Automatic EV Charging System with Electromagnetic Battery Extraction

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Electric vehicles such as forklifts, golf carts, and automated guided vehicles require manual charging and battery replacement, which is time-consuming and inefficient.

Innovation Solution

An automatic charging system that includes a battery assembly and multiple charging devices, allowing electric vehicles to move to idle charging stations for automatic unloading and reloading of battery packs, utilizing electromagnets and rollers for seamless electrical connection and disconnection, enabling simultaneous charging and reducing wait times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual charging and battery replacement is used, then operational control is maintained, but charging time increases and efficiency decreases

Engineering Contradiction:
Improvecharging efficiencyVSAvoidcharging time
Core Design Contradiction:
ProductivityVSLoss of time

Solution Approach 1:

The system enables automatic charging through self-service mechanisms where the charging cart autonomously navigates to vehicles, automatically connects charging cables via robotic arms, monitors charging status, and disconnects when complete. This eliminates manual intervention entirely, resolving the contradiction by making the charging process both faster and more efficient without requiring human operators.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical operations with an automated robotic system featuring programmable controllers, robotic arms for cable connection, and automated navigation. This substitution of manual mechanical systems with automated mechanical systems directly addresses the contradiction by reducing charging time while maintaining operational control through electronic control systems.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If multiple vehicles charge simultaneously, then utilization rate increases, but system complexity increases

Engineering Contradiction:
Improveutilization rateVSAvoidsystem complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The charging system is segmented into independent modular charging carts, each capable of autonomously serving one vehicle. Multiple identical modules can operate simultaneously on the same production line without interfering with each other. This segmentation allows multiple vehicles to charge at once while keeping each individual charging unit relatively simple, resolving the contradiction between high utilization rate and system complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each charging cart is designed as a universal multi-functional unit that can serve any vehicle type on the production line. The standardized interface and programmable control allow the same hardware to perform multiple charging tasks across different vehicle models. This universality enables simultaneous charging of multiple vehicles without requiring complex specialized equipment for each vehicle type.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system significantly reduces the time required for charging and replacement, increasing the utilization rate of electric vehicles by allowing multiple vehicles to charge simultaneously and automating the process, thereby improving operational efficiency.

Implementation Method 1

an electromagnetic fitting member 33 for generating a magnetic force to attract the magnetic member 23

Methodology Applied
Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS11088555B2Electric vehicle automatic charging system and electric vehicle automatic charging method
Publication Date: 2021.08.10 FU TAI HUA IND SHENZHEN
  • US11088555B2 patent drawing
  • US11088555B2 patent drawing
  • US11088555B2 patent drawing

AI summary

An electric vehicle automatic charging system includes an electric vehicle including a receiving cavity with an opening and a shutter for closing the opening, a battery assembly receiving in the receiving cavity and a charging device. The battery assembly includes a battery pack including an electrode connecting member and a movable bracket including a magnetic member. The charging device includes a support table, a support plate, an electromagnetic fitting member being capable of generating a magnetic force for attracting the magnetic member, and a charger. When the shutter comes into contact with the support plate, the shutter changes from a closed state to an open state, the movable bracket drives the battery pack to move away from the receiving cavity along the support plate by the magnetic force until the electrode connecting member is electrically connected to the charger. An electric vehicle automatic charging method is also provided.