Autonomous EV Charging Arm with Dual Linear Drives

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Solution Overview

Problem

Existing electric vehicle charging systems require human interaction and are not suitable for autonomous charging, as they are complex, costly, and not adaptable to different vehicle lengths or outdoor use.

Innovation Solution

A charging system with a vertical and horizontal charging arm, equipped with two independent linear drive systems, allowing the charging arm to move autonomously in multiple directions for flexible positioning and compatibility with various vehicles, using a charging cable or busbar for efficient and rapid charging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a robot arm with multiple rotary joints is used for automated charging, then automated charging is achieved, but the device complexity and cost increase significantly

Engineering Contradiction:

Improveautomated chargingVSAvoidrobot arm complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The charging arm is divided into two independent linearly movable parts: a vertical charging arm part and a horizontal charging arm part. This segmentation allows each part to be controlled independently by separate drive systems, simplifying the overall structure compared to a complex multi-joint robot arm while achieving the same automated positioning functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces the traditional rotary joint mechanism with linear movement mechanisms. Instead of using multiple rotary joints to achieve positioning, the patent uses two linearly movable charging arm parts with independent linear drive systems, substituting a complex mechanical rotary system with a simpler linear movement system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If a fixed rigid robot arm is used, then structural stability is maintained, but adaptability to different vehicle lengths and charging socket positions is lost

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to different vehicles

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The charging arm structure is made dynamic through the introduction of two independently controllable linear movement mechanisms. The vertical charging arm part can move up and down, while the horizontal charging arm part can extend and retract. This dynamic structure allows the charging plug to reach different positions on vehicles of various lengths and configurations while maintaining structural stability during operation.

Inventive Principle:

Principle #15Dynamics

3Extent of automation

If a complex robot arm system is used, then automated positioning is achieved, but the charging speed decreases due to system complexity

Engineering Contradiction:

Improveautomated positioningVSAvoidcharging speed

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The invention extracts and eliminates the unnecessary complex rotary joint mechanisms from the robot arm system, retaining only the essential linear movement capabilities needed for charging. By removing the redundant mechanical complexity, the system achieves faster response times and quicker positioning while maintaining automated functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

4Device complexity

If traditional charging systems requiring human interaction are used, then system simplicity is maintained, but autonomous charging capability is lost

Engineering Contradiction:

Improvesystem simplicityVSAvoidautonomous charging capability

Core Design Contradiction:

Device complexityVSExtent of automation

Solution Approach 1:

The charging system is designed to serve itself by automatically positioning the charging plug into the vehicle's charging socket without human intervention. The two linearly movable charging arm parts, controlled by independent drive systems, enable the system to autonomously navigate and connect to different vehicles, making the charging process self-service oriented.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20230132562A1Charging system and method for autonomous charging of an electric vehicle

Publication Date: 2023.05.04 SIEMENS AG

AI summary

A charging system for autonomous charging of an electric vehicle with electric energy includes a vertical charging arm part, a charging cable or busbar connectible to the electric vehicle, and an elongate horizontal charging arm part extendible from the vertical charging arm part toward the electric vehicle. The horizontal charging arm part has a first drive system with a first linear operative direction corresponding to a longitudinal direction of the horizontal charging arm part, allowing a vehicle-side end of the horizontal charging arm part to move autonomously using the first drive system, relative to the electric vehicle relative to a first linear degree of freedom. A second drive system has a second linear operative direction moving the horizontal charging arm part autonomously relative to the electric vehicle relative to a second linear degree of freedom. A method for charging an electric vehicle using the charging system is also provided.