Underside EV Charging Floor Unit Linkage
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Solution Overview
Problem
Current electric vehicle charging systems are time-consuming, typically taking up to 10 hours to provide a full charge, and there is a need for faster, safer, and more efficient charging solutions that can be retrofitted into existing vehicles and facilities.
Innovation Solution
A floor unit device with a mechanical linkage system that includes a frame with pivots and a tri-pivot knuckle, an actuating link, and a compliance unit, which positions and connects with a vehicle unit device to enable efficient electrical charging by allowing a flow of current from an electric power supply to the vehicle's battery, facilitating faster and safer charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional power dispensers operate at 200-240 Volt AC with flexible conduits, then the system is easy to implement, but charging time takes up to 10 hours or more
Solution Approach 1:
The patent employs a dynamic mechanical linkage system with multiple pivots (first pivot, second pivot, tri-pivot knuckle) and sliding components that automatically adjust the connector's position and orientation. This dynamic structure enables rapid connection and disconnection while maintaining electrical contact, directly reducing charging time without requiring complex manual intervention
Solution Approach 2:
The mechanical linkage system acts as an intermediary between the power dispenser and the vehicle, providing a controlled mechanism for connector engagement. The system includes intermediate components such as the linear slide, actuating link, and compliance unit that mediate the connection process, enabling faster charging while managing the complexity through modular design
2Manufacturing precision
If the mechanical linkage system includes multiple pivots and sliding components for dynamic positioning, then connection accuracy is improved, but device complexity increases
Solution Approach 1:
The mechanical linkage system is segmented into distinct functional components: a first pivot for primary positioning, a second pivot for secondary positioning, a tri-pivot knuckle for fine adjustment, and a linear slide for lateral positioning. Each segment performs a specific positioning function, achieving high connector positioning accuracy while managing overall system complexity through functional decomposition
Solution Approach 2:
The patent implements a nested arrangement where the tri-pivot knuckle contains three pivot joints that work together in a hierarchical manner. The first pivot provides coarse positioning, the second pivot refines the position, and the tri-pivot knuckle provides fine-tuned adjustment. This nested structure achieves precise connector positioning while compacting the mechanical system
3Reliability
If the compliance unit exerts distally-directed force on the proximal link, then electrical connection reliability is improved, but mechanical system complexity increases
Solution Approach 1:
The compliance unit is designed to automatically exert distally-directed force on the proximal link through its mechanical configuration, maintaining reliable electrical connection without requiring external control systems. The unit self-regulates the force application based on the connection state, improving reliability while avoiding additional complexity from active control mechanisms
Solution Approach 2:
The compliance unit changes the mechanical parameters of the linkage system by introducing controlled flexibility and force modulation. It adjusts the stiffness and force characteristics of the proximal link dynamically, ensuring reliable electrical connection while managing the mechanical system through parameter optimization rather than structural complexity
Data Source
AI summary
Devices, systems, and methods for charging an electric vehicle are disclosed. The system includes a floor unit and a vehicle unit, each having an electrical connector. The method includes positioning the floor unit electrical connector with reference to the mating vehicle unit electrical connector. The method includes inserting the floor unit electrical connector into the mating vehicle unit electrical connector. The method includes initiating an electric vehicle charging process by selectively enabling a flow of electric current from an electric power supply through the matingly coupled vehicle unit and floor unit electrical connectors.