Development of a highly innovative robot for flexible automatic charging of electric vehicles.

Project name: Robot for flexible automatic charging of electric vehicles – Requirements analysis and specification
Project duration: 01.09.2021 – 31.08.2024
Funding ID: 100513978
Location: Aachen, Germany
Project sponsor: Deutsches Zentrum für Luft- und Raumfahrt e.V. (DLR), DLR-Projektträger
Project leader: PEM RWTH Aachen University
Grantor: Bundesministerium für Wirtschaft und Energie (BMWK)

Research objectives

Objective 1

Creation of the requirements and specification documentation

Objective 2

Derivation of the safety goals for the safety-oriented development

Objective 3

Homologation of a fully functional prototype


Identifying the Project’s Challenge

The project aims to analyze the requirements and specifications for a semi-autonomous charging robot for flexible automatic charging of electric vehicles. However, the project faces several challenges that need to be addressed. Firstly, user and operator needs are unexplored, which could lead to a system that does not meet their requirements. Additionally, there are no explicit, normative, legal, and safety-oriented requirements for the charging robot, which could compromise its safety and effectiveness. 

Furthermore, there is no risk assessment for the use of an autonomous charging vehicle in the defined application area, namely in a parking garage. This could lead to safety risks for the users and the environment. Specific test scenarios must be defined for the verification and validation of the system functions, and functional tests must be specified to ensure the prototypes’ functionalities. 

PEM Motion’s Approach

Safe operation of the loading robot must be ensured, and the operational safety must be confirmed by a notified testing body. To address these challenges, PEM Motion is supporting the project by recording customer and operator requirements through in-depth research and studies, including surveys of target groups. PEM Motion is also conducting function-specific standard research and identifying and classifying risks and deriving necessary safety objectives through the creation of a HARA and recommendation of concrete measures to reduce risks. 

With reference to the identified requirements, the validation plan is defined according to the V-model, and test scenarios are discussed. Specific tests are defined to prove the functionality of the single component, subsystems, and the complete product. The previously defined functional tests are carried out with the help of test benches and notified test centers, and the test results are subsequently evaluated. Overall acceptance of the test results and documentation by a notified testing body is necessary for acceptance and CE certification of the loading robot. 

What Has Been Achieved So Far?

So far, the standard research has been completed, and specifications and use cases were defined. Additionally, the item definition and HARA of the vehicle part were created besides the system description and risk assessment of the battery part. These achievements are important steps towards ensuring the safety and effectiveness of the semi-autonomous charging robot.

in collaboration with


Contact Us

Alexander Rötzheim


PEM Motion Seminar at the
11th Electric Vehicle Production Days

System Development in the Automotive Context

Date: October 27th, 2023
Language: German

PEM LV Battery Module

General Specifications

+Wide range of parallel cells configurable

+Welding method: Spot welding

+Projected nickel design

+Customized nickel tab

+Manufacturing partners in Mexico, Germany, Poland and China

+Short time to market

+Individual packaging can be designed

+Advanced interconnect by terminal connection


+Designed with certified cells according to:

+IEC 62133
+UL 2580

Personalized configuration