Autonomous EV Charging Plug Pickup With 3D Correction Markers

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Solution Overview

Problem

Current electric vehicle charging systems using autonomous robots face challenges in accurately picking up charging plugs due to errors in structured light scanning systems, which are exacerbated by limited hardware and software resources in autonomous robots, leading to pick-up failures.

Innovation Solution

A pick-up system for an autonomous charging robot that includes a correction marker providing additional feature points, a scanner for structured light detection, and an analysis unit to calculate pick-up information, allowing the robot to accurately position and move the pick-up unit using electromagnets or permanent magnets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If structured light scanning system is used to detect pick-up target, then automation capability is improved, but measurement precision deteriorates due to scanning errors

Engineering Contradiction:

Improveautonomous pick-up capabilityVSAvoidpick-up target position accuracy

Core Design Contradiction:

Extent of automationVSMeasurement precision

Solution Approach 1:

A correction marker is introduced as an intermediary element between the scanner and the pick-up target. The correction marker provides additional feature points that serve as reference markers to correct positioning errors detected by the structured light scanner, thereby improving measurement precision without reducing automation capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system implements a feedback mechanism where the correction marker's feature points are used to calculate correction values for the scanner's detected positions. These correction values are applied to adjust the pick-up unit's positioning, creating a closed-loop control system that compensates for scanning errors and improves overall measurement accuracy

Inventive Principle:

Principle #23Feedback

2Measurement precision

If additional correction marker and analysis unit are added, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improvepick-up target position accuracyVSAvoidsystem structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system is divided into distinct functional modules: the correction marker as a separate physical component, the analysis unit as a dedicated processing module, and the pick-up unit as the execution component. This segmentation allows each module to perform its specific function independently, making the overall complex system more manageable and maintainable while achieving improved precision

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If correction marker with multiple feature points is used, then measurement precision is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveposition detection accuracyVSAvoidcorrection marker fabrication accuracy

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The correction marker utilizes visual特征 (such as color patterns or reflective properties) that are easily detectable by the scanner but tolerant of manufacturing variations. This allows the marker to provide accurate feature points for correction without requiring extremely tight manufacturing tolerances, thus improving measurement precision without excessively increasing manufacturing precision requirements

Inventive Principle:

Principle #32Color changes

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 system minimizes errors in pick-up operations by simplifying the pick-up process and ensuring high reliability, even with limited resources, by using a correction marker to correct posture and movement, enabling accurate docking of charging plugs into vehicle sockets.

Implementation Method 1

a scanner configured to use structured light, detect a target object including the pick-up target and the correction marker installed around the pick-up target, and create a point cloud including the pick-up feature point and the correction feature points

Methodology Applied

Scientific EffectStructured light: Light

Implementation Method 2

a pick-up unit configured to pick up the pick-up target... allowing the robot to accurately position and move the pick-up unit using electromagnets or permanent magnets

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS12504761B2Pick-up system of autonomous charging robot for electric vehicle

Publication Date: 2025.12.23 HANDA LAB CO LTD

AI summary

Disclosed is a pick-up system including a pick-up target configured to provide a pick-up feature point, a pick-up unit configured to pick up the pick-up target, a correction marker that is a three-dimensional structure installed around the pick-up target, a scanner configured to use structured light, detect a target object including the pick-up target and the correction marker installed around the pick-up target, and create a point cloud including the pick-up feature point and the correction feature points, an analysis unit configured to calculate pick-up information including posture information and movement information, which allow the pick-up unit to pick up the pick-up target, by comparing the pick-up feature point and the correction feature points, and three-dimensional shape information on the pick-up target and the correction marker installed around the pick-up target, and a control unit configured to control a posture and movement of the pick-up unit.