Autonomous Charging Coupler Alignment for Work Machines
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Solution Overview
Problem
Existing systems fail to efficiently and automatically couple large work machines with charging stations, risking damage and requiring manual maneuvering, especially for remote charging.
Innovation Solution
A charging coupler system for work machines that uses geolocation, LIDAR/LADAR, and fiducial detection to autonomously align and mate with a charging unit, enabling automatic power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual maneuvering is used to connect large work machines to charging stations, then the charging process can be completed, but the complexity of operation increases and the risk of damage to the charging station rises
Solution Approach 1:
The work machine autonomously performs the coupling operation with the charging station using its own automation systems, eliminating the need for manual intervention. The machine automatically positions itself, aligns the charging coupler, and completes the connection, thereby reducing operational complexity and minimizing damage risk through controlled, precise movements.
Solution Approach 2:
The patent replaces manual mechanical coupling operations with automated systems including vision guidance, proximity sensors, and controlled movement mechanisms. This substitution eliminates the need for operators to physically maneuver the machine into position, reducing both operational complexity and the risk of accidental damage during connection.
2Ease of operation
If automated coupling systems are implemented, then the ease of operation improves and damage risk decreases, but the device complexity increases
Solution Approach 1:
The charging coupler is designed to serve multiple functions: it acts as both a mechanical coupling device for attaching work tools and an electrical connection interface for charging. This multi-functionality reduces the need for separate dedicated charging equipment, thereby managing device complexity while maintaining automated coupling capabilities.
Solution Approach 2:
The system introduces intermediate components such as vision systems, proximity sensors, and fiducial markers that mediate between the work machine and charging station. These intermediaries facilitate precise alignment and controlled coupling, enabling automated operation while managing overall system complexity through modular, specialized subsystems.
3Manufacturing precision
If precise alignment systems are used for automated coupling, then the manufacturing precision of the connection improves, but the device complexity increases
Solution Approach 1:
Fiducial markers are pre-positioned on the charging station and work machine before the coupling operation. These markers enable the vision system to calculate precise alignment requirements in advance, allowing the control system to adjust the coupling position proactively rather than reactively, thereby achieving high precision while managing system complexity.
Solution Approach 2:
The system uses vision systems to create optical copies or digital representations of the physical coupling interface and fiducial markers. By working with these digital models and calculations, the system achieves precise alignment through computational geometry and coordinate transformation rather than requiring complex mechanical alignment mechanisms.
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
Facilitates safe, efficient, and automated charging of work machines by ensuring precise alignment and minimizing damage, allowing for both fixed and remote charging stations.
Implementation Method 1
Location and alignment systems, including geolocation, LIDAR/LADAR and fiducial detection, may be employed to facilitate precise mating of the charging coupler with the charging unit.
Data Source
AI summary
Coupling a work machine charging coupler with a charging unit for providing electrical power to work machine electrical systems is provided. A charging coupler is attached to the work machine, such as a bulldozer, front-end loader, skid steer, tractor, and the like. The work machine and attached charging coupler may be moved to the charging unit autonomously via an onboard vehicle automation and navigation system. Location and alignment systems, including geolocation, LIDAR/LADAR and fiducial detection, may be employed to facilitate precise mating of the charging coupler with the charging unit. After the charging coupler and the charging unit are mated, the charging station may transfer electrical power to the work machine across an electrical interface formed when the charging coupler and the charging unit are mated.