Robotic EV Charging Transformer With Self-Alignment Coupling
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Solution Overview
Problem
Existing wireless charging systems for electric vehicles face inefficiencies and challenges with resonant frequency matching, foreign object interference, and misalignment issues, particularly for vehicles with varying power levels, leading to overheating and customer dissatisfaction.
Innovation Solution
A system utilizing electromagnetic coupling with conical plug and socket transformers that are resonant-frequency agnostic, allowing for efficient energy transfer across a wide range of power levels, with self-alignment and independent charging of multiple battery packs, facilitated by robotic charging units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If resonant wireless charging systems are used to accommodate larger separation distances between charging and receiving coils, then convenience and flexibility are improved, but charging efficiency drops to 15-40% and circuit complexity increases
Solution Approach 1:
The patent employs a robotic charging unit with multiple degrees of freedom that can dynamically adjust its position and orientation to optimize the coupling between primary and secondary coils. The system transitions from static resonant charging to dynamic mechanical adjustment, allowing the coils to be positioned within 3mm of each other for high efficiency while maintaining the convenience of wireless charging through automated positioning
Solution Approach 2:
The patent replaces the electrical/circuit-based resonant frequency matching system with a mechanical positioning system. Instead of using complex RLC circuit tuning to achieve coupling over large distances, the system uses robotic mechanical adjustment to physically position the coils in optimal proximity, substituting electrical complexity with mechanical precision
2Reliability
If manual plug engagement is used for charging, then connection reliability can be achieved, but the plug becomes heavy and awkward requiring human handling
Solution Approach 1:
The robotic charging unit autonomously performs the plug engagement and disengagement operations without human intervention. The system self-navigates to the vehicle, self-aligns the coils, self-engages the magnetic coupling, and self-disengages after charging, eliminating the need for heavy manual handling while maintaining reliable connection through controlled mechanical engagement
Solution Approach 2:
The robotic charging unit acts as an intermediary between the power source and the vehicle battery. It provides the mechanical coupling and positioning functions that would otherwise require direct human handling of heavy plugs, mediating the interaction between infrastructure and vehicle while protecting users from handling heavy components
3Productivity
If fast charging is provided for large vehicles with bigger batteries, then charging speed is improved, but power electronics capability and power grid load capacity requirements increase
Solution Approach 1:
The patent segments the charging function into modular components: a mobile robotic charging unit that can be deployed to multiple vehicles rather than requiring each vehicle to connect to fixed high-power infrastructure. This segmentation allows the same charging unit to serve multiple vehicles sequentially, reducing the peak power demand on any single location's power electronics and grid connection
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 efficient, universal, and cost-effective charging of electric vehicles with varying power requirements, reducing misalignment issues and foreign object interference, while allowing for flexible deployment in residential and commercial settings.
Implementation Method 1
The inductive coupling, or mutual inductance, between two wires, or circuits, can be increased by winding them into coils and placing them close together on a common axis, so the magnetic field of one coil passes through the other coil. This is referred to as electromagnetic induction because the charging circuit creates a changing magnetic field, or flux, around it, per Ampere's circuital law. This in turn induces a voltage in the receiving circuit by Faraday's law of induction.
Data Source
AI summary
A system, method, and apparatus for wirelessly charging a load. A primary transformer coil from an energy source is provided to interface with a load application with a secondary transformer coil. The method of charging is independent of resonance frequency.