Automatic EV Charging Connector with Threaded Linear Actuator
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Solution Overview
Problem
Existing electric vehicle charging systems require manual plug-and-socket mating, are prone to malfunction due to external influences, have a large build height, and lack consistent force and speed in connector movement.
Innovation Solution
An automated connection device with a planar motion stage and linear actuator, featuring a threaded member for converting rotational motion to linear motion, allows for constant force and speed in connector movement, reduced build height, and enhanced resistance to external influences, using a rotatable moving member and adjustable threaded member for precise positioning and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a pantograph mechanism is used to move the connector in the z direction, then the connector can be moved vertically, but the force and speed are not constant and additional technical measures are required
Solution Approach 1:
The patent replaces the traditional pantograph mechanism with a linear actuator that uses a threaded member (screw mechanism) to convert rotational motion into linear motion. This substitution provides constant force and speed control without requiring complex additional mechanical measures, directly resolving the contradiction between maintaining constant movement parameters and avoiding device complexity.
Solution Approach 2:
The threaded member allows precise control of movement parameters (force and speed) by changing the rotational input parameters. The screw mechanism inherently provides a mechanical advantage that maintains constant force output regardless of position, eliminating the need for additional compensation measures required by pantograph systems.
2Extent of automation
If an automated connection device with multiple moving parts is used, then connection automation is achieved, but the device has a large build height and is susceptible to malfunction due to pollutants
Solution Approach 1:
The patent employs sealing elements and protective coverings on the linear actuator and threaded member to create a protected environment that excludes pollutants, debris, and moisture. This allows the device to maintain automation while being resistant to harmful environmental factors, resolving the contradiction between automation and susceptibility to pollutants.
Solution Approach 2:
By replacing the complex pantograph mechanism with a compact linear actuator and threaded member system, the patent reduces the number of exposed moving parts and overall build height, while maintaining full automation capability. The simplified mechanism has fewer points of failure and is easier to seal against environmental contaminants.
3Force
If a threaded member is used to convert rotational motion to linear motion, then constant force and speed are achieved, but the device requires precise motion control
Solution Approach 1:
The threaded member (screw mechanism) inherently provides mechanical advantage and self-locking properties that maintain constant force output. The relationship between rotational input and linear output is determined by the thread pitch, providing precise and repeatable motion control without requiring complex control systems. This resolves the contradiction by achieving both constant force and precise motion through the inherent mechanics of the screw thread.
4Length of stationary object
If the linear actuator is positioned closer to the plane, then the build height is reduced, but the force and speed consistency becomes more difficult to maintain
Solution Approach 1:
The linear actuator with threaded member provides inherent mechanical advantage that maintains constant force and speed output regardless of its position relative to the plane. The screw mechanism's self-locking特性 and mechanical advantage ratio ensure consistent force transmission even when compacted into a smaller build height, resolving the contradiction between compact size and force consistency.
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 solution enables efficient, automated, and reliable electric vehicle charging with reduced susceptibility to malfunctions and external interference, maintaining connection during vehicle height changes, and offering a compact design suitable for various vehicle models.
Implementation Method 1
the linear actuator comprises a threaded member for converting a rotational motion to a linear motion arranged for moving the electrical interface in a direction essentially orthogonal to the plane
Data Source
Figure 1~2C
Figure 3A~4C
AI summary
Automatic connection device for charging an electric vehicle comprising: an interface for providing electrical energy to a contra-interface, a planar motion stage comprising a first moving member, which first moving member is configured for moving the interface within a plane, a linear actuator configured for moving the interface in a direction essentially orthogonal to the plane, wherein the first moving member is configured to rotate the interface about a first axis essentially parallel to the direction, and wherein the linear actuator comprises a threaded member configured for converting a rotational motion to a linear motion for moving the interface in the direction, wherein the threaded member has an adjustable length configured for achieving the linear motion for moving the interface by adjusting the adjustable length between a compressed state for an idle state of the automatic connection device and an extended state for a charging state of the automatic connection device.