Patent Application
20230150382
The present invention relates to the transportation of carts and other loads within, for example, an indoor commercial environment using an autonomous mobile robot. More specifically, the present invention provides for a charging mechanism that allows a mobile robot to efficiently dock and charge through a pivoting charging mechanism.
Transporting goods on wheeled carts is labor intensive, repetitive, exhausting and potentially hazardous work. This is particularly true in healthcare, hospitality, warehouse and industrial settings. Thus, the automatic movement of these carts would provide numerous benefits, financially and otherwise, to an organization and its employees.
Autonomous mobile robots are battery operated machines which require recharging. However, in order to maintain their autonomous nature these machines must be able to self-dock to a precise charging location and mechanism.
It is possible to reduce the level of navigation precision required by the robot and improve its efficiency by altering the charging dock to accommodate multiple angles of approach by the robot and still retain a connection for charging to occur.
The present disclosure is directed toward overcoming one or more of the above-mentioned problems, though not necessarily limited to embodiments that do.
The present invention describes a mechanism for mating a robot with a charging dock for the purposes of charging its onboard battery. The present invention uses a disc with charging contacts attached to a pivoting face on the charging dock. A robot with a receptacle on the traveling side of its frame approaches the dock by virtue of an onboard digital map and localization logic. As the robot approaches the dock, the circular disc on the charging dock enters the receptacle on the robot. As the robot finalizes its docking procedure it is pressed against the pivoting head which then centers the disc into the receptacle on the robot to align the charging contacts.
The present invention allows the robot to self-dock for charging more efficiently and reliably. The charging dock has a pivoting face with a disk fashioned with charging connection points. When a robot encounters the dock, this pivoting face will ensure the charging disk can align with the corresponding charging pickup points within the robot's charging receptor. An advantage of this approach is to improve the efficiency and reliability of the robot's docking procedures.
Additional features, aspects, objects, advantages, and possible applications of the present disclosure will become apparent from a study of the exemplary embodiments and examples described below, in combination with the Figures and the appended claims.
An exemplary embodiment relates to a charging dock. The charging dock includes a charging connector configured to be in electrical connection with an electrical power source, the charging connector comprising electric conductive material. The charging dock includes a pivot mechanism. The charging connector is attached to the pivot mechanism.
In some embodiments, the charging dock includes a casing configured to house the charging connector and the pivot mechanism. The casing is configured to attach to a wall or be part of a stand.
In some embodiments, the casing has a top, a bottom, a front face, a rear face, a first side, and a second side, the rear face configured to attach to a structure. The charging connector has a first end and a second end that extends in a direction from the first side to the second side, the charging connector further extending from the front face. The pivot mechanism is configured to facilitate pivotal motion of the charging connector such that the first and second ends move towards and away from the front face.
In some embodiments, the pivot mechanism includes a member attached to a pivot device.
The charging connector is attached to the member.
In some embodiments, the member is an elongate member having a first end, a second end, and an intermediary point. The member is attached to the pivot device at the intermediary point.
In some embodiments, the charging connector is attached to the member at the intermediary point.
In some embodiments, the charging connector includes a charging contact formed in or on the charging connector.
In some embodiments, the charging connector has a semi-circular disc shape.
In some embodiments, the charging connector has a semi-circular disc shape defined by a straight edge and an arcuate edge. The charging connector straight edge is attached to the pivot mechanism.
In some embodiments, the pivot mechanism is a passive device or an actuated device.
In some embodiments, the pivot mechanism including a biasing mechanism.
In some embodiments, the casing includes a flexible shroud for the pivot mechanism.
In some embodiments, the casing includes a bumper.
An exemplary embodiment relates to a robot charging system. The robot charging system includes a robot having a battery in electrical connection with a charging receptor. The robot charging system includes a charging dock. The charging dock includes a charging connector configured to be in electrical connection with an electrical power source, the charging connector comprising electric conductive material. The charging dock includes a pivot mechanism. The charging connector is attached to the pivot mechanism. The charging connector is configured to insert into the charging receptor and facilitate transfer of electrical power from the electrical power source to the battery.
In some embodiments, the charging receptor includes a guide arm configured to urge the charging connector into a slot formation within the charging receptor.
In some embodiments, the guide arm is beveled.
In some embodiments, the guide arm is attached to a biased pivot mechanism.
An exemplary embodiment relates to a method of operating a robot. The method involves causing a robot to advance towards a charging dock such that a charging connector of the charging dock inserts into a charging receptor of the robot. The method involves further advancing the robot to the charging dock to make physical contact with a pivot mechanism of the charging dock. The method involves causing the pivot mechanism to pivot the charging connector due to the physical contact between the robot and the pivot mechanism.
In some embodiments, the method involves allowing electrical power transfer from the charging connector to the charging receptor.
In some embodiments, the method involves allowing electrical power transfer from the charging receptor to a battery of the robot.
The robot (16) includes a user interface (15), which can be a display screen, keypad, touchscreen, etc. configured to display information, receive input, facilitate command and control of one or more functions of the robot (16) or components of the robot (16), etc. The display of the user interface can be textual display, graphical display, audible display, etc. Command inputs can be textual, haptic, audible, etc.
The robot (16) includes a battery (54). The battery (54) can be rechargeable. The battery (54) can be a NiCd (Nickel-Cadmium) battery, a NiMH (Nickel-Metal Hydride) battery, a Li-ion (Lithium Ion) battery, etc. The battery (54) can include components such as transformers, transducers, converters, etc. to facilitate electrical power conversion and transfer. The battery (54) is in electrical connection with other components (e.g., drive head (51), drive wheel (52), sensor (14), computing unit (53), user interface (15), motors, actuators, servos, encoders, etc.) so as to provide electrical power to any one or combination of them for operation. The battery (54) is also in electrical connection with the charging receptor (13) so as to receive electrical power from the charging receptor (13). The charging receptor (13) is an opening formed in the housing (50) and includes at least one electrical contact 75 (see
The charging receptor (13) opening is configured to receive a charging connector (18) of a charging dock (17). The charging connector (18) comprises electric conductive material (e.g., it is fabricated of electric conductive material, it includes charging contacts (19) that are fabricated from electric conductive material, etc.). In use, the charging connector (18) is in electrical connection with an electrical power source (e.g., a 120 V or 220 V power line), wherein electrical power in the form of electric current is transferred to the electric conductive material. When the charging connector (18) is inserted into the charging receptor (13) of the robot (16), electrical connection between the charging receptor (13) and the charging connector (18) is made due to the electric conductive material making physical or electric contact with an electrical contact of the charging receptor (13). Electrical power from the electrical power source can then be transferred to the battery (54) of the robot (16) via the connection made between the charging connector (18) and the charging receptor (13).
The member (62), at its intermediary point (65), is attach to a pivot device (66) (e.g., a hinge, a rocker arm, a cam, a wheel, gimbal assembly, etc.). The pivot mechanism (20) can be a passive device (e.g., freely rocks about the pivot device (66)). In the alternative, the pivot mechanism (20) can be an actuated device (e.g., connected to a motor, actuator, servo, etc. so as to facilitate active control the rocking motion). Whether actuated or passive, the pivot mechanism (20) can have a biasing mechanism (74) (e.g., a spring) to cause the pivot mechanism (20) to maintain a predetermined orientation (e.g., bias the member (62) so that it is parallel or substantially parallel with the front face (57) unless a force acts upon it to rock the member (62) to a different orientation).
The portion of the casing (55) containing the pivot mechanism (20) can include a shroud (67). The shroud (67) can be flexible/semi-rigid/deformable (e.g., made from rubber, polymer, silicone, etc.). The flexibility of the shroud (67) maintains confinement and protection for the pivot mechanism (20) but also permits rocking motion of the member (62). The shroud (67) includes a charging connector opening (68) that allows the charging connector (18) to protrude through. It is contemplated for the charging connector (18) to be a semi-circular planar member; however, other shapes can be used. For instance, the charging connector (18) can be a semi-circular disc having a straight edge (69) and an arcuate edge (70). The straight edge (69) is attached to the member (62) and the arcuate edge (70) protrudes through the shroud opening (68). Any portion of the charging connector (18) can be made of electric conducting material (e.g., iron, steel, aluminum, copper, etc.) or have at least one charging contact (19) formed in or on the charging connector (18), the charging contact (19) being made of electric conducting material. Placement and configuration of the charging contact (19) is such that when the charging connector (18) is inserted into the charging receptor (13) of the robot (16), the charging contact (19) makes physical and/or electrical contact with the electrical contact of the charging receptor (13).
In some embodiments, the charging connector (18) is attached directly to the pivot mechanism (20). For instance, the straight edge (69) is attached (e.g., welded, attached via adhesive, attached via fasteners, etc.) to the pivot device (66).
In an exemplary embodiment, the charging dock (17) is mounted to a wall (21) (see
If the robot's (16) orientation and/or advance is not square, the charging connector (18) may partially insert into the charging receptor (13) opening. As the robot (16) advances further, the housing (50) makes physical contact with the shroud (67). As the robot advances even further, the robot's (16) advance forces the member (62) to pivot about the pivot device (66) such that the member rocks to a canted orientation. The canted orientation allows there to be a square orientation between the charging connector (18) and the charging receptor (13) opening. Further, the robot (16) can still move forward in an otherwise non-square advance but due to the canted orientation the advance is a square advance. The advance continues until the charging connector (18) inserts into the charging receptor (13) opening fully and a good electrical connection between the charging receptor (13) and the charging connector (18) is made. Electrical power can then be transferred from the electrical power source to the battery (54).
When the robot (16) is finished charging the battery (54), the robot (16) retreats from the charging connector (18). If the pivot mechanism (20) is not biased, it will remain in an orientation the robot (16) forced into. If the pivot mechanism (20) is biased, the biasing mechanism (74) forces the member (62) into the biased orientation.
Referring to
Sensors (14) such as inductance, capacitance, or resistance sensors, for example, can be used to determine whether a good connection between the charging receptor (13) and charging connector (18) is made. For instance, inductance, capacitance, or resistance can be measured based on the electrical current flowing from the charging connector (18) to the charging receptor (13). This measurement can be compared to a threshold value. If the measurement is at or above the threshold value, then it can be determined that a good connection is made. If it is below the threshold value, it can be determined that a bad connection is made. If a bad connection is made, the computing unit (53) can: 1) cause the robot (16) to rotate or turn to provide for a square orientation and advance; 2) cause the pivot device (66) to rock to provide for a square orientation and advance; and/or 3) cause the robot (16) to back away from the charging dock (17), reposition, and advance towards the charging dock (17) at an angle that differs from a previous angle.
In some embodiments, the casing (55) can include a bumper (71). The bumper (71) can be a structure to absorb or deflect impact. For instance, the bumper (71) can be a rubber member, a spring, a roller, etc. In an exemplary embodiment, the casing includes a bumper (71) at each corner of the shroud (67).
As noted herein, the robot (16) includes a computing unit (53). The computing unit (53) can be a controller, a control module, etc. The computing unit includes a processor (72) and associated memory (73). Other components of the robot (16) or system controlling the robot may also have a processor. Any of the processors disclosed herein can be part of or in communication with a machine (e.g., a computer device, a logic device, a circuit, an operating module (hardware, software, and/or firmware), etc.). The processor can be hardware (e.g., processor, integrated circuit, central processing unit, microprocessor, core processor, computer device, etc.), firmware, software, etc. configured to perform operations by execution of instructions embodied in computer program code, algorithms, program logic, control, logic, data processing program logic, artificial intelligence programming, machine learning programming, artificial neural network programming, automated reasoning programming, etc. The processor can receive, process, and/or store data related to operations of the robot (16) or a component of the robot (16).
Any of the processors disclosed herein can be a scalable processor, a parallelizable processor, a multi-thread processing processor, etc. The processor can be a computer in which the processing power is selected as a function of anticipated network traffic (e.g., data flow). The processor can include any integrated circuit or other electronic device (or collection of devices) capable of performing an operation on at least one instruction, which can include a Reduced Instruction Set Core (RISC) processor, a CISC microprocessor, a Microcontroller Unit (MCU), a CISC-based Central Processing Unit (CPU), a Digital Signal Processor (DSP), a Graphics Processing Unit (GPU), a Field Programmable Gate Array (FPGA), etc. The hardware of such devices may be integrated onto a single substrate (e.g., silicon “die”), or distributed among two or more substrates. Various functional aspects of the processor may be implemented solely as software or firmware associated with the processor.
The processor can include one or more processing or operating modules. A processing or operating module can be a software or firmware operating module configured to implement any of the functions disclosed herein. The processing or operating module can be embodied as software and stored in a memory, the memory being operatively associated with the processor. A processing module can be embodied as a web application, a desktop application, a console application, etc.
The processor can include or be associated with a computer or machine readable medium. The computer or machine readable medium can include memory. Any of the memory discussed herein can be computer readable memory configured to store data. The memory can include a volatile or non-volatile, transitory or non-transitory memory, and be embodied as an in-memory, an active memory, a cloud memory, etc. Examples of memory can include flash memory, Random Access Memory (RAM), Read Only Memory (ROM), Programmable Read only Memory (PROM), Erasable Programmable Read only Memory (EPROM), Electronically Erasable Programmable Read only Memory (EEPROM), FLASH-EPROM, Compact Disc (CD)-ROM, Digital Optical Disc DVD), optical storage, optical medium, a carrier wave, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by the processor.
The memory can be a non-transitory computer-readable medium. The term “computer-readable medium” (or “machine-readable medium”) as used herein is an extensible term that refers to any medium or any memory, that participates in providing instructions to the processor for execution, or any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). Such a medium may store computer-executable instructions to be executed by a processing element and/or control logic, and data which is manipulated by a processing element and/or control logic, and may take many forms, including but not limited to, non-volatile medium, volatile medium, transmission media, etc. The computer or machine readable medium can be configured to store one or more instructions thereon. The instructions can be in the form of algorithms, program logic, etc. that cause the processor to execute any of the functions disclosed herein.
Embodiments of the memory can include a processor module and other circuitry to allow for the transfer of data to and from the memory, which can include to and from other components of a communication system. This transfer can be via hardwire or wireless transmission. The communication system can include transceivers, which can be used in combination with switches, receivers, transmitters, routers, gateways, wave-guides, etc. to facilitate communications via a communication approach or protocol for controlled and coordinated signal transmission and processing to any other component or combination of components of the communication system. The transmission can be via a communication link. The communication link can be electronic-based, optical-based, opto-electronic-based, quantum-based, etc. Communications can be via Bluetooth, near field communications, cellular communications, telemetry communications, Internet communications, etc.
Transmission of data and signals can be via transmission media. Transmission media can include coaxial cables, copper wire, fiber optics, etc. Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infrared data communications, or other form of propagated signals (e.g., carrier waves, digital signals, etc.).
Any of the processors can be in communication with other processors of other devices (e.g., a computer device, a computer system, a laptop computer, a desktop computer, etc.). Any of the processors can have transceivers or other communication devices/circuitry to facilitate transmission and reception of wireless signals. Any of the processors can include an Application Programming Interface (API) as a software intermediary that allows two or more applications to talk to each other. Use of an API can allow software of the processor of one device/component to communicate with software of the processor of the other device(s)/component(s).
It is contemplated for the computing unit (53) to be in communication with other components of the robot (16) (e.g., a drive head (51), drive wheel (52), sensor (14), user interface (15), motors, actuators, servos, encoders, etc.) or component of the pivot mechanism (20). Any one or combination of these components may or may not have a processor. The computing unit (53) can send command signals to the processor of these components or control electrical power transmission to these components to operate them directly. In addition, any of the components of the robot (16) can be in communication with another component. The communication can include the transmission of information data, operational data, command signals, etc. In other words, any component of the robot (16) can talk to other components of the system. This talking can be via direct communication between each component, or it can be via indirect communication via the computing unit (53).
Referring to
It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teachings of the disclosure. The disclosed examples and embodiments are presented for purposes of illustration only. Other alternate embodiments may include some or all of the features disclosed herein. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention, which is to be given the full breadth thereof. Additionally, the disclosure of a range of values is a disclosure of every numerical value within that range, including the end points.
This application is related to and claims the benefit of and priority to U.S. Application No. 63/279,276, filed on Nov. 15, 2022, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63279276 | Nov 2021 | US |
