Automated EV Charging Connector Positioning via Actuator Linkage
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Solution Overview
Problem
Electric vehicle charging is a time-consuming process that requires significant user intervention and is not easily automated, making it inconvenient and inefficient for widespread adoption.
Innovation Solution
An automatic charging device (ACD) with a charger link, actuator, sensors, and controller that automatically positions and connects the charger-side electrical connector with the EV-side connector, enabling hands-free charging by determining the EV's position and actuating the connector to mate with the EV-side connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual charging methods are used, then user control and flexibility are maintained, but charging time is excessive (10 hours or more) and user intervention is required
Solution Approach 1:
The charging system performs self-positioning and self-connection operations. The actuator automatically moves the charger link to position the connector, and the system autonomously determines when connection is complete based on sensor feedback, eliminating the need for manual intervention while enabling faster charging
Solution Approach 2:
The patent replaces manual mechanical operations with an automated actuator system. The actuator mechanically positions the connector through controlled movement of the charger link, substituting human manual plugging operations with an automated mechanical system that can operate more quickly and precisely
2Ease of operation
If automated charging systems are implemented, then charging convenience and speed improve, but device complexity increases due to actuators, sensors, and controllers
Solution Approach 1:
The controller serves multiple functions: it processes sensor signals to detect connector position, controls the actuator movement, determines when mating is complete, and manages the charging process. This multi-functionality reduces the need for separate dedicated components for each function, thereby managing complexity while achieving hands-free operation
Solution Approach 2:
The charger link acts as an intermediary flexible conduit that connects the charger-side connector to the EV-side connector. This flexible link allows the rigid actuator system to position the connector accurately while accommodating the flexible positioning needs of the charging interface, simplifying the overall system architecture
3Loss of time
If high power charging is used, then charging time is reduced, but system complexity and installation requirements increase
Solution Approach 1:
The system uses a flexible charger link that can dynamically adjust its position and configuration. This dynamic flexibility allows the system to accommodate different power levels and charging configurations without requiring completely different hardware architectures, enabling high-power charging while managing system complexity
Data Source
AI summary
Devices, methods and software for automated electrical connector positioning for electric vehicle (EV) charging are provided. Using, for example, the disclosed automatic charging device, a method for charging an EV includes determining receipt of an EV-side electrical connector to a charging zone of an EV charging environment. The method includes actuating a charger-side electrical connector from an initial position outside of the charging zone to a final position inside of the charging zone. The final position corresponds to the charger-side electrical connector matingly engaged with the EV-side electrical connector.