Multi-Axis Plug-In Mounting for Sensorless Alignment
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Solution Overview
Problem
Existing plug-in systems for electric vehicles require high-precision and expensive sensor technology to achieve accurate plug alignment, which are sensitive to contamination and cannot use standardized charging plugs, leading to high wear and maintenance issues.
Innovation Solution
A plug-in device with a rotatable and displaceable plug-in unit mounted on multiple axes, using mechanical alignment elements and resilient mounting to compensate for misalignment, allowing precise plug positioning without expensive sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-precision LIDAR sensors are used to position the plug, then positioning accuracy is improved, but cost increases and sensitivity to contamination occurs
Solution Approach 1:
The patent replaces complex optical sensor systems (LIDAR) with a purely mechanical alignment system consisting of alignment elements and bearing units. The mechanical mounting module with multiple bearing units provides passive alignment through physical constraints, eliminating the need for expensive and contamination-sensitive electronic sensors while achieving the required positioning accuracy.
Solution Approach 2:
The invention uses simple, inexpensive mechanical alignment elements instead of expensive, complex sensor systems. These mechanical components are robust, contamination-resistant, and cost-effective, providing a practical alternative to high-tech sensor solutions that are sensitive to environmental conditions.
2Adaptability or versatility
If standardized charging plugs are used, then compatibility is improved, but sensitivity to misalignment increases leading to high wear
Solution Approach 1:
The alignment elements are positioned to perform preliminary alignment of the plug before the actual connection is made. The alignment elements make contact and establish proper orientation prior to the main plug-in action, ensuring that standardized plugs are correctly positioned before force is applied, thereby preventing misalignment-related wear during the connection process.
Solution Approach 2:
The alignment elements act as intermediary components between the plug and the connection point. These elements first engage with the plug to establish proper alignment, serving as a mediator that protects the main contact pins from misalignment damage while maintaining compatibility with standardized plugs.
3Device complexity
If the plug-in unit is rigidly fixed, then structural simplicity is improved, but alignment flexibility decreases
Solution Approach 1:
The mounting module incorporates multiple bearing units that enable the plug-in unit to move dynamically in multiple degrees of freedom. Instead of a rigid fixed mounting, the system uses rotational and translational bearing units that allow the plug to adapt its position and orientation automatically, providing alignment flexibility while maintaining a relatively simple structural design.
Data Source
AI summary
A plug-in device is provided. The plug-in device includes a plug-in unit and a mounting module. The plug-in unit includes a first plug-in element having a plug-in axis and a plug-in direction, and at least one first alignment element. The mounting module includes a first bearing unit, by which the plug-in unit is mounted rotatably about a first axis and is mounted displaceably along the first axis, a second bearing unit (34), by which the plug-in unit is mounted rotatably about a second axis and is mounted displaceably along the second axis, and a third bearing unit, by which the plug-in unit is mounted rotatably about a third axis.