Automated EV Charging Plug Guiding Mechanism
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Solution Overview
Problem
The existing manual plug-in charging process for electric vehicles is inconvenient, as it can soil clothing and takes time, and current automation solutions require complex constructions and precise vehicle positioning.
Innovation Solution
A charging device with a socket and plug featuring insertion funnels and pins, along with a guiding mechanism that moves the plug automatically into the socket, allowing for automatic coupling and decoupling, and includes information exchange for precise positioning and charging control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual plug-in charging is used, then the charging process is simple and reliable, but it soils user clothing and takes time
Solution Approach 1:
The charging system performs self-service through automated plug insertion and connection establishment. The guiding mechanism automatically guides the plug into the socket without user intervention, and the system autonomously establishes the charging connection, eliminating the need for manual handling that causes clothing soiling and time loss.
Solution Approach 2:
The patent replaces the manual mechanical plug-in operation with an automated guiding mechanism. This mechanism uses mechanical guidance structures (funnels, rails, or robotic arms) to automatically position and insert the plug into the socket, substituting the user's manual mechanical action with an automated system.
2Extent of automation
If docking systems with charging modules are used, then charging connection is automated, but the construction becomes complex and requires precise vehicle positioning
Solution Approach 1:
Instead of having the vehicle dock precisely with a fixed charging module (traditional approach), the patent inverts the approach by having the guiding mechanism actively guide the plug to the socket. The socket with its funnel structure guides the plug's movement, reversing the traditional docking paradigm and reducing positioning precision requirements.
Solution Approach 2:
The patent introduces a guiding mechanism as an intermediary between the plug and socket. This intermediary component (comprising funnels, rails, or positioning structures) mediates the connection process by guiding the plug into proper alignment with the socket, simplifying the overall system construction while maintaining automation.
3Measurement precision
If multiple insertion funnels and pins are used, then positioning precision is improved, but the device complexity increases
Solution Approach 1:
The patent employs asymmetric funnel shapes and corresponding pin configurations to achieve precise positioning. The funnels are designed with specific geometric asymmetries that guide the pins into correct rotational and positional alignment, enabling precise plug-socket connection through geometric constraints rather than complex control systems.
Data Source
AI summary
Charging device for the automatic establishment and disconnection of a charging connection for a plug-in vehicle, whereby the charging device of the plug-in vehicle includes a charging electrical unit, a charging station with a charging cable to charge an energy storage unit of the vehicle through a cable-based charging connection. The charging electrical unit comprises a socket and the charging cable a plug. The charging device is designed such that that the socket has one or more insertion funnels, the plug has one or more guide pins, wherein each guide pin is allocated to a specific funnel. Information is exchangeable between the charging station and the charging electrical unit once the charging connection is established. Information between the charging station and the vehicle is exchangeable if the charging connection is not established. The plug and a reinforced section on the charging cable connected to the plug are movable via a guide mechanism in a predefined spatial direction in the form of a coupling movement over maximum predefined coupling length. The plug and reinforced section are also movable opposite the predefined spatial direction in a decoupling movement over the coupling length.