Patent Application
20240030728
This U.S. patent application claims priority under 35 U.S.C. § 119 to: India Application No. 202221041399, filed on Jul. 19, 2022. The entire contents of the aforementioned application are incorporated herein by reference.
The disclosure herein generally relates to a docking system, and, more particularly, to automated docking system for charging chargeable mobile devices.
With advancement in programming technology, programmable electronic devices are becoming more prevalent and are used to perform multiple tasks that are time consuming. Many of such programmable electronic devices are chargeable mobile devices such as autonomous mobile robots. These chargeable mobile devices require regular charging to keep them operational. The charging or docking process could be manual or automated. For automated charging, the chargeable mobile devices need a docking station. Generally, the docking station are idle devices with charging ports to which the chargeable mobile devices automatically get docked. However, conventionally, the chargeable mobile devices fail in docking themselves in a first attempt due to multiple reasons. These multiple reasons may include sensor noise, lack of mechanical flexibility in the docking stations, lack of features for a chargeable mobile device to automatically detect the docking stations, and/or the like. Further, conventional systems generally utilize expensive technology like wireless charging leading to higher cost.
Embodiments of the present disclosure present technological improvements as solutions to one or more of the above-mentioned technical problems recognized by the inventors in conventional systems. For example, in one aspect, there is provided an automated docking system for charging a chargeable mobile device. The automated docking system comprising: a docking station, wherein the docking station comprises: a base assembly, wherein the base assembly comprises: a base plate, wherein the base plate comprises a first end, a second end, a plurality of mounting holes adapted for provisioning grouting and a plurality of mounting holes adapted for provisioning a battery charger mount plate, and wherein the first end of the base plate is connected to a first dead weight and the second end of the base plate is connected to a second dead weight; a rear plate coupled to the base plate through a plurality of coil springs, wherein each of the plurality of coil springs is adapted to provide a cushioning effect for the docking station during an autodocking process of the automated docking system for charging the chargeable mobile device; a floating assembly, wherein the floating assembly comprises: a rod housing, wherein the rod housing comprises a first side and a second side, and wherein each side of the rod housing comprises a set of holes; a floating plate, wherein the floating plate comprises a pair of flanges and a flat portion substantially protruding towards an angular assembly, wherein each flange of the pair of flanges comprises a corresponding hole; a first set of guide rods, wherein each guide rod of the first set of guide rods comprises a first end and a second end, and wherein each guide rod of the first set of guide rods is adapted to pass through a corresponding hole of the set of holes at a corresponding side of the rod housing, and each of the first end and the second end of each of the first set of guide rods is connected to a corresponding flange from the pair of flanges of the floating plate via one or more screws; a pair of stoppers, wherein each stopper from the pair of stoppers is connected to a corresponding side from the first side and the second side of the rod housing and is adapted to adjust a lateral stroke required for the auto docking process of the automated docking system; and a first set of tension springs inserted over the first set of guide rods and positioned between the rod housing and the pair of flanges of the floating plate, wherein the first set of tension springs is adapted to permit a lateral movement of the docking station from an initial position to a desired position during the autodocking process of the automated docking system for charging the chargeable mobile device; a center assembly, wherein the center assembly comprises: a mounting block having a plurality of holes; a second set of guide rods, wherein each guide rod of the second set of guide rods comprises a first end and a second end, and wherein the first end of each guide rod of the second set of guide rods is sliding inside a corresponding hole of the plurality of holes of the mounting block and connected with each other by a small plate and one or more screws, and the second end of each guide rod of the second set of guide rods is coupled to the rod housing; and a second set of tension springs inserted over the second set of guide rods and positioned between the rod housing and the mounting block, wherein the second set of tension springs is adapted to permit a longitudinal movement of the docking station from an initial position to a desired position during the autodocking process of the automated docking system for charging the chargeable mobile device; the angular assembly configured to provide an angular motion to the docking station during the autodocking process of the automated docking system for charging the chargeable mobile device; and a fleet management network comprising a plurality of the chargeable mobile devices to be charged at the docking station.
In accordance with an embodiment of the present disclosure, the angular assembly comprises: a table assembly mounted on the floating plate; a charging pad mounting plate, wherein the charging pad mounting plate comprises a top surface and a bottom surface; a charging pad, wherein the charging pad is coupled to the table assembly through the charging pad mounting plate; a plurality of standoffs, wherein each standoff from the plurality of standoffs comprises a first end and a second end, and wherein the first end of each standoff from the plurality of standoffs is connected to the charging pad mounting plate; a plurality of rollers, wherein each roller from the plurality of rollers is adapted to be connected to a corresponding second end of standoff from the plurality of standoffs via a screwing mechanism; a plurality of self-centering springs, wherein each self-centering spring from the plurality of self-centering springs comprises a first end and a second end, and wherein the first end of each self-centering spring from the plurality of self-centering springs is connected to a first set of pins mounted on the floating plate and the second end of each self-centering spring from the plurality of self-centering springs is connected to a second set of pins mounted on to the bottom surface of the charging pad mounting plate; a ball plunger, wherein the ball plunger comprises a first end and a second end, and wherein the first end of the ball plunger is adapted to be in contact with a hole made on the floating plate when the automated docking system is in an idle state and the second end of the ball plunger is mounted to the charging pad mounting plate; and a plurality of angle restrictors adapted to control the angular motion of the angular assembly, wherein the plurality of angle restrictors are mounted onto the floating plate and positioned adjacent to the ball plunger.
In accordance with an embodiment of the present disclosure, the automated docking system further comprises a housing cover enclosing the docking station and mounted to the base plate of the base assembly, wherein the housing cover comprises a plurality of patterns that enable the plurality of chargeable devices a position and orientation (pose) detection of the docking station.
In accordance with an embodiment of the present disclosure, the battery charger mount plate is adapted to hold a battery charger with help of a toggle clamp which is mounted onto the battery charger mount plate.
In accordance with an embodiment of the present disclosure, the table assembly is a turn table assembly.
In accordance with an embodiment of the present disclosure, the plurality of rollers are configured to guide docking element mounted to each of the plurality of chargeable devices.
In accordance with an embodiment of the present disclosure, the plurality of self-centering springs are configured to ensure keeping the angular assembly at center with help of the ball plunger.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
Exemplary embodiments are described with reference to the accompanying drawings. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the scope of the disclosed embodiments.
Programmable electronic devices are becoming more prevalent in many applications and are used to perform multiple tasks that are time consuming. Many of such programmable electronic devices are chargeable mobile devices such as autonomous mobile robots. These chargeable mobile devices require regular charging. The charging process could be manual or automated. For automated charging, the chargeable mobile devices need a docking station. Generally, the docking station are idle devices with charging ports to which the chargeable mobile devices automatically get dock. However, conventionally, the chargeable mobile devices fail in docking themselves in a first attempt due to multiple reasons. These multiple reasons may include sensor noise, lack of mechanical flexibility in the docking station, lack of features for a chargeable mobile device to automatically detect the docking station, and/or the like. Further, conventional systems generally utilize expensive technology like wireless charging leading to higher cost. The system of the present disclosure addresses the unresolved problem of automated docking in conventional docking systems by enabling precise docking of the chargeable mobile device and also making the docking station intelligent. This leads to the chargeable mobile devices to effectively communicate with the docking station and share data.
The system of the present disclosure provides a generic docking station with internet of things (IoT) interface for heterogeneous chargeable mobile devices. This means that design of the docking station is a generic design with robot sensor fusion which detects the docking station automatically and helps in precise docking. The generic design of the docking station enables docking different category of the chargeable mobile devices such as fork type, unit load type, and/or the like at same docking station with different charging currents. IoT enabled docking station communicates with the chargeable mobile devices and charges them based on battery health, quick/slow charge, category, task duration and/or the like. In other words, all the data connected over IoT is used for further processing to improve charging efficiency and task planning. In an embodiment, the present disclosure brings a design flexibility to the docking station and contact pads, so that the flexible design adjusts itself in translation and rotation axis for certain degrees of freedom if there is an error in docking.
Referring now to the drawings, and more particularly to
Reference numerals of one or more components of the automated docking system 100 for charging a chargeable mobile device 106 as depicted in the
The floating assembly 204 of the docking station 102 comprises a rod housing 414, a floating plate 416, a first set of guide rods 420 A-B, a pair of stoppers 422 A-B, and a first set of tension springs 910 A-B.
As shown in
The center assembly 206 of the docking station 102 comprises a mounting block 302, a second set of guide rods 424 A-B, and a second set of tension springs 810 A-B. The mounting block 302 of the center assembly 206 comprises a plurality of holes 818 A-D.
The second set of tension springs 810 A-B of the center assembly 206 is inserted over the second set of guide rods 424 A-B and positioned between the rod housing 414 and the mounting block 302. In an embodiment, the second set of tension springs 810 A-B is adapted to permit a longitudinal movement of the docking station 102 from an initial position to a desired position during the autodocking process of the automated docking system 100 for charging the chargeable mobile device 106. In other words, use of the second set of tension springs 810 A-B on the second set of guide rods 424 A-B is to always retain the position of the rod housing 414 at a specific position when the docking station 102 is not in operation. When the chargeable mobile device (say mobile robot) tries to get dock, the second set of tension springs 810 A-B allows the docking station 102 to move longitudinally in certain stroke fixed by the stopper mechanism. As shown in
The angular assembly 208 of the docking station 102 is configured to provide an angular motion to the docking station 102 during the autodocking process of the automated docking system 100 for charging the chargeable mobile device 106. The angular assembly comprises a turn table assembly 504 mounted on the floating plate 416, a charging pad mounting plate 426, a charging pad 428, a plurality of standoffs 430 A-D, a plurality of rollers 432 A-D, a plurality of self-centering springs 434 A-B, a ball plunger 506, and a plurality of angle restrictors 436 A-B. In an embodiment, the table assembly 504 of the angular assembly 208 is a turn table assembly. The turn table assembly 504 is mounted to the floating plate 416 on which the charging pad 428 is mounted with help of the charging pad mount plate 426. The charging pad mounting plate 426 of the angular assembly 208 comprises a top surface 426 A and a bottom surface 426 B. The charging pad 428 is coupled to the table assembly 504 through the charging pad mounting plate 426. As shown in
Further, the angular assembly 208 comprises the plurality of self-centering springs 434 A-B. In an embodiment, each self-centering spring from the plurality of self-centering springs 434 A-B comprises a first end 806 A-B and a second end 808 A-B. The first end 806 A-B of each self-centering spring from the plurality of self-centering springs 434 A-B is connected to a first set of pins 906 A-B mounted on the floating plate 416 and the second end 808 A-B of each self-centering spring from the plurality of self-centering springs 434 A-B is connected to a second set of pins 1002 A-B mounted on to the bottom surface 426 B of the charging pad mounting plate 426. In an embodiment, the ball plunger 506 of the angular assembly 208 comprises a first end 506 A and a second end 506 B. The first end 506 A of the ball plunger 506 represents a ball and is adapted to be in contact with a hole 908 made on the floating plate 416 when the automated docking system 100 is in an idle state and the second end 506 B of ball plunger 506 is mounted to the charging pad mounting plate 426. In an embodiment, the plurality of self-centering springs 434 A-B are configured to ensure keeping the angular assembly 208 at center with help of the ball plunger 506. The angular assembly 208 also comprises the plurality of angle restrictors 436 A-B which are mounted onto the floating plate 416 and positioned adjacent to the ball plunger 506. In an embodiment, the plurality of angle restrictors 436 A-B of the angular assembly 208 are adapted to control the angular motion of the angular assembly 208. As shown in
Most of the docking stations are design for automation. As per the requirement by automation system, to bring design flexibility to the docking station 102 and to the charging pad 428, the floating assembly 204 which is connected to the base assembly 202 inside the docking station 102 is designed to provide flexible cushioning for translation using the center assembly 206 and rotation using the angular assembly 208. Rotation flexibility through the angular assembly 208 is achieved through the plurality of self-centering springs 434 A-B which are connected to the charging pad mount plate 426 and the floating plate 416 with help of the first set of pins 906 A-B and the second set of pins 1002 A-B. To this assembly, the charging pad 428 is connected. When the chargeable mobile device 106 comes to automatically dock, a slight translation and rotational error can be expected. In the present disclosure, the base assembly 202 of the docking station 102 aligns itself to get better contact with pads (not shown) on the chargeable mobile device 106.
The automated docking station 100 can be used for charging the chargeable mobile devices 106. One or more sensors comprising a 2D sensor, a 3D sensor or a combination of 2D and 3D sensors (3D+2D) are integrated with the automated docking system 100 which capture information to identify a docking station from a plurality of docking stations 102 in a predefined region and to estimate the position and orientation of the identified docking station. In an embodiment, the one or more sensors may include vision sensors, LIDAR, and other onboarding sensors. In the present disclosure, the one or more sensors are not visible and not depicted in the FIGS. In an embodiment, expression ‘vision sensors’ may be referred as ‘cameras’ or ‘image capturing device’ or ‘video capturing device’ or ‘electronic device’ and may be interchangeably used hereinafter. In an embodiment, the captured information comprises reflection pattern intensity of the docking station 102 obtained using the LIDAR sensors, unique V-shape patterns created on the housing cover 508, a plurality of visual fiducial markers, a combination of 2D and 3D markers. In an embodiment, the 3D marker can have shapes varying from a simple wedge design to predefined patterns, which is uniquely distinguishable from 3D data captured from a 3D camera (not shown) mounted on the chargeable mobile device 106. In an embodiment of the present disclosure, the vision sensor is an electronic device that captures information using a two-dimensional (2D) RGBD camera for identifying the plurality of visual fiducial markers such as April tag. The captured information is fed to sensor fusion where the captured information is fused with corresponding weights to estimate perfect pose for the chargeable mobile device 106 to dock it in global coordinate frame.
Further, the automated docking system 100 is backed by artificial intelligence-based system (e.g., one or more hardware processors 104) which helps in precise docking thereby improving charging efficiency and task planning. In an embodiment, the vision sensors are connected to (or are an integral part of) an external system (e.g., a robot wherein the automated docking system 100 is connected to this system for passing the captured information by the robot to the automated docking system 100 for charging the robot). The automated docking system 100 can handle different category of chargeable mobile devices 106 such as fork type, unit load type, and/or the like at same docking station with different charging currents and can be controlled independently. The docking stations 102 can be scanned via a sensor array for position and orientation. Based on information, the automated docking station 100 utilizes an artificial intelligence-based hardware processor (e.g., wherein the artificial intelligence-based hardware processor is either an integral part of the apparatus 100 or externally connected to the automated docking system 100 via input/output communication interfaces as known in the art) that makes the chargeable mobile devices 106 to dock with ease and effective based on the flexibility provided by the autodocking process of the automated docking system 100 in lateral, longitudinal and angular direction.
In an embodiment, the chargeable mobile device 106 includes one or more hardware processors 1206, communication interface device(s) or input/output (I/O) interface(s) 1204 (also referred as interface(s)), and one or more data storage devices or memory 1202 operatively coupled to the one or more hardware processors 1206. The one or more processors 1206 may be one or more software processing components and/or hardware processors. In an embodiment, the hardware processors can be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor(s) is configured to fetch and execute computer-readable instructions stored in the memory. In an embodiment, the chargeable mobile device 106 can be implemented in a variety of computing systems, such as laptop computers, notebooks, hand-held devices, workstations, mainframe computers, servers, a network cloud, robot, and the like.
The I/O interface device(s) 1204 can include a variety of software and hardware interfaces, for example, a web interface, a graphical user interface, and the like and can facilitate multiple communications within a wide variety of networks N/W and protocol types, including wired networks, for example, LAN, cable, etc., and wireless networks, such as WLAN, cellular, or satellite. In an embodiment, the I/O interface device(s) 1204 can include one or more ports for connecting a number of devices to one another or to another server.
The automated docking system 100 may be equipped with a 2D and/or a 3D camera (also referred as an electronic device) which provides information the plurality of visual fiducial markers, a combination of 2D and 3D markers to the automated docking system 100, wherein the docking system 100 enables identification of available charging stations and pose estimation the identified charging stations for charging the chargeable mobile devices 106.
The memory 1202 may include any computer-readable medium known in the art including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes. In an embodiment, a database 1208 is comprised in the memory 1202, wherein the database 1208 comprises information, for example, charging status of the chargeable mobile devices 106, unoccupied charging stations, power capability, and their location. The information stored in the database 1208 may further comprise position and estimation of docking stations estimated by the automated docking system 100 or the hardware processors 1206. The information stored in the database 1208 may further comprise information captured by the LIDAR sensors, vision sensors, shape patterns created on the housing cover 508, and/or the like. The memory 1202 further comprises (or may further comprise) information pertaining to input(s)/output(s) of each step performed by the systems and methods of the present disclosure. In other words, input(s) fed at each step and output(s) generated at each step are comprised in the memory 1202 and can be utilized in further processing and analysis.
In an embodiment, the automated docking system 100 is connected to the chargeable mobile devices 106 or an external system via one or more coupling systems (e.g., wired connectors as known in the art or wireless systems) or input/output interfaces as known in the art. The chargeable mobile device 106 comprises (or may comprise) the components as shown in
The written description describes the subject matter herein to enable any person skilled in the art to make and use the embodiments. The scope of the subject matter embodiments is defined by the claims and may include other modifications that occur to those skilled in the art. Such other modifications are intended to be within the scope of the claims if they have similar elements that do not differ from the literal language of the claims or if they include equivalent elements with insubstantial differences from the literal language of the claims.
It is to be understood that the scope of the protection is extended to such a program and in addition to a computer-readable means having a message therein; such computer-readable storage means contain program-code means for implementation of one or more steps of the method, when the program runs on a server or mobile device or any suitable programmable device. The hardware device can be any kind of device which can be programmed including e.g. any kind of computer like a server or a personal computer, or the like, or any combination thereof. The device may also include means which could be e.g. hardware means like e.g. an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or a combination of hardware and software means, e.g. an ASIC and an FPGA, or at least one microprocessor and at least one memory with software processing components located therein. Thus, the means can include both hardware means and software means. The method embodiments described herein could be implemented in hardware and software. The device may also include software means. Alternatively, the embodiments may be implemented on different hardware devices, e.g. using a plurality of CPUs.
The embodiments herein can comprise hardware and software elements. The embodiments that are implemented in software include but are not limited to, firmware, resident software, microcode, etc. The functions performed by various components described herein may be implemented in other components or combinations of other components. For the purposes of this description, a computer-usable or computer readable medium can be any apparatus that can comprise, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
The illustrated steps are set out to explain the exemplary embodiments shown, and it should be anticipated that ongoing technological development will change the manner in which particular functions are performed. These examples are presented herein for purposes of illustration, and not limitation. Further, the boundaries of the functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternative boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Alternatives (including equivalents, extensions, variations, deviations, etc., of those described herein) will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein. Such alternatives fall within the scope of the disclosed embodiments. Also, the words “comprising,” “having,” “containing,” and “including,” and other similar forms are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Furthermore, one or more computer-readable storage media may be utilized in implementing embodiments consistent with the present disclosure. A computer-readable storage medium refers to any type of physical memory on which information or data readable by a processor may be stored. Thus, a computer-readable storage medium may store instructions for execution by one or more processors, including instructions for causing the processor(s) to perform steps or stages consistent with the embodiments described herein. The term “computer-readable medium” should be understood to include tangible items and exclude carrier waves and transient signals, i.e., be non-transitory. Examples include random access memory (RAM), read-only memory (ROM), volatile memory, nonvolatile memory, hard drives, CD ROMs, DVDs, flash drives, disks, and any other known physical storage media.
It is intended that the disclosure and examples be considered as exemplary only, with a true scope of disclosed embodiments being indicated by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202221041399 | Jul 2022 | IN | national |
