Robotic EV Charging Arm With Safe Positioning and High-Force Plugging
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Solution Overview
Problem
Existing robotic charging stations for electric vehicles are costly and pose safety risks due to the need for extensive safety features, while inherently safe robots are limited in application and force exertion.
Innovation Solution
A robot arm with adjustable links and joints, including positioning and sliding drives, allows for separate positioning and plugging operations, ensuring the maximum positioning force is lower than the maximum plugging force, thereby achieving inherent safety without additional safety devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robot is designed with extensive safety features (monitors, sensors, safe controls) to eliminate danger to people, then safety is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent applies the principle of inherent safety by designing the robot's mechanical system to be inherently safe through limited force capability. The robot arm is designed with a maximum force limit that prevents injury to humans, converting the potential harm of robotic operation into a beneficial safety feature. This eliminates the need for extensive safety monitoring systems while maintaining human safety during operation.
2Reliability
If a robot is designed to be inherently safe with limited force capability, then safety is improved, but the robot's application range and effectiveness are reduced
Solution Approach 1:
The patent segments the charging operation into two distinct phases: positioning phase and plugging phase. The positioning phase uses the inherently safe robot arm with limited force, while the plugging phase utilizes a separate plugging device with higher force capability. This segmentation allows the robot to maintain inherent safety during movement while achieving effective connector engagement through the dedicated plugging mechanism.
3Force
If a robot uses strong drives and materials to perform plugging operations, then plugging effectiveness is improved, but safety risk to humans increases
Solution Approach 1:
The patent introduces a plugging device as an intermediary between the robot arm and the connector. The robot arm positions the connector near the target, and then the plugging device takes over to apply the high force needed for engagement. This intermediary mechanism allows high plugging force to be applied without requiring the robot arm itself to have strong driving capability, thereby maintaining inherent safety while achieving effective plugging.
Data Source
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AI summary
One aspect of the invention relates to a robot for automatically charging or fuelling a vehicle, having: - a robotic arm; an end effector provided on the robotic arm and a connector provided on the end effector, wherein: the robotic arm has multiple members which can be moved together, relative to one another by means of one or more positioning articulations and associated positioning drives, in order to position the end effector in the space, with the application of a maximum positioning force; the robotic arm has one or more sliding pair(s), and in particular associated linear actuators; at least parts of the connector can be inserted into a mating connector of a vehicle, with the application of a maximum insertion force; and the maximum insertion force is greater than the maximum positioning force. The invention also relates to a corresponding electric connector.