Rail-Guided EV Charging End Effector for Port Cover Handling
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Solution Overview
Problem
Conventional EV charging systems require manual intervention, which is inconvenient, time-consuming, and poses safety risks, especially for individuals with mobility or dexterity issues, as operators need to manually connect and disconnect charging connectors.
Innovation Solution
An automated EV charging system utilizing a robotic arm with an end effector that includes a support rail, gripper unit, and plug handler, controlled by a controller to autonomously open the EV's external cover, connect the charging connector, and manage the charging process without human assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual charging connection is used, then device complexity is reduced, but ease of operation deteriorates and safety risks increase
Solution Approach 1:
The charging system performs operations automatically without human intervention. The robotic arm autonomously navigates to the EV, opens the charging port cover, connects the charging connector, and manages the charging process, allowing the system to serve itself rather than requiring manual user operations.
Solution Approach 2:
Manual mechanical operations are replaced with an automated robotic system. The robotic arm with gripper and end effector substitutes human hands and manual manipulation, using controlled mechanical movement to perform charging connection tasks that were previously done manually.
2Extent of automation
If automated robotic arm is used, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The robotic charging system is divided into distinct functional modules: the robotic arm for positioning, the end effector for manipulation, the gripper for holding components, and the controller for coordination. This segmentation allows each component to perform its specific function independently while working together as an integrated automated system.
Solution Approach 2:
The robotic arm and end effector are designed to perform multiple functions: navigating to the EV, opening the charging port cover, connecting the charging connector, and potentially disconnecting it. This multi-functionality reduces the need for separate specialized devices for each operation, managing system complexity while achieving high automation.
3Reliability
If manual connector connection is required, then safety risks increase, but manufacturing precision requirements are reduced
Solution Approach 1:
The system uses sensors to detect the position of the EV charging port and the state of the charging connection. This feedback allows the robotic arm and end effector to adjust their movements in real-time, ensuring precise alignment and connection while maintaining safety through automated control and monitoring.
Solution Approach 2:
The end effector acts as an intermediary between the robotic arm and the charging connector. It provides a specialized interface that facilitates precise and safe connection, combining the positioning capability of the robotic arm with the manipulation precision needed for connector engagement.
4Productivity
If automated end effector is used, then productivity is improved, but device complexity increases
Solution Approach 1:
The robotic arm positions the end effector and charging connector near the EV charging port before making the actual connection. This preliminary positioning reduces the time and complexity of the final connection operation, improving overall charging speed while managing the complexity of the automated system.
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
Enables safe, efficient, and convenient EV charging without the need for manual intervention, reducing charging time and ensuring accessibility for all users.
Implementation Method 1
a suction unit configured to apply a vacuum to a suction chamber defined by the suction gripper to enable the suction gripper to grip the external cover
Data Source
AI summary
An end effector for an automated electric vehicle charging system includes a chassis including a chassis connector for coupling the end effector to an end of a robotic arm; and a support rail unit coupled to the chassis and including an elongate support rail, a carriage slidably coupled to the support rail and including a carriage connector configured to couple to an electric distributor charging connector of the electric vehicle charging system, and a carriage actuator coupled between the support rail and the carriage for transporting the carriage along the support rail.