EV Charging Manipulator With Triangulated 3D Positioning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing automatic charging systems for electric vehicles face limitations in precision, require complex and numerous moving elements, and struggle with shielding sensitive components from pollution, while offering limited positioning freedom.

Innovation Solution

A manipulator using three pivotally connected links and actuators for precise positioning in a 3D volume through triangulation, with stationary actuators and linear trajectories to simplify shielding and reduce the number of moving elements, allowing for high positioning freedom and easy shielding of sensitive components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If stacked linear actuators are used to move the charging coil in horizontal plane, then positioning freedom is improved, but precision is limited and device complexity increases

Engineering Contradiction:

Improvepositioning freedomVSAvoidpositioning precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical stacked linear actuators with a magnetic field-based levitation system. The charging coil is levitated using magnetic forces, eliminating mechanical contact and the need for complex actuator stacks. This substitution enables high-precision positioning through magnetic field control while maintaining positioning freedom, directly resolving the contradiction between adaptability and precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If stacked rotary and linear actuators are used to move the plug in volume, then positioning freedom is improved, but precision is limited and shielding difficulty increases

Engineering Contradiction:

Improvepositioning freedomVSAvoidshielding difficulty

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces mechanical actuators with a magnetic levitation system that uses electromagnetic fields for positioning. This eliminates the need for complex mechanical actuator stacks that are difficult to shield, while maintaining full three-dimensional positioning freedom. The magnetic field-based approach inherently reduces shielding requirements compared to powered mechanical components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If lifting means with geometrical features are used for alignment, then device complexity is reduced, but positioning precision requirement increases

Engineering Contradiction:

Improvestructure complexityVSAvoidvehicle positioning precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical lifting means with geometrical alignment features with a magnetic levitation system. The magnetic field enables precise positioning without requiring complex mechanical lifting mechanisms or extremely precise vehicle positioning. The levitation system actively maintains positioning through magnetic field control, eliminating the need for high-precision mechanical tolerances.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If multiple stacked actuators are used for charging coil movement, then positioning freedom is improved, but the number of moving elements increases

Engineering Contradiction:

Improvepositioning freedomVSAvoidnumber of moving elements

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces multiple stacked mechanical actuators with a single magnetic levitation system. The magnetic field provides three-dimensional positioning freedom without requiring multiple stacked mechanical components. This substitution dramatically reduces the number of moving elements while maintaining full positioning adaptability in the horizontal plane and vertical direction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3822043B1Manipulator for handsfree charging electric vehicles

Publication Date: 2023.11.01 PRODRIVE TECH INNOVATION SERVICES BV

Figure 1~3
Figure 4~6
Figure 7

AI summary

Manipulator (10) for handsfree charging electric vehicles, comprising: a first link (16) and a second link (14), wherein each one of the first and second links comprises a first end, a junction connected to the first link and to the second link and allowing the second link (14) to pivot relative to the first link (16), an energy transfer unit (17) connected to the junction, a support, a first (13) and a second (11) actuator connected to the support and operably coupled to the first link and the second link, respectively, for moving the first ends of the respective first link and second link along a respective first and second trajectory, characterized in that the manipulator further comprises a third link (15), comprising a first end and being pivotally connected to the junction, and a third actuator (12) connected to the support and operably coupled to the third link (15) for moving the first end of the third link along a third trajectory, wherein linear extrapolations through end points of the first, the second and the third trajectory have one of a list consisting of: an intersection having an angle less than 90 degrees, preferably less than 60 degrees and even more preferably less than 30 degrees and no intersection.