a charging system with two separated charge-receiving elements on the container vehicle and corresponding charge-providing elements at the charging station, featuring flat contact surfaces that allow for increased tolerance in positioning and robust contact, enabling higher charging capacity without the limitations of traditional horizontal plug/socket connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional horizontal plug/socket interface is used for charging, then the charging connection can be established, but the friction and force required for connection/disconnection increase, limiting the practical charging current
Solution Approach 1:
The charging interface is changed from a horizontal plug/socket connection to a vertical contact surface arrangement. The charge-providing element and charge-receiving element are positioned vertically with their contact surfaces facing each other, allowing the container vehicle to lower vertically onto the charging station. This dimensional change eliminates the horizontal sliding friction that limited previous designs.
Solution Approach 2:
The contact geometry is changed from point/line contact in traditional plugs to large flat contact surfaces. This increases the contact area, distributes the force, and allows for higher current capacity without increasing the force required for connection. The contact surfaces can be made robust and durable while maintaining low connection forces.
2Power
If a larger plug/socket interface is used to increase charging capacity, then more current can be transmitted, but the friction and wear increase, reducing efficiency
Solution Approach 1:
By transitioning to a vertical contact surface interface, the system eliminates horizontal sliding motion that causes frictional energy loss. The vehicle simply lowers vertically onto the contact surfaces, and the charging connection is established without lateral movement, significantly reducing energy loss to friction.
Solution Approach 2:
The contact surface area is increased in the vertical interface design, allowing higher current capacity without increasing contact pressure or friction. The distributed contact across large flat surfaces reduces stress and wear while maintaining high power transmission capability.
3Reliability
If a traditional plug/socket interface is used, then the charging connection can be made, but the precision requirements are high, making the system complex
Solution Approach 1:
The interface geometry is changed to large flat contact surfaces that are tolerant of positioning variations. Unlike precise plug/socket alignments, the contact surfaces can accommodate larger tolerances in horizontal positioning while maintaining reliable electrical contact, simplifying manufacturing and installation requirements.
Solution Approach 2:
The vertical approach to connection allows the vehicle to locate itself horizontally with greater tolerance, then simply lower vertically to establish contact. This separates the horizontal positioning requirement from the vertical connection action, reducing the overall precision requirements compared to horizontal plug insertion.
Data Source
AI summary
A container vehicle includes a rechargeable power source; two separated charge-receiving elements connected to the power source and each comprising a first contact surface; and a first set of wheels and a second set of wheels for moving the container vehicle along a rail grid. The container vehicle is operable to change between: a first configuration, a second configuration, and a third configuration. In the first configuration, the first set of wheels may move the container vehicle in a first direction. The first and the second sets of wheels are in contact with the rail grid such that movement of the container vehicle is prevented. In the third configuration, the second set of wheels may move the container vehicle in a second direction. The first contact surfaces are arranged to be in contact with corresponding second contact surfaces of separated charge-providing elements themselves connected to a power source charger when the container vehicle is positioned adjacent the charge-providing elements and the container vehicle is in the second configuration.