EV Charging Manipulator Linkage for Precise Tilt-Free Alignment
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Solution Overview
Problem
Existing automatic electric vehicle charging systems face limitations in precision, require multiple moving elements, and struggle with shielding against pollution due to complex actuator systems and limited positioning freedom.
Innovation Solution
A manipulator using three link assemblies with pivotal connections and prismatic joints for precise positioning in a 3D volume, ensuring no tilting and simplifying shielding of sensitive components with a static power connection, allowing high positioning freedom and easy shielding against pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If lifting means are used to move charging head towards vehicle underbody, then charging head can reach vehicle for connection, but charging head tilts causing misalignment of electrical contacts
Solution Approach 1:
The manipulator is divided into three independent link assemblies (first, second, and third link assemblies), each capable of independent pivotal movement. This segmentation allows each link to contribute to both reaching the vehicle and maintaining proper orientation, resolving the contradiction between reach distance and alignment precision.
Solution Approach 2:
The link assemblies incorporate pivotal joints that enable dynamic adjustment of the manipulator's configuration. This dynamic capability allows the system to adapt its geometry during movement to simultaneously achieve the required reach distance and maintain precise alignment of electrical contacts without tilting.
2Adaptability or versatility
If stacked linear actuators are used for moving charging coil, then positioning freedom is improved, but precision is limited and shielding becomes difficult
Solution Approach 1:
The system transitions from linear actuator movement to pivotal rotation in a different dimensional space. The three link assemblies rotate about pivotal joints to position the manipulator stage in three-dimensional space, achieving both positioning freedom and high precision through angular movement rather than linear extension.
Solution Approach 2:
The patent replaces the mechanical stacked linear actuator system with a linkage-based manipulator system using pivotal joints. This substitution eliminates the need for stacked actuators while achieving superior positioning precision and easier shielding, as the linkage mechanism provides inherent mechanical advantage and stability.
3Adaptability or versatility
If multiple moving elements are used in manipulator, then positioning freedom is improved, but device complexity increases and shielding becomes difficult
Solution Approach 1:
The three link assemblies are merged into a coordinated manipulator system where the pivotal joints serve multiple functions. Each pivotal joint contributes to both positioning freedom and structural stability, reducing the need for additional separate moving elements while maintaining high adaptability for positioning the energy transfer unit.
4Adaptability or versatility
If prismatic joints are positioned at multiple locations, then positioning capability is improved, but shielding of sensitive components becomes difficult
Solution Approach 1:
The pivotal joints are extracted and positioned exclusively at the manipulator stage, away from the pollution-prone environment near the vehicle underbody. This extraction allows the majority of the manipulator structure and sensitive components to remain in the shielded charging station environment, reducing exposure to harmful factors while maintaining full positioning capability.
Data Source
Figure 1A~2B
Figure 3~4
Figure 5A~5B
AI summary
Manipulator for handsfree charging electric vehicles, comprising a first, a second and a third prismatic joint, a manipulator stage, and a first, a second and a third link assembly, wherein the first, the second and the third link assembly each comprise a first link comprising a first endpoint comprising a first joint configured for pivotally connecting the first link to the first, the second and the third prismatic joint, respectively, and a second endpoint comprising a second joint configured for pivotally connecting the first link to the manipulator stage, and wherein the first, the second and the third link assemblies are configured for preventing at least two, preferably three rotational degrees of freedom of the manipulator stage, wherein the first, the second and the third prismatic joint are configured for moving the corresponding first endpoints of the first links along a first, a second and a third trajectory, wherein at least two of the first, second and third trajectory define a first plane and wherein projections of each one of the first, the second and the third trajectory on the first plane have with respect to projections of each other one of the first, the second and the third trajectory on the first plane one of a list of: an acute angle (α, β, γ) of less than 60 degrees, preferably less than 30 degrees, more preferably less than 10 degrees and even more preferably less than 5 degrees and no angle.