Self-aligning mechanical fastener

Abstract

A self-aligning mechanical fastener includes an active device and a passive device and is configured to have a locked state and an unlocked state. The active device includes a motor that drives the shaft in a first direction to advance the plunger toward the passive device to transition the fastener to the locked state. The plunger includes a tapered distal end that mechanically engages the locking body. The locking body moves laterally through the tapered distal end to apply a force to the locking frame located in a slot defined in a housing of the passive device. The force causes the mechanical fastener to be locked. To unlock the mechanical fastener, the motor drives the shaft in a second direction to retract the plunger away from the passive device.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Application No. 18 / 056,048, filed on November 16, 2022, entitled “Self-Aligning Mechanical Fastener,” which claims the benefit and priority of U.S. Provisional Application No. 63 / 364,074, filed on May 3, 2022, entitled “Self-Aligning Mechanical Fastener,” which are incorporated herein by reference. Technical Field

[0003] The present application relates generally to mechanical fasteners for mating physical components of equipment. Background Art

[0004] Physical components usually need to be matched or linked together to form a device. Such components can be matched or linked together using adhesives (e.g., glue), clamps, nails, screws, bolts, or similar devices. Screws and bolts include a head and a threaded shaft that is driven into one or more physical components to mechanically fix these components together. A driving device (screwdriver, wrench, hexagonal wrench, or similar device) drives the head, which causes the threaded shaft to rotate. Bolts or nuts can be attached to the proximal end of the threaded shaft, which can be rotatably tightened to generate mechanical force between the head and the bolt / nut, thereby fixing one or more parts between them.

[0005] In order to drive the head, precise mechanical alignment is required between the driving device and the head. For example, the screw head or bolt head includes a recess to receive the corresponding end of a flat head or Philips screwdriver. The bolt head may also have a convex or concave hexagonal shape that allows the bolt to be engaged by a wrench. In addition, precise mechanical alignment is required between the threaded shaft and the bolt or nut to drive the threaded shaft into the bolt / nut.

[0006] Although this mechanical alignment can be done relatively easily by humans manually, challenges arise in automated systems. For example, robotic systems require expensive and complex optical devices for guidance and alignment. In addition, robotic systems need to manipulate and track multiple loose / detached components (e.g., screws, bolts, etc.).

[0007] The present application provides an improved and lower cost alignment system for mechanical fasteners. Summary of the invention

[0008] The exemplary embodiments described herein have innovative features, none of which is indispensable and none of which is entirely responsible for its intended attributes. The following description and accompanying drawings set forth in detail certain illustrative embodiments of the present disclosure, which indicate several exemplary ways in which the various principles of the present disclosure may be implemented. However, the illustrative examples are not exhaustive of the many possible embodiments of the present disclosure. Without limiting the scope of the claims, some advantageous features will now be summarized. Other objects, advantages, and novel features of the present disclosure will be set forth in the following detailed description of the present disclosure when considered in conjunction with the accompanying drawings, which are intended to illustrate, but not to limit, the present invention.

[0009] One aspect of the present invention relates to a self-aligning mechanical fastener, which includes an active device and a passive device. The active device includes: an active housing, which defines a channel extending along a first axis; a shaft, which is disposed in the channel and extends along the first axis, the shaft having an external thread defined on a threaded area; a motor, which is configured to rotate the shaft around the first axis; a plunger, which has a channel defined from a proximal end of the plunger to a distal end thereof, the channel being defined by an inner wall, the inner wall having an internal thread, the internal thread engaging with the external thread on the threaded area of ​​the shaft, the distal end having a tapered shape; a cap, which is attached to the active housing and disposed at the distal end of the shaft, the cap having a proximal surface and a distal surface, the proximal surface defining a gap with the active housing; and a locking body disposed on the proximal surface of the cap. The passive device includes: an alignment housing having a hole extending parallel to a first axis from a proximal end of the alignment housing toward a distal end of the alignment housing, the hole being configured to receive an active housing, the proximal end of the alignment housing forming a tapered alignment guide defined by an inner wall of the alignment housing so that the hole has a width that decreases from the proximal end of the alignment guide to the distal end of the alignment guide, the width being measured about a second axis orthogonal to the first axis; and a pressure frame disposed in a slot defined in the alignment housing, the hole extending through a hollow central region of the pressure frame. The self-aligning mechanical fastener has a locked state and an unlocked state. To convert the self-aligning mechanical fastener from the unlocked state to the locked state: the active housing is inserted into the hole and the locking body is aligned with the pressure frame, the motor causes the shaft to rotate in a first direction to advance the plunger toward the cap, and the distal end of the plunger applies a force on the locking body, the force causing the locking body to mechanically engage the pressure frame, thereby mechanically fixing the active device to the passive device. To convert the self-aligning mechanical fastener from the locked state to the unlocked state: the motor causes the shaft to rotate in a second direction to retract the plunger away from the cap, thereby releasing the force on the locking body to thereby unlock the active device from the passive device.

[0010] In one or more embodiments, the locking body is a first locking body, the self-aligning mechanical fastener further comprises a second locking body disposed on a proximal surface of the cap and in the gap, and the shaft is disposed between the first locking body and the second locking body. In one or more embodiments, the first locking body and the second locking body comprise a first cylinder and a second cylinder, respectively.

[0011] In one or more embodiments, the notch is defined by a flat inner wall in the alignment housing at a distal portion of the notch, and the pressure frame has a flat outer surface on a distal end of the pressure frame, the flat outer surface contacting the flat inner wall. In one or more embodiments, the flat outer surface and the flat inner wall are parallel to a plane orthogonal to the first axis, the pressure frame has a flat engagement surface connected to the flat outer surface, the flat engagement surface defines an acute angle with the plane, and the flat engagement surface is configured to engage the locking body when the self-aligning mechanical fastener is in a locked state. In one or more embodiments, the acute angle ranges from about 35° to about 45°.

[0012] In one or more embodiments, the acute angle is a first acute angle, the pressure frame has a flat alignment surface connected to the flat engagement surface, the flat engagement surface is located between the flat alignment surface and the flat outer surface, the flat alignment surface defines a second acute angle with the plane, and the flat alignment surface is configured to engage with the locking body when the active housing is partially removed from the hole. In one or more embodiments, the first acute angle ranges from about 35° to about 45°, and the second acute angle ranges from about 70° to about 80°.

[0013] In one or more embodiments, each inner wall defining the tapered alignment guide has a cross-sectional thickness that increases from a proximal end of the tapered alignment guide to a distal end of the tapered alignment guide, the cross-sectional thickness being measured along a corresponding axis orthogonal to the first axis, and the inner wall includes an opposing first wall and a second wall aligned about the second axis. In one or more embodiments, the inner wall includes a third wall aligned about a third axis orthogonal to the first axis and the second axis, the third wall being connected to the opposing first wall and the second wall.

[0014] In one or more embodiments, the proximal end of the plunger includes a plurality of flat outer surfaces configured to engage with corresponding flat inner surfaces of the active housing when the shaft is rotated about the first axis, thereby causing the plunger to advance when the self-aligning mechanical fastener transitions from an unlocked state to a locked state and to retract when the self-aligning mechanical fastener transitions from a locked state to an unlocked state.

[0015] In one or more embodiments, the pressure frame is configured to float within the slot about the second axis and / or about a third axis orthogonal to the first axis and the second axis.

[0016] In one or more embodiments, the active device further comprises a controller in electrical communication with the motor, the controller being configured to: generate a first drive signal causing the motor to rotate the shaft in a first direction so as to advance the plunger toward the cap, thereby converting the self-aligning mechanical fastener from an unlocked state to a locked state; and generate a second drive signal causing the motor to rotate the shaft in a second direction so as to retract the plunger away from the cap, thereby converting the self-aligning mechanical fastener from a locked state to an unlocked state. In one or more embodiments, the active device comprises a limit switch in electrical communication with the controller, the limit switch being configured to output a limit switch signal when the distal end of the plunger is advanced to a predetermined position by rotating the shaft in the first direction, and the controller being configured to generate a stop output signal when the self-aligning mechanical fastener system is converted from the unlocked state to the locked state and after the controller receives the limit switch signal, the stop output signal causing the motor to stop in response to a feedback signal from the motor. In one or more embodiments, the feedback signal is a drive current of the motor, and the controller is configured to generate the stop output signal when the drive current is greater than or equal to a predetermined value.

[0017] In one or more embodiments, the predetermined value is a first predetermined value, and the controller is configured to generate a stop output signal when the drive current is greater than or equal to a second predetermined value while the self-aligning mechanical fastener system is transitioning from an unlocked state to a locked state and before a limit switch signal is received, and the second predetermined value is greater than the first predetermined value.

[0018] In one or more embodiments, the limit switch is a first limit switch, the limit switch signal is a first limit switch signal, the predetermined position is a first predetermined position, the active device includes a second limit switch electrically communicating with the controller, the second limit switch is configured to output a second limit switch signal when the distal end of the plunger is retracted to a second predetermined position by rotating the shaft along a second direction, and the controller is configured to generate a stop output signal in response to receiving the second limit switch signal when the self-aligning mechanical fastener system is switched from a locked state to an unlocked state.

[0019] Another aspect of the present invention relates to an assembly, comprising: a first object, a second object, an active device attached to the first object, a passive device attached to the second object, and a controller. The active device comprises: an active housing defining a channel extending along a first axis; a shaft disposed in the channel and extending along the first axis, the shaft having an external thread defined on a threaded region; a motor configured to rotate the shaft about the first axis; a plunger having a channel defined from a proximal end of the plunger to a distal end thereof, the channel being defined by an inner wall having an internal thread engaged with an external thread on the threaded region of the shaft, the distal end having a tapered shape; a cap attached to the active housing and disposed at the distal end of the shaft, the cap having a proximal surface and a distal surface, the proximal surface defining a gap with the active housing; and a locking body disposed on the proximal surface of the cap. The passive device includes: an alignment housing having a hole extending parallel to a first axis from a proximal end of the alignment housing toward a distal end of the alignment housing, the hole being configured to receive an active housing, the proximal end of the alignment housing forming a tapered alignment guide defined by an inner wall of the alignment housing, such that the hole has a width that decreases from the proximal end of the alignment guide to the distal end of the alignment guide, the width being measured about a second axis orthogonal to the first axis; and a pressure frame disposed in a slot defined in the alignment housing, the hole extending through a hollow central region of the pressure frame. The controller is in electrical communication with the motor. The active device and the passive device are configured to form a self-aligning mechanical fastener having a locked state and an unlocked state. To convert the self-aligning mechanical fastener from an unlocked state to a locked state: the active housing is inserted into the hole and the locking body is aligned with the pressure frame, the controller generates a first drive signal, the first drive signal causes the motor to rotate the shaft in a first direction to advance the plunger toward the cap, and the distal end of the plunger applies a force on the locking body, the force causing the locking body to mechanically engage the pressure frame, thereby mechanically fixing the active device to the passive device. To convert the self-aligning mechanical fastener from a locked state to an unlocked state: the controller generates a second drive signal, the second drive signal causes the motor to rotate the shaft in a second direction to retract the plunger away from the cap, thereby releasing the force on the locking body, to thereby unlock the active device from the passive device.

[0020] In one or more embodiments, the controller is disposed on the first object. In one or more embodiments, the first object includes an interface plate configured for attachment to a vehicle, and the second object includes a battery tray.

[0021] In one or more embodiments, the active device is a first active device, the passive device is a first passive device, the self-aligning mechanical fastener is a first self-aligning mechanical fastener, and the assembly further comprises: a second active device attached to the first object; and a second passive device attached to the second object. The first active device is aligned with the first passive device. The second active device is aligned with the second passive device, and the second active device and the second passive device are configured to form a second self-aligning mechanical fastener.

[0022] Another aspect of the present invention relates to a method for releasably mechanically coupling objects, the method comprising: inserting an active device into a passive device, the active device being mechanically coupled to a first object, and the passive device being mechanically coupled to a second object. The active device comprises: an active housing defining a channel extending along a first axis; a shaft disposed in the channel and extending along the first axis, the shaft having an external thread defined on a threaded region; a motor configured to rotate the shaft about the first axis; a plunger having a channel defined from a proximal end of the plunger to a distal end thereof, the channel being defined by an inner wall having an internal thread that engages with an external thread on a threaded region of the shaft, the distal end having a tapered shape; a cap attached to the active housing and disposed at the distal end of the shaft, the cap having a proximal surface and a distal surface, the proximal surface defining a gap with the active housing; and a locking body disposed on the proximal surface of the cap. The passive device includes: an alignment housing having a hole extending parallel to a first axis from a proximal end of the alignment housing toward a distal end of the alignment housing, the hole being configured to receive an active housing, the proximal end of the alignment housing forming a tapered alignment guide defined by an inner wall of the alignment housing such that the hole has a width that decreases from the proximal end of the alignment guide to the distal end of the alignment guide, the width being measured about a second axis orthogonal to the first axis; and a pressure frame disposed in a slot defined in the alignment housing, the hole extending through a hollow central region of the pressure frame. The method also includes: rotating the shaft in a first direction relative to the first axis with a motor to advance the plunger toward the cap; bringing the distal end of the plunger into mechanical contact with a locking body; applying a force on the locking body with the distal end of the plunger, the force causing the locking body to mechanically engage with the pressure frame; and constraining movement of the locking body with the distal end of the plunger and the pressure frame to mechanically secure the active device to the passive device. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] For a more complete understanding of the nature and advantages of the concepts disclosed herein, reference is made to the detailed description of the preferred embodiments and to the accompanying drawings.

[0024] Figure 1is a perspective view of a self-aligning mechanical fastener in an unlocked state according to one embodiment.

[0025] Figure 2 yes Figure 1 A cross-sectional view of a self-aligning mechanical fastener is shown.

[0026] Figure 3 yes Figure 2 Isolated cross-sectional view of the active device shown.

[0027] Figure 4 yes Figure 3 Isolated perspective view of the axes shown.

[0028] Figure 5 and Figure 6 yes Figure 3 An isolated side perspective view of the plunger is shown.

[0029] Figure 7 yes Figure 2 Isolated cross-section of the passive device shown.

[0030] Figure 8 is an isolated perspective view of the pressure frame floating on the lower part of the housing.

[0031] Fig. 9 is an isolated perspective view of the lower portion of the housing with the pressure frame removed.

[0032] Fig.10 is a separate partially transparent perspective view of the lower part of the housing and the pressure frame.

[0033] Fig.11 yes Figure 8 An isolated isometric perspective view of the pressure frame shown.

[0034] Fig.12 yes Fig.11 A cross-section of the pressure frame shown.

[0035] Fig.13 is a cross-sectional view of a self-aligning mechanical fastener in an inserted state.

[0036] Fig.14 is a cross-sectional view of a self-aligning mechanical fastener in a locked state.

[0037] Fig.15 is an enlarged view of the distal end of the active device when the self-aligning mechanical fastener is in the locked state.

[0038] Fig.16 is a perspective cutaway view of a control system for a self-aligning mechanical fastener when the self-aligning mechanical fastener is in a locked state.

[0039] Fig.17 is a perspective cutaway view of a control system for a self-aligning mechanical fastener when the self-aligning mechanical fastener is in an unlocked state.

[0040] Fig.18 is a perspective view of a fastener in an inserted and / or locked state.

[0041] Fig.19 is a perspective view of an assembly according to one embodiment.

[0042] Fig. 20 is a perspective view of a battery tray according to one embodiment.

[0043] Fig.21 is a perspective and partially exploded view of an interface board and a battery tray according to one embodiment.

[0044] Fig. 22 yes Fig. 20 A perspective view of the interface board and battery tray is shown.

[0045] Fig.23 is a block diagram of a bottom portion of an electric vehicle according to one embodiment.

[0046] Fig.24 is a flow chart of a method for releasably mechanically coupling objects according to one embodiment. DETAILED DESCRIPTION

[0047] The self-aligning mechanical fastener includes an active device and a passive device and is configured to have a locked state and an unlocked state. The active device includes one or more locking bodies that can mechanically engage a locking frame in the passive device. The active device includes a motor that can drive a shaft along a first direction to advance a plunger along a vertical axis toward a distal end of the active device and toward the passive device. The plunger includes a tapered distal end that is configured to mechanically engage the locking body when the plunger is pushed distally. In the locked state, the plunger applies a force on the locking body, which applies a force on the locking frame to mechanically fix the active device and the passive device. In the unlocked state, the force is released and the plunger is at least partially retracted.

[0048] The active device may include a lower limit switch that can be activated when the plunger reaches a predetermined lower position as the fastener transitions from an unlocked state to a locked state. When the lower limit switch is activated, the lower limit switch generates a first limit switch output signal that can be received by a controller that is also in electrical communication with the motor. As the fastener transitions from an unlocked state to a locked state, the controller can monitor the drive current (or other electrical characteristics) of the motor. Before the controller receives the first limit switch output signal, the controller can compare the drive current of the motor with a first predetermined maximum drive current. When the drive current exceeds the first predetermined maximum drive current, the controller can generate a stop output signal that causes the motor to stop. After the controller receives the first limit switch output signal, the controller can compare the drive current of the motor with a second predetermined maximum drive current that is lower than the first predetermined maximum drive current. When the drive current exceeds the second predetermined maximum drive current, the controller can generate a stop output signal to stop the motor. The first predetermined maximum drive current can correspond to misalignment or damage of threads on the shaft and / or on the plunger. The second predetermined maximum drive current may correspond to a predetermined locking force applied by the plunger to the locking body.

[0049] In addition, the active device may include an upper limit switch that can be activated when the plunger reaches a predetermined upper position as the fastener transitions from a locked state to an unlocked state. When the upper limit switch is activated, the upper limit switch generates a second limit switch output signal that can be received by the controller. In response to receiving the second limit switch output signal, the controller can generate a stop output signal to stop the motor. When the fastener is in the unlocked state, the second limit switch output signal can correspond to a fully retracted position of the shaft and plunger.

[0050] An assembly may include an active device attached to a first object and a passive device attached to a second object. When the active device and the passive device are configured as self-aligning mechanical fasteners in a locked state, the first object and the second object are mechanically coupled.

[0051] Figure 1 is a perspective view of a self-aligning mechanical fastener 10 according to one embodiment. The fastener 10 includes an active device 100 and a passive device 200. The active device 100 can be inserted into the passive device 200, wherein the active device 100 and the passive device 200 can be releasably locked (e.g., mechanically fixed) together to form the fastener.

[0052] Figure 2 The self-aligning mechanical fastener 10 penetrates Figure 1 A cross-sectional view of plane 20 in FIG. Figure 1 and Figure 2 In the embodiment, the fastener 10 is in an unlocked state.

[0053] Figure 3 1 is an isolated cross-sectional view of an active device 100. The active device 100 includes a housing 110, a shaft 120, a plunger 130, a cap 140, one or more locking bodies 150, and a motor 160. The active device 100 has a distal end 102 (e.g., a first end) and a proximal end 104 (e.g., a second end). The housing 100 defines a hollow region 112 that includes a housing channel 114 extending along a central vertical axis 300 (e.g., a first axis).

[0054] The shaft 120 is positioned or disposed in the housing passage 114. The shaft 120 extends along or parallel to the first axis 300. In addition, the shaft 120 includes a threaded region 122 on which an external thread 124 is defined. The shaft 120 is configured for rotation about the vertical axis 300 similar to a screw or bolt.

[0055] Figure 4 1 is an isolated perspective view of the shaft 120. This view shows that a key hole 400 is defined in the shaft 120. The key hole 400 is configured to be used with the bevel gear 162 ( Figure 3 ) are mechanically engaged, and these bevel gears 162 are driven by the motor 160 to transmit the rotational drive force from the motor 160 to the shaft 120, so that the shaft can rotate in a first direction (e.g., clockwise) around the central vertical axis 300 when the motor 160 is in a first state, and rotate in a second direction (e.g., counterclockwise) around the central vertical axis 300 when the motor 160 is in a second state.

[0056] The plunger 130 includes a distal end 502 and a proximal end 504. Figure 5 As shown. The distal end 502 may have a tapered shape, such as a wedge, arrow, anchor, or other shape. The distal end 502 may include a flat outer surface 510. A notch 520 may be defined on the outer surface of the lateral side of the plunger 130. The notch may define another notch 520 on the outer surface of the opposite lateral side of the plunger 130. The notch 520 extends parallel to the central vertical axis 300. The plunger 130 may include a plurality of flat outer surfaces 540 that are configured to frictionally engage with corresponding flat inner surfaces 116 in the housing 110 that define the housing passage 114.

[0057] In addition, if Figure 6As shown, a plunger passage 530 is defined in the plunger 130. The plunger passage 530 extends from the proximal end 504 of the plunger 130 to the distal end 502 thereof along and / or parallel to the central vertical axis 300. The plunger passage 530 is defined by an inner wall 550 of the plunger 130. An internal thread 560 is defined on the inner wall 550. The plunger passage 530 is configured to receive the shaft 120, and the internal thread 560 in the inner wall 540 is configured to engage (e.g., rotationally engage) the external thread 124 on the shaft 120 so that the relative position of the plunger 130 with respect to the shaft 120 can be adjusted by rotating the shaft 120 relative to the plunger 130.

[0058] Return to Figure 3 , the cap 140 is attached to or is a part of the housing 110 (e.g., integrally connected to the housing 110). The cap 140 has a distal side 142 and a proximal side 144. The distal side 142 may include a flat distal surface 143. The proximal side 144 includes one or more flat proximal surfaces 145 that are configured to mechanically support one or more locking bodies 150. A proximal hole 146 may be defined in the proximal side 142 to receive the distal end of the shaft 120. The cap 140 also includes tapered alignment sides 147 that are disposed closer to the central vertical axis 300 at the distal side 142 of the cap 140 than at or near the proximal side 144 of the cap 140. Figure 3 , two opposite tapered sides 147 are shown on the left and right sides of the cap 140. One or more additional tapered sides 147 may be positioned in front and / or rear of the cap 140, for example, in relation to the Figure 3 The tapered sides 147 can be used to align the active device 100 with the passive device 200 as the distal end 102 of the active device 100 is inserted into the passive device 200 . Figure 3 The tapered side 147 shown in FIG. 1 can align the active device 100 about a second axis 310 that is orthogonal to the first axis 300. Figure 3 The tapered side 147 in the cross-section shown, which is orthogonal to the cross-section, may align the active device 100 with a third axis 320 that is orthogonal to the first axis 300 and the second axis 310 .

[0059] Figure 72 is an isolated cross-sectional view of a passive device 200. The passive device 200 includes an alignment housing 210 and a pressure frame 220. The alignment housing 210 includes a tapered alignment guide 230 located at a proximal end 202 of the passive device 200 and the alignment housing 210. The tapered alignment guide 230 includes a plurality of walls 240 having tapered inner surfaces 242 in which a distal end 244 of the inner surface 242 is disposed closer to a central vertical axis 300 than a proximal end 246 of the inner surface 242. In one embodiment, the thickness of the wall 240 at the proximal end 246 can be less than that of the distal end 244, such that the thickness increases from the proximal end 246 to the distal end 244 to provide the wall 240 in which a distal end 244 of the inner surface 242 is disposed closer to the central vertical axis 300 than a proximal end 246 of the inner surface 242. In another embodiment, the walls 240 may have a substantially uniform thickness and slope inwardly to provide walls 240 in which the distal ends 244 of the inner surfaces 242 are disposed closer to the central vertical axis 300 than the proximal ends 246 of the inner surfaces 242 .

[0060] The wall 240 may include a pair of opposing walls (e.g., a wall 240A and another wall 240B (not shown) on opposite sides of the cross section). The pair of walls 240A, 240B provide an alignment guide 250 that is tapered about the second axis 310. The wall 240 may also include a wall 240C, which is positioned between the walls 240A, 240B orthogonally to the walls 240A, 240B. The wall 240C provides an alignment guide that is tapered about the third axis 320. An optional wall 240 opposite to the wall 240C (e.g., wall 240D (not shown)) may also provide an alignment guide that is tapered about the third axis 320 in combination with the wall 240C.

[0061] The housing 210 defines a hole or passage 260 extending from the proximal end 202 of the passive device 200 toward the distal end 204 thereof along or parallel to the central vertical axis 300. The hole 260 is configured to receive the active device 100. The proximal portion of the hole 260 is at least partially defined by the wall 240 (e.g., walls 240A-C or walls 240A-D). The hole 260 is further defined by an interior flat wall or surface 262 and an interior sidewall 264 of the housing 210. The hole 260 extends through the hollow center region 222 of the pressure frame 220.

[0062] The housing 210 further defines a slot 270 configured to receive and / or retain the pressure frame 220. The slot 270 is configured to provide a gap 272 between the outer edge 224 of the pressure frame 220 and one of the planar inner housing walls 212 that partially defines the slot 270. The gap 272 enables the pressure frame 220 to float within the slot 270 about the third axis 320, so that the pressure frame 220 can slide in either direction along the third axis 320 up to the length of the gap 272, so that the pressure frame 200 can float within the slot 270 about (or parallel to) the third axis 330.

[0063] Figure 8 is an isolated perspective view of the pressure frame 220 on the lower portion of the housing 210 to further illustrate the gap 272 about (or parallel to) the third axis 320 . Fig. 9 2 is an isolated perspective view of a lower portion of the housing 210 with the pressure frame 220 removed to further illustrate the slot 270. The length 900 of the slot 270 measured about the second axis 310 is greater than the corresponding length 1000 of the body portion 1010 of the pressure frame 220, which is configured to be placed in the slot 270, as shown in FIG. Fig.10 As shown, Fig.10 2 is a perspective view of a lower portion of the housing 210 and the pressure frame 220. The difference between the length 900 of the slot 270 and the length 1000 of the body portion 1010 of the pressure frame 220 provides a gap 1072 about (or parallel to) the second axis 310. The gap 1072 enables the pressure frame 220 to float about the second axis 310 within the slot 270 so that the pressure frame 220 can slide in either direction along the second axis 310 up to the length of the gap 1072 so that the pressure frame 220 can float about (or parallel to) the third axis 310 within the slot 270. The ability of the pressure frame 220 to float about (or parallel to) the second axis 310 and / or the third axis 320 provides an additional self-alignment feature of the fastener 10.

[0064] Fig.11 2 is an isolated isometric perspective view of a pressure frame 220 according to one embodiment. The pressure frame 220 includes opposing body portions 1010 aligned along (or parallel to) the third axis 320. Each body portion 1010 includes a body protrusion 1110 that extends away from the pressure frame 220 (e.g., parallel to the vertical axis 300) and is configured to be received in the slot 270. The length 1000 of the body portion 1010 including the body protrusion 1110 is less than the corresponding length 900 ( Fig. 9 and Fig.10) so that the pressure frame 220 can float within the slot 270 about (or parallel to) the third axis 310.

[0065] Fig.12 It is the penetration of the pressure frame 220 Fig.11 1200 in a cross-sectional view. The body protrusion 1110 includes a flat sliding surface 1201 located on the distal side of the pressure frame 220. The flat sliding surface 1201 is parallel to a plane defined by the second axis 310 and the third axis 320. The flat sliding surface 1201 is configured to rest on and slidably engage with a portion of the frame 210 that defines the notch 270.

[0066] Each body portion 1010 also includes a flat engagement surface 1210 connected to the flat sliding surface 1201. The flat engagement surface 1210 is configured to engage the corresponding locking body 150 ( Figure 3 ). The flat engagement surface 1210 is inclined inwardly toward the hollow center area 222 of the pressure frame 220. The flat engagement surface 1210 is oriented at an acute angle 1220 with respect to a plane 1230 defined by the flat sliding surface 1201. In addition, the flat engagement surface 1210 is oriented at an obtuse angle 1240 with respect to the flat sliding surface 1201. The acute angle 1220 may range from about 30° to about 50°, including about 35°, about 40°, about 45°, and / or any value or range between any two of the above angles. The obtuse angle 1240 may range from about 130° to about 150°, including about 135°, about 140°, about 145°, and / or any value or range between any two of the above angles. The sum of the acute angle 1220 and the obtuse angle 1240 is preferably about 180°.

[0067] Each body portion 1010 may also include a flat alignment surface 1250 connected to the flat engagement surface 1210. The flat engagement surface 1210 is placed between the flat sliding surface 1201 and the flat alignment surface 1250. The flat alignment surface 1250 is inclined inwardly toward the hollow center area 222 of the pressure frame 220 and is configured to align with the corresponding locking body 150 ( Figure 3) engagement. Flat alignment surface 1250 is oriented at an acute angle 1260 with respect to plane 1230. In addition, flat alignment surface 1250 is oriented at an obtuse angle 1270 with respect to flat engagement surface 1210. Acute angle 1260 can have a range of about 65° to about 85°, including about 70°, about 75°, about 80°, and / or any value or range between any two of the above angles, including about 70° to about 80°. Obtuse angle 1270 can have a range of about 95° to about 115°, including about 100°, about 105°, about 110°, and / or any value or range between any two of the above angles. The sum of acute angle 1260 and obtuse angle 1270 is preferably about 180°.

[0068] The inner edge of the flat alignment surface 1250 defines a snap fillet 1280 that is configured to snap and engage the corresponding locking body 150 as a safety mechanism when the active device 100 is only partially inserted into the passive device 200 (or vice versa). The snap fillet 1280 can retain the locking body 150 (and thereby the active device 100), and the distal movement of the plunger 140 can cause the locking body 150 to slide along the flat alignment surface 1250 to fully insert the active device 100 into the passive device 200 (or vice versa).

[0069] Each body portion 1010 may also include a flat surface 1290 that is inclined outwardly relative to the hollow central region 222 of the pressure frame 220 .

[0070] Fig.13 is a cross-sectional view of the fastener 10 in the inserted state. The fastener 10 is also in the unlocked state. Figure 2 and Fig.13 The cross-section of the fastener 10 is the same, but the relative positions of the active device 100 and the passive device 200 are different. Fig.13 In the embodiment, the active device 100 is inserted into a hole or channel 260 in the passive device 200 (e.g., Figure 7-10 ). In this relative position, the flat distal surface 143 of the cap 140 is placed on the inner flat surface 262 of the housing 210 of the passive device 200. To switch from the unlocked state to the locked state, the motor 160 is activated to cause the shaft 120 to rotate in a first direction (e.g., clockwise), thereby causing the external threads 124 on the shaft 120 to engage with the internal threads 560 in the plunger 130 ( Figure 6 ) rotational engagement. This rotational engagement causes the flat outer surface 540 of the plunger 130 to frictionally engage with the corresponding flat inner surface 116 in the housing 110, which causes the plunger 130 to move downwardly toward the cap 140 along the central vertical axis 300, as shown in FIG. Fig.14 shown.

[0071] As the plunger 130 moves downward, the tapered distal end 502 of the plunger 130 physically contacts and mechanically engages the inner side of the locking body 150 to apply a force thereto, thereby causing the locking body 150 to slide and / or rotate laterally (e.g., away from the central vertical axis 300) along or parallel to the second axis 320, as shown in FIG. Fig.15 As the locking body 150 slides and / or rotates laterally, the outer side of the locking body 150 physically contacts and mechanically engages with the flat engagement surface 1210 of the locking frame 220, thereby placing the fastener 10 in a locked state. In the locked state, the plunger 130 exerts an outward force on the locking body 150, and the locking body 150 exerts a force on the locking frame 220. The position of the locking frame 220 is limited and / or constrained by the inner housing wall 212 defining the notch 270, thereby locking (e.g., mechanically fixing) the active device 100 and the passive device 200.

[0072] Fig.15 The housing 110 is also shown to include a lip, ridge, or downward protrusion 1500 that extends toward the cap 140 parallel to the central vertical axis 300. The lip 1500 reduces the height 1530 of the gap 1510 between the distal side 1520 of the housing 110 and the flat proximal surface 145 of the cap 140, which is measured about the central vertical axis 300. The height 1530 between the lip 1500 and the flat proximal surface 145 is less than the corresponding dimension 152 (e.g., height or diameter) of the locking body 150, which can limit lateral movement of the corresponding locking body 150 (e.g., parallel to the third axis 330). Additionally or alternatively, the flat proximal surface 145 can include a lip, ridge, or upward protrusion (e.g., that extends toward the housing 110 parallel to the central vertical axis 300) to reduce the height 1530 of the gap 1510.

[0073] Fig.15 Further shown is an optional ring 1540 around the shaft 120 on the flat proximal surface 145 of the cap 140. The ring 1540 may be formed of a relatively soft or compliant material (e.g., rubber or plastic) to prevent the plunger 130 from contacting the cap 140 if the plunger 130 is advanced too far downward along the central vertical axis 300. The ring 1540 may prevent or reduce damage to the plunger 130 and / or the cap 140.

[0074] To switch from the locked state to the unlocked state, the motor 160 is activated to rotate the shaft 120 in a second direction (eg, counterclockwise), thereby causing the external threads 124 on the shaft 120 to engage with the internal threads 560 (eg, in the plunger 130). Figure 6 ) rotational engagement. This rotational engagement causes the flat outer surface 540 ( Fig.13) and the corresponding flat inner surface 116 ( Fig.13 ) frictionally engages, which causes the plunger 130 to move upwardly away from the cap 140 along the central vertical axis 300, as Fig.13 As the plunger 130 moves upward, the flat alignment surface 1250 contacts the outside of the locking body 150 and pushes them inward toward the central vertical axis 300. The active device 100 and the passive device 200 can then be separated. For example, gravity can cause the passive device 200 to slide downward along the central vertical axis 300 away from the active device 100.

[0075] Fig.16 and Fig.17 1 is a perspective cutaway view of a control system 1600 for fastener 10. Control system 1600 includes a first limit switch 1610 (e.g., a lower limit switch), a second limit switch 1620 (e.g., an upper limit switch), and a controller 1630. Controller 1630 is in electrical communication with first limit switch 1610 and second limit switch 1620. Limit switches 1610, 1620 are located behind and / or inside housing 110 and are therefore Figure 2 , Figure 3 , Fig.13 and Fig.14 It is not visible.

[0076] The first limit switch 1610 is configured to generate a first output signal (eg, a first limit signal) when the plunger 130 is lowered to a predetermined position along the central vertical axis 300. Fig.16 The predetermined position corresponds to the position at which the plunger 130 begins to engage with the locking body 150 (eg Fig.14 and Fig.15The first limit switch 1610 may be activated (e.g., the state of the first limit switch 1610 may be changed) when the distal end 502 of the plunger 130 physically contacts the first limit switch 1610 and causes the first limit switch 1610 to pivot away from the plunger 130, for example, by a predetermined pivot angle (e.g., about 10°, about 15°, about 20°, or another angle) compared to the default or original position of the first limit switch 1610. Additionally or alternatively, the physical contact of the distal end 502 of the plunger 130 with the first limit switch 1610 may change an electrical characteristic (e.g., voltage, current, resistance, impedance, and / or another electrical characteristic) of the first limit element 1610. For example, the first limit switch 1610 may be conductive, the plunger 130 may be resistive, and when the distal end 502 of the plunger 130 and the first limit switch 1610 are in physical contact, the voltage or impedance measured at the first limit switch 1610 may increase compared to when they are physically separated. In another embodiment, the first limit switch 1610 may include an optical switch that may change state when the distal end 502 of the plunger 130 is lowered in front of the optical switch.

[0077] To switch from the unlocked state to the locked state, the motor 160 (e.g., Fig.13 ) rotates the shaft 120 in a first direction to lower the plunger 130. During this transition, the controller 130 can monitor the drive current of the motor 160. The controller 130 can compare the drive current with a first predetermined maximum current. As long as the drive current remains at or below the first predetermined maximum current, the motor 160 can continue to drive the shaft 120. When the controller 130 determines that the drive current is higher than the first predetermined maximum current, the controller 130 can stop the motor 160 (e.g., by generating a stop output signal). A drive current higher than the first predetermined maximum current can indicate that the external thread 124 of the shaft 120 and the internal thread 560 of the plunger 130 are misaligned and / or damaged, respectively. The first predetermined maximum current can be about 4 amperes, about 5 amperes, about 6 amperes, or any value or range between any two of the above currents.

[0078] When the controller 1630 receives the first output signal, the controller 1630 begins comparing the drive current to a second predetermined maximum current that is lower than the first predetermined maximum current. The second predetermined maximum current may be about 3 amps, about 3.5 amps, about 4 amps, about 4.5 amps, or any value or range between any two of the above currents. The drive current being higher than the second predetermined maximum current may indicate that the plunger 130 applies a minimum force to the locking body 150 to switch the fastener 10 to the locked state. When the drive current is higher than the second predetermined maximum current, the controller 130 stops the motor 160 (e.g., by generating a stop output signal).

[0079] The second limit switch 1620 is configured to generate a second output signal (eg, a second limit switch signal) when the plunger 130 is raised to a predetermined position along the central vertical axis 300, such as Fig.17 150. The predetermined position corresponds to an unlocked state of the fastener 10 at a position where the plunger 130 is disengaged from the locking body 150 and retracted relative thereto. The second limit switch 1620 is located in the notch 520 defined in the plunger 130. When the plunger is raised to the predetermined position, the distal or bottom edge 1640 of the notch 520 can physically contact and activate the second limit switch 1620 (e.g., change its state). For example, the second limit switch 1620 can be activated when the bottom edge 1640 of the notch 520 physically contacts the second limit switch 1620 and causes the second limit switch 1620 to pivot away from the plunger 130, such as by a predetermined pivot angle (e.g., about 10°, about 15°, about 20°, or another angle) compared to the default or original position of the second limit switch 1620. Additionally or alternatively, physical contact of the bottom edge 1640 of the notch 520 with the second limit switch 1620 can change an electrical characteristic (e.g., voltage, current, resistance, impedance, and / or another electrical characteristic) of the second limit switch 1620. For example, the second limit switch 1620 can be conductive and the plunger 130 can be resistive, and when the bottom edge 1640 of the notch 520 and the second limit switch 1620 are in physical contact, a voltage or impedance measured at the second limit switch 1620 can increase compared to when they are physically separated. In another embodiment, the second limit switch 1620 can include an optical switch that can change state when the bottom edge 1640 of the notch 520 is lowered in front of the optical switch.

[0080] In order to switch from the locked state to the unlocked state, the plunger 130 is raised by rotating the shaft 120 in the second direction using the motor 160. During this conversion, the controller 130 can monitor the drive current of the motor 160. The controller 130 can compare the drive current with the first predetermined maximum current. As long as the drive current remains at or below the first predetermined maximum current, the motor 160 can continue to drive the shaft 120, which can indicate that the external thread 124 of the shaft 120 and the internal thread 560 of the plunger 130 are misaligned and / or damaged, respectively, as described above. When the controller 1630 receives the second output signal, the controller 1630 (e.g., by generating a stop output signal) causes the motor 160 to stop.

[0081] In an alternative embodiment, reference numeral 1630 may represent an electronic device and / or a local controller for limit switches 1610, 1620, and / or another controller 1650 may be configured to perform some or all of the functions described above with respect to controller 1630. For example, controller 1630 and / or 1650 may monitor the drive current of motor 160 and may compare the drive current with a first and / or second predetermined maximum current. If / when the drive current exceeds the first and / or second predetermined maximum current and / or in response to a second output signal from second limit switch 1620, controller 1630 and / or 1650 may also stop motor 160 (e.g., by generating a stop output signal). In this embodiment, electronic device and / or local controller 1630 may send an output signal to controller 1650 indicating that first limit switch 1610 has been activated and / or second limit switch 1620 has been activated. Additionally or alternatively, the electronic device and / or the local controller 1630 may relay the first output signal and / or the second output signal to the controller 1650 .

[0082] The controller 1630 and / or 1650 may generate a first drive signal that causes the motor 160 to rotate the shaft 120 in a first direction (e.g., clockwise) to switch the fastener 10 from the unlocked state to the locked state. The controller 1630 and / or 1650 may generate a second drive signal that causes the motor 160 to rotate the shaft 120 in a second direction (e.g., counterclockwise) to switch the fastener 10 from the locked state to the unlocked state.

[0083] Fig.18 is a perspective view of the fastener 10 in an inserted state. Fig.13 As shown, the fastener 10 can be in an inserted and unlocked state, or in an inserted and locked state, such as Fig.14 and Fig.15 The fastener 10 is also in the unlocked state. Fig.13 and Fig.14 The cross section shown is through Fig.18 The plane 1300 in the image is obtained.

[0084] Fig.191 is a perspective view of an assembly 1900 according to an embodiment. The assembly 1900 includes a self-aligning mechanical fastener 10, a first object 1901, and a second object 1902. The active device 100 is attached and / or mechanically coupled to the first object 1901 (e.g., at the proximal end of the active device 100). The passive device 200 is attached and / or mechanically coupled to the second object 1902 (e.g., at the distal end of the active device 100). When the self-aligning mechanical fastener 10 is in a locked state, the first object 1901 and the second object 1902 are releasably mechanically coupled. In some embodiments, the first object 1901 may include a controller 1920, which may be the same as the controller 1650. Each object 1901, 1902 may include a plate, a housing, a tray, a mechanical load, or another object.

[0085] Fig. 20 2 is a perspective view and partially exploded view of a battery tray 2000 according to one embodiment. The battery tray 2000 is configured to accommodate one or more battery modules 2010. A passive device 200 is preferably located in each corner 2002 of the battery tray 2000. Each passive device 200 is mechanically coupled to a housing 2004 of the battery tray 2000. The passive device 200 is configured to be releasably mechanically secured and locked to a corresponding active device 100, which can be mechanically coupled to an interface board 2100, such as Fig.21 As shown, the interface plate 2100 can be fixed to the bottom of the electric vehicle. The interface plate 2100 can be mechanically coupled to a plurality of battery trays 2000 using self-aligning mechanical fasteners 10. The interface plate 2100 and the battery trays 2000 can correspond to the first object 1901 and the second object 1902, respectively. The battery trays 2000 can be raised and lowered to the interface plate 2100 using a lift such as a robot lift. Fig.21 The partially exploded view in FIG. 1 shows one of the battery trays 2000 to show the active device 100 on the interface board 2100 corresponding to the battery tray 2000 in the exploded view. Fig. 22 The self-aligning mechanical fasteners 10 in mechanically connect all battery trays 2000 to the interface board 2100.

[0086] Fig.23is a block diagram of a bottom portion of an electric vehicle 2300 to which an interface board 2100 has been mechanically secured. A plurality of battery trays 2000 are releasably attached (e.g., locked) to the interface board 2100 using self-aligning mechanical fasteners 10. In a preferred embodiment, a plurality of passive components 200 are mechanically coupled to the battery tray 2000 and a plurality of active components 100 are mechanically coupled to the interface board 2100. In another embodiment, a plurality of active components 100 are mechanically coupled to the battery tray 2000 and a plurality of passive components 200 are mechanically coupled to the interface board 2100. In another embodiment, the active components 100 and the passive components 200 are mechanically coupled to the battery tray 2000 and the interface board 2100.

[0087] In some embodiments, the interface board 2100 can be the same or substantially the same as the interface board disclosed in U.S. patent application No. 17 / 221,510, entitled “Interface for Coupling Electric Battery and Vehicle Systems,” filed on April 2, 2021, which is incorporated herein by reference.

[0088] Fig.24 24 is a flow chart of a method 2400 for releasably mechanically coupling objects according to one embodiment. The method 2400 may be performed using the self-aligning mechanical fastener 10, the assembly 1900, the interface plate 2100, and the battery module 2000 or the electric vehicle 2300.

[0089] In step 2401, active device 100 is inserted into passive device 200. Active device 100 is mechanically coupled to a first object, such as object 1901 or interface board 2100. Passive device is mechanically coupled to a second object, such as object 1902 or battery module 2000.

[0090] In step 2402, motor 160 rotates shaft 120 in a first direction relative to first axis 300 to advance plunger 130 toward cap 140. Rotating shaft 120 causes threaded region 122 of shaft 120 to rotationally engage internal threads 560 defined in plunger passage 530.

[0091] In step 2403, the tapered distal end 502 of the plunger 130 is brought into mechanical contact with the locking body 150, such as Fig.14 shown.

[0092] In step 2404 , the tapered distal end 502 of the plunger 130 applies a force (eg, a lateral force) on the locking body 150 that causes the locking body 150 to mechanically engage the pressure frame 220 in the passive device 200 .

[0093] In step 2405 , the tapered distal end 502 of the plunger 130 and the pressure frame 220 restrict movement of the locking body 150 to lock (eg, mechanically secure) the active device 100 to the passive device 200 .

[0094] The present invention should not be considered to be limited to the above-mentioned specific embodiments. After reading this disclosure, those skilled in the art to which the present invention relates will easily understand various modifications, equivalent processes, and many structures to which the present invention may be applicable. The above-mentioned embodiments can be implemented in a variety of ways. One or more aspects and embodiments related to the execution of a process or method can be performed or controlled by program instructions that can be executed by a device (e.g., a computer, a processor, or other device) to execute these processes or methods.

[0095] In this regard, various inventive concepts may be embodied as a non-transitory computer-readable storage medium (or multiple non-transitory computer-readable storage media) (e.g., any applicable type of computer memory, including transient or non-transitory digital storage units, circuit configurations in field programmable gate arrays or other semiconductor devices, or other tangible computer storage media), encoded with one or more programs that, when executed on one or more computers or other processors, perform methods that implement one or more of the various embodiments described above. When implemented in software (e.g., as an application program), the software code may be executed on any applicable processor or collection of processors, whether provided in a single computer or distributed among multiple computers.

[0096] Furthermore, it should be understood that the computer may be implemented in any of a variety of forms, such as, by way of non-limiting example, a rack-mounted computer, a desktop computer, a laptop computer, or a tablet computer. In addition, the computer may be embedded in a device that is not generally regarded as a computer but has appropriate processing capabilities, including a personal digital assistant (PDA), a smart phone, or any other suitable portable or fixed electronic device.

[0097] In addition, the computer may have one or more communication devices that can be used to interconnect the computer with one or more other devices and / or systems, for example, with one or more networks (including local area networks or wide area networks, such as enterprise networks and intelligent networks (IN) or the Internet) in any suitable form. Such networks can be based on any suitable technology and can operate according to any suitable protocol, and can include wireless networks or wired networks.

[0098] In addition, the computer may have one or more input devices and / or one or more output devices. These devices may be used, in particular, to present a user interface. Examples of output devices that may be used to provide a user interface include a printer or display screen for visual presentation of output, and a loudspeaker or other sound generating device for auditory presentation of output. Examples of input devices that may be used for a user interface include a keyboard and a pointing device, such as a mouse, a touch pad, and a digitized tablet computer. As another example, a computer may receive input information via speech recognition or other audible formats.

[0099] One or more non-transitory computer readable media may be transportable so that the program stored thereon can be loaded onto one or more different computers or other processors to implement one or more of the above aspects. In some embodiments, the computer readable medium may be a non-transitory medium.

[0100] The terms "program", "application" and "software" are used in a general sense herein to refer to any type of computer code or computer executable instruction set that can be used to program a computer or other processor to implement the various aspects described above. In addition, it should be understood that, according to one aspect, one or more computer programs that perform the methods of the present application when executed do not need to reside on a single computer or processor, but can be distributed in a modular manner among multiple different computers or processors to implement various aspects of the present application.

[0101] Computer executable instructions can be in various forms, such as program modules that are executed by one or more computers or other devices. Typically, program modules include routines, programs, objects, components, data structures, etc. that perform specific tasks or implement specific abstract data types. In various embodiments, the functions of the program modules can be combined or distributed as needed.

[0102] In addition, the data structure can be stored in a computer-readable medium in any suitable form. To simplify the description, the data structure can be shown as having fields that are related by position in the data structure. This relationship can also be achieved by allocating storage space for the fields, which has positions in the computer-readable medium that convey the relationship between the fields. However, any suitable mechanism can be used to establish a relationship between the information in the fields of the data structure, including by using pointers, tags, or other mechanisms that establish a relationship between data elements.

[0103] Thus, the present disclosure and claims include new and novel improvements over existing methods and techniques that were neither previously known nor implemented to obtain the above-described useful results. Given the impact that the specific modifications described herein have on the system and its output to users of the method and system, these users will gain tangible benefits from the functionality that is now possible. It is expected that after practicing the present invention, significantly improved operations can be achieved using the technical components described herein.

[0104] In addition, as described above, some aspects may be embodied as one or more methods. The actions performed as part of the method may be ordered in any applicable manner. Therefore, embodiments may be constructed that perform actions in a sequence different from the sequence shown, which may include performing some actions simultaneously, even if shown as sequential actions in an exemplary embodiment.

Claims

1. A self-aligning mechanical fastener comprising: An active device, the active device comprising: an active housing defining a passage extending along a first axis; a shaft disposed in the passage and extending along the first axis, the shaft having external threads defined on a threaded region; a motor configured to rotate the shaft about the first axis; a plunger having a passage defined from a proximal end of the plunger to a distal end of the plunger, the passage being defined by an inner wall having internal threads that engage the external threads on the threaded region of the shaft, the distal end having a tapered shape; a cap attached to the active housing and disposed at the distal end of the shaft, the cap having a proximal surface and a distal surface, the proximal surface defining a gap with the active housing; and a locking body disposed on the proximal surface of the cap; and Passive device, the passive device comprising: an alignment housing having a bore extending parallel to the first axis from a proximal end of the alignment housing toward a distal end of the alignment housing, the bore being configured to receive the active housing, the proximal end of the alignment housing forming a tapered alignment guide defined by an inner wall of the alignment housing such that the bore has a width that decreases from a proximal end of the alignment guide to a distal end of the alignment guide, the width being measured about a second axis orthogonal to the first axis; and a pressure frame disposed in a slot defined in the alignment housing, the aperture extending through a hollow central region of the pressure frame, in: The self-aligning mechanical fastener has a locked state and an unlocked state, To convert the self-aligning mechanical fastener from the unlocked state to the locked state: inserting the active housing into the hole and aligning the locking body with the pressure frame, the motor causes the shaft to rotate in a first direction to advance the plunger toward the cap, and the distal end of the plunger exerts a force on the locking body that causes the locking body to mechanically engage the pressure frame, thereby mechanically securing the active device to the passive device, To convert the self-aligning mechanical fastener from the locked state to the unlocked state: The motor causes the shaft to rotate in a second direction to retract the plunger away from the cap, thereby releasing the force on the locking body to thereby unlock the active device from the passive device.

2. The self-aligning mechanical fastener of claim 1, wherein: The locking body is a first locking body, and the self-aligning mechanical fastener further includes a second locking body disposed on the proximal surface of the cap in the gap, the shaft being disposed between the first locking body and the second locking body.

3. The self-aligning mechanical fastener of claim 2, wherein: The first locking body and the second locking body include a first cylinder and a second cylinder, respectively.

4. The self-aligning mechanical fastener of claim 1, wherein: The slot is defined in part by a flat inner wall in the alignment housing at a distal end of the slot, and The pressure frame has a flat outer surface on a distal side of the pressure frame, the flat outer surface contacting the flat inner wall.

5. The self-aligning mechanical fastener of claim 4, wherein: The flat outer surface and the flat inner wall are parallel to a plane orthogonal to the first axis, The pressure frame has a flat engagement surface connected to the flat outer surface, The planar engagement surface defines an acute angle with the plane, and The planar engagement surface is configured for engaging the locking body when the self-aligning mechanical fastener is in the locked state.

6. The self-aligning mechanical fastener of claim 5, wherein: The acute angle ranges from about 35° to about 45°.

7. The self-aligning mechanical fastener of claim 5, wherein: The acute angle is a first acute angle, the pressure frame having a planar alignment surface connected to the planar engagement surface, the planar engagement surface being located between the planar alignment surface and the planar outer surface, The planar alignment surface and the plane define a second acute angle, and The planar alignment surface is configured for engagement with the locking body when the active housing is partially removed from the aperture.

8. The self-aligning mechanical fastener of claim 7, wherein: The first acute angle ranges from about 35° to about 45°, and The second acute angle ranges from about 70° to about 80°.

9. The self-aligning mechanical fastener of claim 1, wherein: each inner wall defining the tapered alignment guide has a cross-sectional thickness that increases from a proximal end of the tapered alignment guide to a distal end of the tapered alignment guide, the cross-sectional thickness being measured along a respective axis orthogonal to the first axis, and The inner wall includes opposing first and second walls aligned about the second axis.

10. The self-aligning mechanical fastener of claim 9, wherein: The inner wall includes a third wall aligned about a third axis orthogonal to the first axis and the second axis, the third wall being connected to the opposing first and second walls.

11. The self-aligning mechanical fastener of claim 1, wherein: The proximal end of the plunger includes a plurality of flat outer surfaces configured to engage with corresponding flat inner surfaces of the active housing when the shaft is rotated about the first axis, thereby causing the plunger to advance when the self-aligning mechanical fastener is switched from the unlocked state to the locked state, and to retract when the self-aligning mechanical fastener is switched from the locked state to the unlocked state.

12. The self-aligning mechanical fastener of claim 1, wherein: The pressure frame is configured to float within the slot about the second axis and / or about a third axis orthogonal to the first axis and the second axis.

13. The self-aligning mechanical fastener of claim 1, wherein: The active device also includes a controller in electrical communication with the motor, the controller being configured to: generating a first drive signal that causes the motor to rotate the shaft in the first direction to advance the plunger toward the cap, thereby switching the self-aligning mechanical fastener from the unlocked state to the locked state, and A second drive signal is generated that causes the motor to rotate the shaft in the second direction to retract the plunger away from the cap, thereby transitioning the self-aligning mechanical fastener from the locked state to the unlocked state.

14. The system of claim 13, wherein: The active device includes a limit switch in electrical communication with the controller, the limit switch being configured to output a limit switch signal when the distal end of the plunger is advanced to a predetermined position by rotating the shaft in the first direction, and The controller is configured to generate a stop output signal in response to a feedback signal from the motor while the self-aligning mechanical fastener system is transitioning from the unlocked state to the locked state and after the controller receives the limit switch signal, the stop output signal causing the motor to stop.

15. The system of claim 14, wherein: The feedback signal is a driving current of the motor, and the controller is configured to generate the stop output signal when the driving current is greater than or equal to a predetermined value.

16. The system of claim 15, wherein: The predetermined value is a first predetermined value, and The controller is configured to generate the stop output signal when the drive current is greater than or equal to a second predetermined value when the self-aligning mechanical fastener system switches from the unlocked state to the locked state and before receiving the limit switch signal, and the second predetermined value is greater than the first predetermined value.

17. The system of claim 13, wherein: The limit switch is a first limit switch, The limit switch signal is a first limit switch signal, The predetermined position is a first predetermined position, The active device includes a second limit switch in electrical communication with the controller, the second limit switch being configured to output a second limit switch signal when the distal end of the plunger is retracted to a second predetermined position by rotating the shaft in the second direction, and The controller is configured to generate the stop output signal in response to receiving the second limit switch signal when the self-aligning mechanical fastener system transitions from the locked state to the unlocked state.

18. An assembly comprising: first object; Second object; an active device attached to the first object, the active device comprising: an active housing defining a passage extending along a first axis; a shaft disposed in the passage and extending along the first axis, the shaft having external threads defined on a threaded region; a motor configured to rotate the shaft about the first axis; a plunger having a passage defined from a proximal end of the plunger to a distal end of the plunger, the passage being defined by an inner wall having internal threads that engage the external threads on the threaded region of the shaft, the distal end having a tapered shape; a cap attached to the active housing and disposed at the distal end of the shaft, the cap having a proximal surface and a distal surface, the proximal surface defining a gap with the active housing; and a locking body disposed on the proximal surface of the cap; and a passive device attached to the second object, the passive device comprising: an alignment housing having a bore extending parallel to the first axis from a proximal end of the alignment housing toward a distal end of the alignment housing, the bore being configured to receive the active housing, the proximal end of the alignment housing forming a tapered alignment guide defined by an inner wall of the alignment housing such that the bore has a width that decreases from a proximal end of the alignment guide to a distal end of the alignment guide, the width being measured about a second axis orthogonal to the first axis; and a pressure frame disposed in a slot defined in the alignment housing, the aperture extending through a hollow central region of the pressure frame; and a controller in electrical communication with the motor, in: The active device and the passive device are configured to form a self-aligning mechanical fastener having a locked state and an unlocked state, To convert the self-aligning mechanical fastener from the unlocked state to the locked state: inserting the active housing into the hole and aligning the locking body with the pressure frame, the controller generates a first drive signal that causes the motor to rotate the shaft in a first direction to advance the plunger toward the cap, and the distal end of the plunger exerts a force on the locking body that causes the locking body to mechanically engage the pressure frame, thereby mechanically securing the active device to the passive device, To convert the self-aligning mechanical fastener from the locked state to the unlocked state: The controller generates a second drive signal that causes the motor to rotate the shaft in a second direction to retract the plunger away from the cap to release the force on the locking body to thereby unlock the active device from the passive device.

19. The assembly of claim 18, wherein: The controller is disposed on the first object.

20. The assembly of claim 18, wherein: The first object includes an interface plate configured to be attached to a vehicle, and The second object includes a battery tray.

21. The assembly of claim 18, wherein: The active device is a first active device, The passive device is a first passive device, The self-aligning mechanical fastener is a first self-aligning mechanical fastener, and The components also include: a second active device attached to the first object; and a second passive device attached to the second object, in: The first active device is aligned with the first passive device, and The second active device is aligned with the second passive device, the second active device and the second passive device being configured to form a second self-aligning mechanical fastener.

22. A method for releasably mechanically coupling objects, comprising: inserting an active device into a passive device, the active device being mechanically coupled to a first object and the passive device being mechanically coupled to a second object, in: The active device comprises: an active housing defining a passage extending along a first axis; a shaft disposed in the passage and extending along the first axis, the shaft having external threads defined on a threaded region; a motor configured to rotate the shaft about the first axis; a plunger having a passage defined from a proximal end of the plunger to a distal end of the plunger, the passage defined by an inner wall having internal threads that engage the external threads on the threaded region of the shaft, the distal end having a tapered shape; a cap attached to the active housing and disposed at the distal end of the shaft, the cap having a proximal surface and a distal surface, the proximal surface defining a gap with the active housing; and a locking body disposed on the proximal surface of the cap; and The passive device includes: an alignment housing having a bore extending parallel to the first axis from a proximal end of the alignment housing toward a distal end of the alignment housing, the bore being configured to receive the active housing, the proximal end of the alignment housing forming a tapered alignment guide defined by an inner wall of the alignment housing such that the bore has a width that decreases from a proximal end of the alignment guide to a distal end of the alignment guide, the width being measured about a second axis orthogonal to the first axis; and a pressure frame disposed in a slot defined in the alignment housing, the aperture extending through a hollow central region of the pressure frame; rotating the shaft relative to the first axis in a first direction using the motor to advance the plunger toward the cap; bringing the distal end of the plunger into mechanical contact with the locking body; applying a force on the locking body with the distal end of the plunger, the force causing the locking body to mechanically engage the pressure frame; and The active device is mechanically fixed to the passive device by constraining movement of the locking body using the distal end of the plunger and the pressure frame.

Images