EV Charging Manipulator With Fewer Moving Parts for Robust Positioning
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Solution Overview
Problem
Existing charging systems for electric vehicles require accurate positioning and are sensitive to fouling due to the use of multiple moving parts, which complicates shielding and increases the risk of misalignment.
Innovation Solution
A manipulator with a support and stage, connected by a first link with pivoting connections, and actuating mechanisms that exert forces on the link to position an energy transfer unit, reducing the number of moving parts and improving robustness while allowing non-axisymmetric energy transfer units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple stacked linear actuators and pantograph mechanisms are used to enable positioning freedom, then the vehicle positioning flexibility is improved, but the device complexity increases and the system becomes sensitive to fouling
Solution Approach 1:
The positioning function is segmented between the manipulator system (which provides coarse positioning) and the charging head (which provides fine alignment). This allows the manipulator to use a simpler mechanism with fewer moving parts while still achieving the required positioning freedom through the combination of manipulator movement and charging head adjustment capabilities.
Solution Approach 2:
The complex alignment function is extracted from the manipulator and assigned to the charging head itself. The manipulator is responsible for positioning the charging head within a work volume, while the charging head's own adjustment mechanisms handle the precise alignment with the vehicle connector, reducing the manipulator's mechanical complexity.
2Adaptability or versatility
If multiple stacked linear actuators and pantograph mechanisms are used to enable positioning freedom, then the vehicle positioning flexibility is improved, but the reliability decreases due to sensitivity to fouling
Solution Approach 1:
By segmenting the positioning and alignment functions between the manipulator and charging head, the system reduces the number of moving parts in the manipulator that are exposed to fouling environments. Fewer moving elements mean fewer points of failure and reduced sensitivity to contamination.
Solution Approach 2:
The alignment-sensitive functions are extracted from the manipulator and placed in the charging head, which can be designed with better protection against fouling. The manipulator's simpler mechanism has fewer exposed moving parts that could be affected by contamination.
3Adaptability or versatility
If a rotatable platform with stacked linear actuators is used to move the charging head, then the positioning flexibility is improved, but the device complexity increases and shielding becomes difficult
Solution Approach 1:
The positioning function is segmented so that the manipulator handles theç²— positioning within the work volume while the charging head's own mechanisms handle fine alignment. This eliminates the need for a rotatable platform with multiple actuators, simplifying the overall system.
Solution Approach 2:
The complex rotation and alignment functions are extracted from the manipulator and assigned to the charging head. This allows the manipulator to use a simpler mechanism that is easier to shield, while the charging head performs the precise rotational alignment needed for connection.
4Adaptability or versatility
If a rotatable platform is used to position the charging head, then the positioning flexibility is improved, but the reliability decreases due to sensitivity to fouling
Solution Approach 1:
By segmenting the positioning and alignment functions, the system reduces the number of moving parts in the manipulator that are exposed to fouling environments. The simpler manipulator mechanism has fewer points of failure and reduced sensitivity to contamination.
Solution Approach 2:
The rotation and alignment functions are extracted from the manipulator and placed in the charging head, which can be designed with better protection against fouling. This reduces the manipulator's exposure to contaminated environments.
5Adaptability or versatility
If an axisymmetric charging head is used with a rotatable platform, then the positioning flexibility is improved, but the device complexity increases
Solution Approach 1:
The positioning and alignment functions are segmented between the manipulator and charging head, allowing the charging head to have a non-axisymmetric design optimized for the specific connection task while the manipulator provides the positioning flexibility.
Solution Approach 2:
The rotation function is extracted from the manipulator and assigned to the charging head. This allows the charging head to be non-axisymmetric and optimized for its specific function, while the manipulator uses a simpler mechanism that is easier to shield and maintain.
6Measurement precision
If conductive charging with lifting means is used to move the charging head, then the positioning accuracy is improved, but the force required for alignment increases
Solution Approach 1:
The positioning function is segmented between the manipulator (coarse positioning) and the charging head (fine alignment). This allows the system to achieve positioning accuracy with reduced force requirements by distributing the alignment task across both systems.
Solution Approach 2:
The fine alignment function is extracted from the manipulator and assigned to the charging head. This reduces the force required on the manipulator's lifting mechanism, as the charging head's own adjustment mechanisms handle the precise alignment with minimal force requirements.
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
A manipulator for positioning an end effector for charging vehicles comprises a support, a stage comprising the end effector, a first link comprising a first end providing a first pivoting connection connected to the support and a second end providing a second pivoting connection connected to the stage. The first link defines a first longitudinal axis between the first end and the second end. A first and a second actuating mechanism providing an actuatable connection between the stage and the support through the first link. Each of the first and the second actuating mechanisms are configured to exert a first actuating force on the first link for moving the second end of the first link through a volume. The manipulator further comprises a second link comprising a first end providing a first pivoting connection connected to the support and a second end providing a second pivoting connection connected to the stage at a first position offset from the second pivoting connection of the first link.