Robotic Coupler for Autonomous EV Charging
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Solution Overview
Problem
Existing charging systems for electrified vehicles require manual connection and disconnection of charging cables, which is inconvenient and does not allow for autonomous charging.
Innovation Solution
A hands-free charging system that includes an electrical power source, a ground unit with an energy-storage device and a robotic coupler, and a controller that autonomously connects and disconnects the connector from the power source to couple with the vehicle charge port, enabling automatic charging without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual connection and disconnection of charging cables is used, then the operator can charge the vehicle at multiple locations, but the charging process requires manual intervention and is inconvenient
Solution Approach 1:
The robotic coupler autonomously performs the charging connection and disconnection tasks without human intervention. The system self-manages the entire charging process including navigating to the vehicle, coupling the connector, and disconnecting after charging completes, thereby eliminating manual operation requirements while achieving full automation
Solution Approach 2:
The patent replaces the manual mechanical operation of plugging and unplugging charging cables with an automated robotic mechanical system. The robotic coupler uses actuators and controlled mechanical movements to perform functions that previously required human hands and physical manipulation of the charging connector
2Reliability
If the connector is energized during connection, then power transfer can begin immediately, but it creates safety hazards during the connection process
Solution Approach 1:
The robotic coupler completes the entire physical connection process before establishing electrical contact and energizing the connector. The system performs preliminary mechanical coupling actions, ensures proper alignment and secure connection, and only then activates power transfer, thereby prioritizing safety while maintaining efficient charging operation
Solution Approach 2:
The charging connection process is divided into distinct sequential stages: mechanical approach and alignment, physical coupling of connector, verification of connection integrity, and finally electrical energization. This segmentation allows the system to ensure each step is completed safely before proceeding to the next, separating safety-critical mechanical steps from power-transfer steps
3Extent of automation
If an automated robotic coupler is used, then autonomous charging is enabled, but the system complexity increases with additional components like energy-storage devices and actuators
Solution Approach 1:
The robotic coupler is designed as a multi-functional integrated system that combines navigation to the vehicle, precise positioning, mechanical coupling, connection verification, and safe disconnection capabilities within a single device. This universal design consolidates multiple functions into one automated unit, reducing the need for separate systems and managing overall complexity through functional integration
Solution Approach 2:
The energy-storage device serves as an intermediary power source that provides electrical power to the actuators and control systems of the robotic coupler during the connection process. This intermediary power supply enables autonomous operation of the robotic system without requiring external power connections during the critical coupling phase, simplifying the overall power architecture
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
Enables automatic and efficient charging of vehicles by using energy stored in the ground unit to power the robotic coupler for connection to the vehicle charge port, ensuring safe and reliable operation while maintaining the connector de-energized during initial connection, thus addressing the inconvenience of manual charging.
Implementation Method 1
The ground unit has an energy-storage device and a robotic coupler with an actuator configured to move a connector into engagement with a vehicle charge port. The energy-storage device is configured to power the actuator.
Data Source
AI summary
A hands-free charging system includes an electrical power source and a ground unit electrically connected to the power source. The ground unit includes an energy-storage device and a robotic coupler having a connector and an actuator configured to move the connector into engagement with a vehicle charge port. The energy-storage device is configured to power the actuator. A switching arrangement is configured to selectively electrically connect the power source to the energy-storage device and to the connector. A controller is programmed to, in response to a request to charge a vehicle, connect the connector to a charge port when the connector is electrically disconnected from the power source using an internal power source.