Robotic Plug Bearing Alignment for Sensor-Free EV Charging
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Solution Overview
Problem
Existing plug-in systems for electric vehicles require expensive and sensitive LiDAR sensors for precise positioning, which are prone to dirt and angular misalignment issues, leading to high wear on contact pins and increased costs.
Innovation Solution
A plug-in device with a flexible bearing module allowing rotational and translational alignment, using mechanical alignment elements and a gimbal storage system to compensate for offsets, enabling precise plug-in without high-resolution sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If LiDAR sensors are used for precise positioning of the charging plug, then positioning accuracy is improved, but manufacturing cost increases and the system becomes sensitive to dirt
Solution Approach 1:
The patent replaces the optical LiDAR sensing system with a mechanical alignment system consisting of alignment elements (such as alignment pins or mechanical guides) that physically guide the charging plug into precise alignment with the charging socket. This mechanical substitution eliminates the need for expensive and dirt-sensitive optical sensors while achieving the required positioning accuracy through pure mechanical means.
2Measurement precision
If LiDAR sensors are used for precise positioning, then positioning accuracy is improved, but the system becomes sensitive to external influences like dirt
Solution Approach 1:
The patent replaces the optical LiDAR sensing system with a mechanical alignment system consisting of alignment elements (such as alignment pins or mechanical guides) that physically guide the charging plug into precise alignment with the charging socket. This mechanical substitution eliminates the need for expensive and dirt-sensitive optical sensors while achieving the required positioning accuracy through pure mechanical means.
3Ease of operation
If the connector face is modified to reduce misalignment sensitivity, then ease of operation is improved, but compatibility with standardized plugs is lost
Solution Approach 1:
The patent introduces alignment elements as intermediary components between the charging plug and charging socket. These alignment elements (such as guide pins or mechanical alignment features on the robot's end effector) act as mediators that ensure precise alignment before the actual plug insertion occurs, allowing the use of standardized plug connectors without modification while still achieving the required alignment precision.
Solution Approach 2:
The patent performs alignment actions before the actual plug insertion. The alignment elements establish the correct positional and angular relationship between the charging plug and socket in advance, ensuring that when the standardized plug is inserted, it is already properly aligned. This preliminary alignment action eliminates the need to modify the connector face while maintaining compatibility with standardized plugs.
4Ease of operation
If angular misalignment occurs during plugging, then ease of operation deteriorates, but wear on contact pins increases
Solution Approach 1:
The patent introduces alignment elements as intermediary components between the charging plug and charging socket. These alignment elements (such as guide pins or mechanical alignment features on the robot's end effector) act as mediators that ensure precise alignment before the actual plug insertion occurs, allowing the use of standardized plug connectors without modification while still achieving the required alignment precision.
Solution Approach 2:
The patent performs alignment actions before the actual plug insertion. The alignment elements establish the correct positional and angular relationship between the charging plug and socket in advance, ensuring that when the standardized plug is inserted, it is already properly aligned. This preliminary alignment action eliminates the need to modify the connector face while maintaining compatibility with standardized plugs.
Data Source
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AI summary
Plugging device (10) comprising: • a plugging unit (12) comprising ∘ a first plugging element (14) with a plugging axis (16) and a plugging direction (18), at least a first alignment element (20), • a bearing module (28) comprising ∘ a first bearing unit (30) by means of which the plugging unit (12) is rotatably mounted about a first axis (32) and displaceably mounted along the first axis (32), ∘ a second bearing unit (34) by means of which the plugging unit (12) is rotatably mounted about a second axis (36) and displaceably mounted along the second axis (36), and ∘ a third bearing unit (38) by means of which the plugging unit (12) is rotatably mounted about a third axis (40), as well as a plugging system with a plugging device (10) and a robot with a plugging device (10).