Autonomous EV Charging Connector Alignment Mechanism
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Solution Overview
Problem
Manual electric vehicle charging systems are inconvenient and potentially dangerous, especially in adverse weather conditions, due to the need for manual handling of high-voltage cables and connectors, which can be cumbersome and require significant force to couple and uncouple, posing challenges for operators, especially the elderly or disabled.
Innovation Solution
An autonomous charging station with a movable frame that can move in three-dimensional space, featuring a mount and bracket system that allows the charging connector to move independently and securely couple with the vehicle's charge port, using actuators and sensors for precise alignment and connection, enabling automatic coupling and uncoupling without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling of high-voltage cables and connectors is used, then the charging system is simple in structure, but it poses safety risks and is inconvenient for operators, especially the elderly or disabled
Solution Approach 1:
The charging system performs coupling and uncoupling operations autonomously without requiring manual intervention. The automated coupling mechanism independently handles the connection between charging cables and vehicle ports, eliminating safety risks associated with manual handling while maintaining operational simplicity
Solution Approach 2:
The patent replaces manual mechanical operations with an automated coupling mechanism that uses controlled mechanical movement to perform connector coupling and uncoupling. This substitution eliminates the need for operators to physically handle high-voltage connectors, improving safety while introducing controlled system complexity
2Ease of operation
If manual coupling and uncoupling of connectors is performed, then the device structure is simple, but significant force is required which is cumbersome and dangerous
Solution Approach 1:
The coupling mechanism autonomously performs the coupling operation by generating and applying the necessary force through its automated movement system. The mechanism self-regulates the force application during coupling and uncoupling, eliminating the need for operators to exert significant physical force while maintaining simple operational interface
Solution Approach 2:
The patent replaces manual force application with an automated mechanical system that uses controlled actuation to generate coupling force. The automated mechanism handles all force-related operations, making the system easy to operate while managing the physical forces required for connector coupling
3Ease of operation
If an autonomous charging station with movable frame is used, then operator effort and risk are reduced, but the device complexity increases
Solution Approach 1:
The charging station incorporates a movable frame that can dynamically adjust its position and orientation to align with the vehicle charging port. This dynamic capability enables autonomous coupling operations, reducing operator effort while the complexity is managed through controlled mechanical degrees of freedom
Solution Approach 2:
The movable frame structure serves multiple functions: positioning the charging connector, aligning with various vehicle ports, and providing structural support. This multi-functionality reduces the need for separate components, managing overall system complexity while achieving autonomous operation that minimizes operator involvement
Data Source
AI summary
A charging station can be autonomously coupled to an electric vehicle. Sensors on the vehicle determine a location of the vehicle, and the vehicle is positioned within a connection envelope. A travel path for bringing a charging connector into contact with a charging port on the vehicle can be determined, and then the travel path is autonomously carried out. A charging station may include a mount, a bracket, and a charging connection.