Mobile Charging Connector Alignment for Industrial Electric Vehicles
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Solution Overview
Problem
Industrial electric vehicles face challenges such as limited operational range, long downtime for recharging, high initial costs, inadequate charging infrastructure, and the need for vehicle-specific charging stations, which hinder productivity and flexibility in diverse industrial operations.
Innovation Solution
A modular and transportable charging system with a charger module and connector module, capable of converting and delivering high power to various industrial electric vehicles, featuring adjustable actuators for precise connector alignment and wireless or conductive charging, and a controller for intelligent vehicle detection and communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed charging stations are installed at industrial sites, then charging infrastructure is provided, but it creates oversizing and unnecessary costs when charging demand varies
Solution Approach 1:
The charging system is divided into modular units (charging modules) that can be independently deployed and configured. Each module can serve specific vehicles or operations, allowing the infrastructure to be scaled precisely to actual charging demand without oversizing the entire system.
Solution Approach 2:
The charging infrastructure transitions from fixed, static installations to mobile, dynamic units that can be relocated based on changing charging demands. This allows the system to adapt to varying operational needs and vehicle locations, optimizing infrastructure utilization.
2Adaptability or versatility
If vehicle-specific charging stations are provided for diverse industrial electric vehicles, then each vehicle type can be charged appropriately, but the number of charging stations required increases
Solution Approach 1:
The charging modules are designed with universal interfaces and adaptable configurations that can accommodate multiple vehicle types through a single modular unit. The system can adjust its charging parameters and physical configuration to serve different IEV models, eliminating the need for dedicated charging stations for each vehicle type.
3Length of moving object
If IEVs are operated with oversized batteries to extend operational range, then operational range is improved, but initial cost and weight increase
Solution Approach 1:
The system enables preliminary charging actions during operational breaks or idle periods rather than requiring full overnight charging. Mobile charging modules can quickly top up batteries during short windows, allowing vehicles to operate with smaller batteries that are frequently topped up rather than relying on large capacity batteries.
4Power
If IEVs are charged for extended durations at remote locations, then charging capacity is sufficient, but productivity is reduced due to long downtime
Solution Approach 1:
The system replaces traditional high-power fixed charging infrastructure with mobile charging units that can deliver substantial power capacity while being positioned optimally near vehicles. This allows high-capacity charging to occur at the vehicle's location during brief intervals, eliminating the need for extended charging sessions that reduce productivity.
Data Source
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AI summary
A charging system for an industrial electric vehicle is described. The charging system includes a charger module; a connector module; and a controller. The charger module is configured for receiving an input power from a primary power source, converting the input power into an output power and providing the output power to the connector module. The connector module is electrically connected, by an electrical connection, to the charger module for providing the output power to the connector module. The connector module comprises a charging connector electrically connected to the charger module. The charger module is configured for receiving the output power from the charger module for transiently connecting the charging connector to a receiving connector of the industrial electric vehicle, for charging the industrial electric vehicle with the output power. The connector module further comprising a first actuator for adjusting a vertical position of the charging connector, and a second actuator for adjusting a horizontal position of the charging connector. The controller is configured for detecting a position of the receiving connector, controlling the first actuator to adjust the position of the charging connector according to the position of the receiving connector, and controlling the second actuator to connect the charging connector to the receiving connector. The connector module, and optionally the charger module, is/are arranged on a movable frame, the movable frame comprising a coupling device, wherein the coupling device is configured for coupling the movable frame to a transport device for transporting the movable frame.