Vehicle-Side Refueling Coupling for Automatic Coil Alignment
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Solution Overview
Problem
Existing refueling systems for electric drive batteries and fluid tanks in movable vehicles are complex, prone to faults, and require manual settings, leading to inefficiencies and increased costs due to the need for sophisticated electronics and software for optimal positioning of charging coils.
Innovation Solution
A multi-part refueling device with a vehicle-side coupling device and a stationary ground coupling device, featuring a contact plate that can be lowered and moved automatically using a displacement mechanism, allowing for fully automatic, maintenance-free refueling by optimizing the positioning of the contact plate relative to the charging coil or tank neck without requiring complex electromechanics in the ground coupling device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex electromechanical positioning systems with sensors and actuators are used to optimize coil alignment, then positioning precision is improved, but device complexity increases and reliability decreases
Solution Approach 1:
The patent replaces complex electromechanical positioning systems with a purely mechanical guidance system. The ground coupling device has a fixed geometric structure with guiding elements that mechanically guide the vehicle-side coupling device into the correct position. This eliminates sensors, actuators, and control electronics while achieving precise alignment through mechanical constraints alone.
Solution Approach 2:
The system uses passive mechanical guidance where the geometry of the ground coupling device automatically guides the vehicle-side coupling device into proper alignment without requiring active control systems. The mechanical structure itself provides the positioning function, making the system self-aligning and eliminating the need for complex positioning electronics.
2Extent of automation
If sophisticated control electronics and software are implemented for automated positioning, then automation extent is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent replaces automated electronic control systems with passive mechanical guidance. The fixed geometric structure of the ground coupling device provides automatic guidance through its physical design, eliminating the need for control electronics and software while maintaining automated positioning functionality.
3Productivity
If movable primary coil with adjustment mechanisms is used for position optimization, then charging efficiency is improved, but device complexity increases
Solution Approach 1:
Instead of making the ground-based primary coil movable with complex adjustment mechanisms, the patent inverts the approach by making the vehicle-side secondary coil assembly movable. The vehicle approaches the fixed ground coupling device, and the vehicle-side assembly contains the adjustment mechanisms, simplifying the ground infrastructure while maintaining charging efficiency.
4Ease of operation
If manual positioning and settings are required for refueling, then ease of operation is worsened, but device complexity is reduced
Solution Approach 1:
The system provides automated self-alignment through its mechanical guidance structure. When the vehicle approaches the ground coupling device, the geometric constraints automatically guide the vehicle-side coupling device into the correct position, eliminating the need for manual positioning and settings while keeping the system simple.
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 simplified, reproducible, and safe refueling with reduced energy losses and electromagnetic emissions, achieving efficient and fault-resistant charging or fluid transfer with minimal user intervention and reduced complexity in the stationary components.
Implementation Method 1
The primary charging coil is typically mounted on the floor of a garage and connected to charging electronics, enabling the generation of an electromagnetic charging field.
Implementation Method 2
Both coils act as electromagnets, attracting and pushing each other depending on the induced current or magnetic field.
Data Source
Figure 1a~1b
Figure 2
AI summary
In a multi-part refueling device for refueling an electric drive battery (A) or a fluid tank (B) of a mobile vehicle, a simplified and reproducible refueling process should be achieved.This is achieved by the coupling device (connecting means) carried on the vehicle side having a connection means (230) as at least one charging coil, in the form of charging contacts or as a charging nozzle (230) and a lowering mechanism (24) for lowering the contact plate (23) to the ground, a movement mechanism (25) for moving the contact plate (23) in the plane of the ground to a center of the stationary ground coupling device and a lowering mechanism (26) for lowering the connecting means (230) or contact plate (23) as a whole with the connecting means (230) onto the charging coil (30), the charging contacts (30) or a refueling nozzle (30), wherein positioning of the contact plate (23) on the stationary ground device is enabled automatically controlled by a computer and control unit (21).