Autonomous EV Charging via Suspension-Actuated Coupler
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Solution Overview
Problem
Conventional electric vehicle charging systems using pin-type connectors are inadequate for frequent use, such as in fleets of vehicles, due to durability issues and safety concerns, requiring manual connection and disconnection which increases costs and poses safety risks.
Innovation Solution
A system where a charging box mounted under the vehicle automatically connects to a charge coupler using an adjustable suspension system, eliminating the need for complex connectors and allowing larger, more durable contacts for efficient charging without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pin-type electrical connectors are used for charging, then the charging system can be manually connected and disconnected, but the connectors become insufficiently durable for frequent use and pose safety risks
Solution Approach 1:
The charging system performs the connection and disconnection operations automatically without human intervention. The vehicle autonomously approaches the charge coupler, the suspension system lowers the charging box to establish electrical contact, and after charging completes, the vehicle raises itself to disconnect. This self-service mechanism eliminates manual handling while ensuring consistent, safe connections.
Solution Approach 2:
The patent replaces the manual mechanical connector system with an automated suspension-based system. Instead of manually plugging and unplugging pin-type connectors, the vehicle uses its adjustable suspension to control the positioning and contact of the charging box with the charge coupler, substituting human-operated mechanical connection with an automated mechanical system.
2Object-affected harmful factors
If manual connection and disconnection of charging connectors is required, then operational flexibility is maintained, but costs increase and safety risks arise from manual handling
Solution Approach 1:
The charging system performs the connection and disconnection operations automatically without human intervention. The vehicle autonomously approaches the charge coupler, the suspension system lowers the charging box to establish electrical contact, and after charging completes, the vehicle raises itself to disconnect. This self-service mechanism eliminates manual handling while ensuring consistent, safe connections.
3Productivity
If frequent charging cycles are required for vehicle fleets, then operational continuity is maintained, but conventional connectors wear out quickly and become unsuitable
Solution Approach 1:
The patent replaces the manual mechanical connector system with an automated suspension-based system. Instead of manually plugging and unplugging pin-type connectors, the vehicle uses its adjustable suspension to control the positioning and contact of the charging box with the charge coupler, substituting human-operated mechanical connection with an automated mechanical system.
Solution Approach 2:
The automated charging system enables continuous operation without interruption. The vehicle can autonomously connect to charge, complete the charging cycle, and disconnect without requiring manual intervention between cycles. This continuity allows fleet vehicles to maintain operational readiness through frequent charging cycles while eliminating the wear and tear associated with manual connector handling.
4Productivity
If larger, more durable electrical contacts are used, then charging efficiency improves, but the connection system becomes more complex and requires automation
Solution Approach 1:
The patent replaces the manual mechanical connector system with an automated suspension-based system. Instead of manually plugging and unplugging pin-type connectors, the vehicle uses its adjustable suspension to control the positioning and contact of the charging box with the charge coupler, substituting human-operated mechanical connection with an automated mechanical system.
Data Source
AI summary
A system for charging a battery carried by a vehicle may include a charging box for coupling to a vehicle chassis and including interface electrical contacts electrically coupled to the battery. The system may also include a charge coupler including coupler electrical contacts for electrically coupling to the interface electrical contacts from under the vehicle and configured to be coupled to an electrical power supply. The charging box may include an interface activation surface, and the charge coupler may include a housing for enclosing the coupler electrical contacts and including a base for supporting the coupler electrical contacts, a coupler activation surface opposite the base, an opening, and a door configured to open the opening to expose the coupler electrical contacts as the interface activation surface contacts the coupler activation surface and moves the coupler activation surface toward the base.