AUTOMATIC COUPLER ASSEMBLY

Abstract

A socket of an automatic coupler assembly is arranged for receiving a plug along a first direction. The socket includes a first means for limiting the movement of the plug in the first direction and a second means for blocking the movement of the plug in a second direction opposite to the first direction.

Claims

1. A socket for an automatic coupler assembly for charging electric vehicles, wherein the socket is arranged for receiving a plug along a first direction, the socket comprising: a limiter configured to limit movement of the plug in the first direction; and a gripper configured to block movement of the plug in a second direction opposite to the first direction.

2. The socket according to claim 1, wherein at least a directional component of the first direction is upward.

3. The socket according to claim 1, wherein the limiter is configured to at least in part provide a first alignment of the plug and socket for mating.

4. The socket according to claim 3, wherein the first alignment comprises a first translational alignment along a first axis of translation (Z) substantially parallel to the first direction and a first rotational alignment about a first axis of rotation (X) substantially orthogonal to the first direction.

5. The socket according to claim 1, wherein the limiter is a physical limiter providing an abutting surface.

6. (canceled)

7. The socket according to claim 1, wherein the gripper is configured to at least in part provide a second alignment of the plug and socket for mating, wherein the second alignment comprises a second rotational alignment about a third axis of rotation (Z) parallel to the first direction and a second translational alignment along a second axis of translation (X) substantially orthogonal to the first direction.

8. (canceled)

9. The socket according to claim 1, wherein the gripper is configured to engage the plug, the gripper comprising two engaging members moveable relative to one another in a third direction having at least a directional component perpendicular to the first direction.

10. The socket according to claim 9, wherein the at least one of the two engaging members is configured to align a plug for mating with the socket.

11. The socket according to claim 9, wherein at least one of the two engaging members comprises at least one electrical connector.

12. The socket according to claim 9, wherein at least one of the two engaging members is arranged for retaining the plug by blocking the movement of the plug in the second direction.

13. (canceled)

14. The socket according to claim 9, having a first state wherein the two engaging members define a cavity for configured to receive the plug, when the two engaging members are at a distant location with respect to one another, and a second state for blocking movement of the plug in the second direction, when the two engaging members are at a proximal location with respect to one another.

15. The socket according to claim 14, wherein in the second state the two engaging members are configured to abut opposing surfaces of the plug.

16. The socket according to claim 9, wherein a surface of a first one of the two engaging members facing a second one of the two engaging members comprises a first geometry configured to complement a second geometry of a reciprocal surface of the plug.

17. The socket according to claim 16, wherein the first geometry comprises at least one of a protuberance and a depression towards the second one of the two engaging members for aligning the plug.

18-21. (canceled)

22. The socket according to claim 9, wherein the gripper further comprises an ejecting means configured to eject the plug from the socket.

23. The socket according to claim 22, wherein the ejecting means are configured to eject the plug along the third direction.

24. An automatic coupler assembly, comprising: claim 1; and a plug, wherein the plug comprises a second surface comprising a first geometry for complementing a second geometry of a reciprocal surface of the socket configured for aligning the plug and the socket for mating.

25. The automatic coupler assembly according to claim 24, wherein the plug comprises a first surface configured to provide a first alignment of the plug and the socket for mating, wherein the first alignment comprises a first translational alignment along a first axis of translation substantially parallel to the first direction and a first rotational alignment about a first axis of rotation substantially orthogonal to the first direction.

26-27. (canceled)

28. The automatic coupler assembly according to claim 24, further comprising a charging station, wherein the charging station comprises the plug, a mover, and a hinging member, wherein the hinging member is configured to connect the plug to the mover and configured to offer degrees of freedom for aligning the plug, wherein the mover is configured to move the plug between a first position more distant from the socket than a second position.

29. A vehicle comprising the socket of claim 1, wherein the socket is arranged on an underside of the vehicle.

30-35. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0112] FIG. 1 shows a side view of a socket and a plug according to an embodiment of the present disclosure.

[0113] FIG. 2A, 2B, 2C, 2D shows steps of a method for mating a socket and plug according to an embodiment of the present disclosure in consecutive order.

[0114] FIG. 3A shows an exploded view of a vertical mover of a charging station according to an embodiment of the present disclosure equipped with a ball joint for connecting a plug to the vertical mover.

[0115] FIG. 3B shows a side view of the vertical mover of FIG. 3A.

[0116] FIG. 4A shows a schematic bottom view of a socket according to an embodiment of the present disclosure in a closed state.

[0117] FIG. 4B shows a schematic bottom view of the socket of FIG. 4A in a first (open) state and a plug according to an embodiment of the present disclosure positioned in a cavity of the socket.

[0118] FIG. 4C shows a schematic bottom view of the socket of FIG. 4A in a second (blocking) state with the plug of FIG. 4B electrically coupled to the socket.

[0119] FIG. 5A shows a schematic perspective view of the socket of FIG. 4A in the closed state.

[0120] FIG. 5B shows a schematic perspective view of the socket of FIG. 4B in the first (open) state and the plug positioned in the cavity of the socket.

[0121] FIG. 5C shows a schematic perspective view of the socket of FIG. 4C in the second (blocking) state wherein the plug is electrically coupled to the socket.

DETAILED DESCRIPTION

[0122] Referring to FIG. 1 and FIG. 3, the present disclosure is related to an automatic coupler assembly such as a vehicle coupler for charging electric vehicles, comprising socket 10 provided as a vehicle unit and plug 20 that will self-align during mating while allowing for sufficient parking misalignment. The plug 20 is mounted to a ground unit (see FIGS. 3A-B) comprising a mover 30 also referred to as a handler, a manipulator, a robot or an off-board robot handler, advantageously through a hinge point (e.g. a spherical joint such as ball joint 31) providing the required (passive) degrees of freedom.

[0123] The mating direction of the plug and socket of the vehicle coupler assembly is advantageously in the horizontal plane (e.g. parallel to the x,y plane). The force required for mating is delivered by a (short) linear movement of at least one of the engaging members 11, 14 of the vehicle socket 10. Therefore, the off-board robot handler 30 can be limited to a low force handler (about 5N and less than 200N). Because of the low force design the handler 30 will be fully backdrivable. This fully backdrivable robot handler 30 does not require additional provisions to provide compliance when the car moves after mating.

[0124] The plug 20 itself comprises contra-connectors 21, potentially comprising three phase power contacts, a neutral potential contact, a protective earth contact and 2 communication contacts 25 (similar to the standard type 2 plug) and a plastic housing.

[0125] It advantageously does not contain any moving parts or springs. This greatly improves the reliability and simplicity of the plug.

[0126] Referring to FIG. 1, the vehicle coupler assembly can comprise one or a combination of the following elements: [0127] Plug 20 providing a connection device attached to a tip of an off-board robot handler 30, comprising electrical contra-connectors 21 arranged for engaging electrical connectors (not shown) provided in the socket 10. [0128] First vehicle socket engaging member 11 forming a receptacle for the plug 20 provided in socket 10 and comprising connectors, which are electrically connected to the onboard charger. [0129] Landing plane 13 providing an abutting surface 16 as a physical limiter. This feature in the socket is capable of accepting the plug with an offset in the XY plane and forms the reference for parallel alignment of the first surface 23 of the plug with the abutting surface 16, e.g. providing a horizontal alignment. [0130] Second vehicle socket engaging member 14 providing a catch plate, which is a feature in the vehicle unit that advantageously co-operates with the first vehicle socket engaging member 11. Either one or both are shaped with a geometry 15 to align the plug 20 with the vehicle socket 10 in a horizontal plane (rotation and offset). [0131] Alignment features/ribs 12, 22 may be provided on the plug 20 as extending fins 22, preferably provided on the outer contra-connectors, and the first vehicle socket engaging member 11 as a protruding edge. These geometrical features are configured to co-operate. Together these geometrical features make sure the electrical contra-connector pins 21 will align with the connectors provided in the socket before mating, such as when the first engaging member 11 abuts the plug 20 and moves towards the second engaging member 14. [0132] Cavity 17 for receiving the plug which may be provided by the two engaging members 11, 14 and the landing plane 13. [0133] Covers (not shown) for covering socket and/or plug during idle time.

[0134] Alignment principle by orienting and centering the plug 20 along the three axes:

[0135] Plug 20 is pushed by handler 30 against the landing plane 13 of the socket inside the bottom plate of the vehicle so that the plug abuts against the abutting surface. This orients the plug in the correct x,y plane. The first vehicle socket engaging member 11 moves in −X towards second engaging member 14 and pushes the plug 20 against a catch plate 15. The alignment features 12, 22 co-operate to orient the plug in the correct x,z plane such that the connectors and contra-connectors are correctly oriented for mating. The centring geometries 15, 24 co-operate for centering the plug by translation along the y axis such that the connectors and contra-connectors are correctly aligned for mating.

[0136] The plug 20 advantageously comprises alignment features/ribs 22 to make sure the plug is rotated to the correct orientation to allow for mating.

[0137] The catch plate and plug advantageously comprise complementary rounded geometries (e.g. convex, concave) to make sure that misalignment in XY and possibly orientation is corrected for when the vehicle socket is pushed to the plug. An alternative can be a triangular shape which exhibits similar behavior.

[0138] The lock between the vehicle unit 10 and the ground unit 20, 30 can be realized by means of features integrated in the socket and the plug.

[0139] The plug and the socket comprise one or more electrical connectors, such as pins 21 provided on the plug providing female contra-connectors and complementary male connectors (not shown) provided on the socket. These electrical connectors can be placed next to each other in the horizontal plane to reduce the height of the module for easier fitting in an electric vehicle.

[0140] The landing plane 13 is advantageously larger than the plug 20 to allow for misalignments in all directions.

[0141] The mating procedure can comprise one or a combination of the following steps, preferably in the following order (see FIGS. 2A-D): [0142] 1. Car is parked above a ground unit comprising an off-board robot 30, preferably inside the parking range, e.g. using short range positioning as a car guidance system; [0143] 2. vehicle unit cover opens; [0144] 3. Ground unit cover opens (e.g. FIG. 2A); [0145] 4. Ground unit handler 30 moves the plug 20 along the z-axis inside the vehicle unit landing pad/cavity 17 (e.g. FIG. 2B); [0146] 5. Vehicle unit detects the plug on the landing pad confirmation that the plug is present on the landing; [0147] 6. Ground unit provides small holding force along the z-axis and releases all other axes; [0148] 7. First vehicle unit engaging member 11 starts moving along the x-axis providing orientation, centering and mating (e.g. FIG. 2C); [0149] 8. Mating is completed, e.g. confirmed by a pilot pin (e.g. FIG. 2D); [0150] 9. Ground unit releases the z-axis providing compliance in 6 DOFs; [0151] 10. Charging starts. [0152] 11. Charging stops (e.g. when battery is full) [0153] 12. Vehicle units open [0154] 13. Plug is ejected from socket by an ejecting mechanism 18 (described further) [0155] 14. Plug is retracted by the ground unit handler [0156] 15. Vehicle unit closes [0157] 16. Ground unit closes

[0158] Referring to FIGS. 4A-C and 5A-C, several states of a socket 10 according to an embodiment of the present disclosure are shown. FIGS. 4A and 5A show a socket 10 in a closed state, wherein the first engaging member 11 and second engaging member 14 are in their most proximal position, configured for shielding parts of the socket 10 from fouling, debris or moisture. In the closed state the two engaging members 11, 14 may abut one another and for instance the second engaging member 14 provides a lid for the first engaging member 11, for instance for shielding electrical components and connectors housed in the first engaging member 11. The second engaging member 14 providing the lid may be slidably arranged on at least one or preferably two linear guides, driven by linear driving means 19 and configured for moving relative to the first engaging member 11 along a third direction.

[0159] FIGS. 4B and 5B show a socket 10 in a first (open) state configured for receiving a plug 20. In the open state, the second engaging member 14 providing the lid is a positioned at a distance from the first engaging member 11 along the third direction such that a cavity 17 is formed for receiving the plug 20. The lid 14 can be displaced between the closed and open state using a linear driving means 19. In the event that lid 14 comprises a surface 15 arranged for aligning the plug 20 the driving means 19 can also be used for aligning the plug with the socket 10 when the engagement members 11, 14 approach one another and geometry 15 abuts a reciprocal surface 24 of the plug 20.

[0160] FIGS. 4C and 5C show a socket 10 in a second (blocking) state wherein a plug 20 is electrically coupled to the socket 10. In this blocking state, an electrical contra-connector on a surface of the plug 20 opposite to surface 24 is mated with a connector of the first engaging member 11. Surface 15 of the second engaging member 14 in this state may abut surface 24 of the plug 20. During the mating procedure ejecting means 18 (e.g. spring loaded pins) may be displaced by the plug into the first engaging member 11. After charging the ejecting means may be used for ejecting the plug by pushing the plug 20 away from the first engaging member 11. Such ejecting means may also be displaced by the second engaging member 14, for instance by surface 15 (see FIGS. 4A and 5A) which may fit into recess of the first engaging member 11.