Robotic Charging Connector Alignment With Vision-Guided Latching

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Solution Overview

Problem

Existing robotic vehicle charging systems face challenges in accurately aligning and establishing electrical connections between charging connectors and vehicle charging ports, particularly due to variations in port positioning and alignment.

Innovation Solution

Employing a computer vision system with a camera and latch arm mechanism to align the charging connector with the vehicle's charging port, using machine learning to recognize the port and adjust the connector's position through motor control signals, and a latching mechanism to establish a secure electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a robotic charging system is used to automate vehicle charging, then productivity and ease of operation are improved, but alignment precision and connection reliability deteriorate due to variations in port positioning

Engineering Contradiction:

Improvecharging automation efficiencyVSAvoidconnector-port alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The camera captures an image of the charging port before the connector makes contact, allowing the system to pre-determine the optimal insertion position and orientation based on the detected port features, thereby ensuring precise alignment despite manufacturing variations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses computer vision to detect the actual position and orientation of the charging port, compares it with the expected position, and generates motor control signals to adjust the connector's approach path and insertion angle in real-time, creating a closed-loop control system that maintains high alignment precision

Inventive Principle:

Principle #23Feedback

2Ease of manufacture

If the charging connector is designed with a simple structure, then ease of manufacture is improved, but connection reliability deteriorates due to inability to secure firm electrical contact

Engineering Contradiction:

Improveconnector structure simplicityVSAvoidelectrical connection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The latching mechanism is designed as a separate, independently controllable component that can be actuated after the connector is positioned, allowing the main connector body to remain simple while adding complexity only where needed for secure engagement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The latch arm is designed to automatically engage with the port's latch feature when the connector is properly inserted, and can be released by a simple actuation signal, making the connection and disconnection processes self-contained and reliable without requiring complex control mechanisms

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12552273B2Charging port alignment methods and apparatus for robotic car chargers

Publication Date: 2026.02.17 PROCOM ENG

AI summary

An apparatus for interconnecting a vehicle charging connector with a charging port of a vehicle wherein a latch arm is slidably mounted in the charging connector to slide toward and away from the charging port and toward and into an opening in the charging port. A tip portion is positioned on the latch arm so as to be insertable downwardly into a cavity formed in an interior surface of the opening of the charging port and a linear actuator is configured to drive the latch arm towards and away from the charging connector. In an illustrative embodiment, the charging connector comprises part of a robot configured to move the tip of the latch arm downwardly into the cavity in the opening of the charging port to enable pulling the charging connector and charging port together to establish electrical contact.