A method for unloading force on a charging pile using a robot

Abstract

This invention discloses a method for unloading charging piles using a robot, comprising the following steps: the robot obtains a return-to-pile command and the torque required for charging pile alignment; the robot navigates to the charging pile according to its positioning and makes contact with the charging pads of the charging pile; the robot adjusts the motor torque to the torque required for charging pile alignment and slowly moves to the preset charging contact distance. This reduces mechanical stress during charging pile alignment, protects the structural integrity of the charging pads and the charging pile, and thus extends the service life of the charging system.

Description

Technical Field

[0001] This invention relates to the field of robot charging, and more particularly to a method for unloading force on a pile during robot charging. Background Technology

[0002] In the robotics industry, automated charging systems are a key component for achieving unmanned operation. Currently, most robots utilize physical buffer mechanisms (such as springs and rubber pads) on the robot or charging station to absorb impact energy and reduce direct collisions between the charging pads and related structural components when the robot collides with the charging station. While these physical buffer mechanisms can reduce impact to some extent, the insufficient precision of force control during robot collisions still results in significant impact forces. This not only accelerates the wear of the buffer mechanisms but may also damage the charging pads or structural components of the charging station, thus affecting the reliability and lifespan of the entire charging system. Summary of the Invention

[0003] Therefore, it is necessary to provide a method for unloading the force of the robot charging pile, so as to solve the problem of insufficient force control accuracy when the robot charges the pile and the large impact force on the charging plate and related structural components of the charging pile.

[0004] To achieve the above objectives, this embodiment provides a method for unloading force from a charging pile using a robot, comprising the following steps:

[0005] The robot receives the command to return the pile to the pile and the torque required for the pile.

[0006] The robot navigates to the charging station based on its location and makes contact with the charging pad.

[0007] The robot adjusts the motor torque to the torque required for contact with the pile and slowly moves to the preset charging contact distance.

[0008] Furthermore, the required torque for the pile is obtained through the following steps:

[0009] Obtain the elastic coefficient k of the buffer mechanism connected to the charging plate;

[0010] The sensor detects the compression amount x of the buffer mechanism connected to the charging plate when the robot travels to the preset charging contact distance;

[0011] The stress F of the buffer mechanism during pile driving is obtained by the following formula: F = kx;

[0012] The required torque T for the pile can be obtained by the following formula: T = Fr, where r is the tire radius.

[0013] Furthermore, when slowly driving to reach the preset charging contact distance, the following steps are also included:

[0014] The sensor detects the actual stress in the buffer mechanism connected to the charging pad on the charging pile;

[0015] Determine whether the actual stress detected by the sensor is within ±10% tolerance of the stress F of the buffer mechanism when the pile is in use;

[0016] If not, the robot adjusts the motor torque until the actual stress is within ±10% of the stress F of the buffer mechanism during pile driving.

[0017] Furthermore, it also includes the following steps:

[0018] The sensor determines whether the buffer mechanism connected to the charging pad on the charging pile is within a reasonable compression range;

[0019] If yes, the charging station charges the robot via the charging pad; otherwise, the robot exits the charging station and re-aligns with it.

[0020] Furthermore, the sensor is a pressure sensor or a position sensor.

[0021] Furthermore, when the charging station charges the robot via the charging pad, the following steps are also included:

[0022] The robot's power system determines whether the charging parameters are abnormal;

[0023] If so, the robot will exit the charging station and re-align with the station.

[0024] Furthermore, it also includes the following steps:

[0025] The robot's main controller switches the drive motor to speed mode via the electric drive system, maintaining the speed at zero, thus parking the robot.

[0026] Furthermore, it also includes the following steps:

[0027] Robotic mechanical braking for parking.

[0028] Furthermore, when the robot navigates to the charging station based on its location, the following steps are also included:

[0029] The robot navigates to the charging station's docking point based on its location;

[0030] The robot's main controller switches the motor to position mode via the electric drive system, then drives towards the charging pad of the charging station and makes contact with it.

[0031] Furthermore, the robot is a cleaning robot.

[0032] Unlike existing technologies, the above technical solution has the following beneficial effects:

[0033] Upon receiving the return-to-charging-pile command, the robot activates its automatic navigation system. It can navigate to the target charging pile using laser navigation, visual navigation, or other high-precision positioning methods, and retrieves the ideal torque value required for alignment from a pre-set database. Once the robot contacts the charging pad, the control system adjusts the motor's output torque in real time, maintaining it within the required range to prevent impact caused by excessive torque. While adjusting the torque, the robot advances slowly and steadily until the charging pad and charging pile reach the preset charging contact distance. At this point, the buffer mechanism's elasticity exceeds the robot's driving force, preventing further forward movement. This reduces mechanical stress during alignment, protects the structural integrity of the charging pad and charging pile, and extends the lifespan of the charging system.

[0034] The above description of the invention is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0035] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of the present invention and other related contents, and should not be considered as limitations on this application.

[0036] Figure 1 This is one of the flowcharts for the robot charging and pile unloading method in this embodiment;

[0037] Figure 2 This is the second flowchart of the robot charging and pile unloading method in this embodiment;

[0038] Figure 3 This is the third flowchart of the robot charging and pile unloading method in this embodiment;

[0039] Figure 4 This is the fourth flowchart of the robot charging and pile unloading method in this embodiment;

[0040] Figure 5 This is the fifth flowchart of the robot charging and pile unloading method in this embodiment. Detailed Implementation

[0041] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0042] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0043] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0044] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.

[0045] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.

[0046] Unless otherwise specified, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0047] Similar to the understanding in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0048] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0049] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this application, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this application pertains, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0050] Please see Figures 1 to 5 This embodiment of a robot charging and pile unloading method includes the following steps:

[0051] Step S101: The robot obtains the pile return command and the torque required for the pile.

[0052] In step S102, the robot navigates to the charging station based on its positioning and makes contact with the charging pad of the charging station.

[0053] In step S103, the robot adjusts the motor torque to the torque required for the pile and slowly moves to the preset charging contact distance.

[0054] Upon receiving the return-to-charging-pile command, the robot activates its automatic navigation system. It can navigate to the target charging pile using laser navigation, visual navigation, or other high-precision positioning methods, and retrieves the ideal torque value required for alignment from a pre-set database. Once the robot contacts the charging pad, the control system adjusts the motor's output torque in real time, maintaining it within the required range to prevent impact caused by excessive torque. While adjusting the torque, the robot advances slowly and steadily until the charging pad and charging pile reach the preset charging contact distance. At this point, the buffer mechanism's elasticity exceeds the robot's driving force, preventing further forward movement. This reduces mechanical stress during alignment, protects the structural integrity of the charging pad and charging pile, and extends the lifespan of the charging system.

[0055] In step S103, the main controller calculates and sends the target current to the electric drive system based on the current slope (the charging pile is usually equipped with a ramp in front of the charging plate) and the walking force, so that the drive motor runs at an optimal and small torque, and slowly increases the current to a certain value (the maximum stress value of the buffer system under the ideal contact condition between the robot and the charging pile itself - the maximum target torque).

[0056] Furthermore, due to material, batch, or installation process issues, each robot and pile may exhibit different buffer mechanism force characteristics. The given maximum target torque is the most difficult variable to control. A deep learning algorithm can be used: the robot can be repeatedly trained using a deep neural network. Initially, the torque can be increased slowly until the pressure sensor or positioning sensor is triggered. Through numerous pile-setting cycles, the neural network learns the optimal pile-setting force under different environments.

[0057] Please see Figure 2 In this embodiment, the required torque on the pile is obtained through the following steps:

[0058] Step S201: Obtain the elastic coefficient k of the buffer mechanism connected to the charging plate;

[0059] Step S202: The sensor detects the compression amount x of the buffer mechanism connected to the charging plate when the robot travels to the preset charging contact distance;

[0060] Step S203: The stress F of the buffer mechanism during pile driving is obtained by the following formula: F = kx;

[0061] The required torque T for the pile can be obtained by the following formula: T = Fr, where r is the tire radius.

[0062] Specifically, since the buffer mechanism is pre-assembled at the factory, the required torque for the pile can be obtained in advance. The buffer mechanism usually adopts a spring design, and its working principle is based on Hooke's Law, that is, the spring force formula: F = kx, where: F is the elastic force generated by the spring (unit: Newton, N), k is the spring constant or elastic coefficient (unit: Newton per meter, N / m), which represents the force required for the spring to deform per unit length, and x is the compression of the spring (unit: meter, m).

[0063] In this embodiment, when the vehicle slowly travels to the preset charging contact distance, the following steps are also included:

[0064] The sensor detects the actual stress in the buffer mechanism connected to the charging pad on the charging pile;

[0065] Determine whether the actual stress detected by the sensor is within ±10% tolerance of the stress F of the buffer mechanism when the pile is in use;

[0066] If not, the robot adjusts the motor torque until the actual stress is within ±10% of the stress F of the buffer mechanism when aligning with the pile. This indicates that the contact pressure is too high or too low. The robot's main controller will immediately adjust the motor torque to bring it back to the ±10% tolerance range of the torque required for aligning with the pile, thus avoiding problems caused by excessive or insufficient stress and ensuring the best contact condition.

[0067] If so, the robot maintains the torque of the motor.

[0068] For example, it is known from the factory that the stress F of the buffer mechanism during pile driving is 10N, the tire radius r is 0.2m, and the torque T is 2N·m, which can be stored in the main controller. During actual pile driving, the motor's torque output is stably 10N. If the detector detects that the actual stress is within the range of 9 to 11N, it can continue to maintain this level. If the detector detects that the actual stress is less than 9N or greater than 11N, the motor torque is finely adjusted until it reaches the normal range (9 to 11N).

[0069] Please see Figure 3 In this embodiment, the method further includes the following steps:

[0070] Step S104: The sensor determines whether the buffer mechanism connected to the charging pad on the charging pile is within a reasonable retraction range.

[0071] Step S105: If yes, the charging station charges the robot via the charging pad.

[0072] If not, the robot exits the charging station and re-aligns with the station, returning to step S102.

[0073] During the charging process, the robot gradually compresses the buffer mechanism, which is typically an elastic material like a spring or rubber pad that contracts under pressure. If the buffer mechanism is within a reasonable range of compression, it indicates that the robot has reached the preset charging contact distance. The robot's main controller determines whether the buffer mechanism is within the reasonable range of compression. This step ensures that the buffer mechanism is correctly compressed and will not be damaged by over-compression or cause poor contact due to insufficient compression. Furthermore, the charging station will only begin charging when the buffer mechanism is within the reasonable range of compression, avoiding safety hazards caused by abnormalities in the buffer mechanism.

[0074] In this embodiment, the sensor is a pressure sensor or a positioning sensor, which can be installed on the robot or the charging station. For example, using a spring as the buffer mechanism and a pressure sensor as the sensor: a pressure sensor is installed at the end of the spring on the charging station. As the robot gradually approaches the charging station and applies pressure, the pressure sensor can monitor the contact pressure between the two in real time. Alternatively, using a spring as the buffer mechanism and a positioning sensor as the sensor: the positioning sensor can utilize the displacement or deformation generated during spring compression to trigger a sensor signal, such as using a linear encoder or Hall effect sensor, or sensing it through a rocker-type limit switch. By introducing sensors, a closed-loop control system is formed, which can not only monitor the actual stress and position status in real time, but also dynamically adjust the robot's behavior as needed, ensuring the safety and effectiveness of the entire docking process.

[0075] Please see Figure 5 In this embodiment, when the charging pile charges the robot through the charging pad, the following steps are also included:

[0076] Step S106: The robot's power system determines whether the charging parameters are abnormal.

[0077] If so, the robot exits the charging station and re-aligns with the station, returning to step S102;

[0078] If not, continue charging.

[0079] Charging parameters include charging current, charging voltage, and charging temperature. Abnormal conditions include charging voltage exceeding the battery's maximum allowable value, charging current exceeding the battery's or charging system's maximum capacity, and excessively high charging speed. When any abnormal condition is detected, the robot automatically exits charging and retryes the charging station to avoid safety hazards or equipment damage caused by the abnormal condition.

[0080] Please see Figure 5 In this embodiment, after normal charging, the following steps are also included:

[0081] In step S107, the robot's main controller switches the drive motor to speed mode via the electric drive system, maintaining the speed at zero to park the robot. The electric drive system can monitor the actual motor speed in real time according to the feedback mechanism and adjust the current or voltage through the control algorithm to strictly maintain the motor speed at zero, even under the action of the buffer mechanism. When the motor enters speed mode, the electric drive system will adaptively apply reverse torque to support it and prevent it from being ejected by the buffer mechanism.

[0082] In this embodiment, after switching the speed mode, the following steps are also included:

[0083] Step S108: The robot mechanically brakes and parks.

[0084] After the robot completes alignment with the target and begins charging, in addition to switching the drive motor to speed mode via the electric drive system to maintain stationary position, the robot's main controller further triggers a mechanical braking device (such as a holding brake or caliper brake) to achieve physical parking and locking. If the robot's travel system has a holding brake or caliper brake, the mechanical brake can be engaged to park the robot. Once the mechanical braking device is activated and successfully locks the vehicle, the main controller disables the motor, cutting off its power supply and putting the motor in an inactive state. In this state, the motor no longer consumes power or generates heat.

[0085] In this embodiment, when the robot navigates to the charging station based on its location, the following steps are also included:

[0086] The robot navigates to the charging station's docking point based on its location;

[0087] The robot's main controller switches the motor to position mode via the electric drive system, then drives towards the charging pad of the charging station and makes contact with it.

[0088] After receiving the return-to-charging-pile command, the robot first navigates to the pre-set alignment point in front of the charging pile using its positioning and navigation system. The robot can complete initial positioning before approaching the charging pile, ensuring sufficient time and space for subsequent precise positioning adjustments. During this process, sensors such as LiDAR, photoelectric sensors, and ultrasonic sensors acquire data about the robot's surroundings, including its posture and distance traveled, and upload this data to the main controller. The motors in position mode provide higher precision, enabling the robot to move precisely and ensure initial docking between the charging pads, improving docking efficiency. Once the robot has made contact with the charging pad, the motors switch from position mode to current (torque) mode.

[0089] In this embodiment, the robot is a cleaning robot. Cleaning robots typically operate autonomously in indoor or outdoor environments. After completing tasks such as sweeping, vacuuming, and mopping, they automatically return to a charging station to recharge, ensuring continuous operation. The cleaning robot is equipped with an advanced positioning and navigation system (such as LiDAR, visual sensors, photoelectric sensors, and ultrasonic sensors), enabling it to accurately locate charging stations in complex environments and achieve high-precision driving and charging station alignment through multi-sensor fusion technology.

[0090] The technical solution of this application has the following advantages:

[0091] 1. Suitable for indoor and outdoor two-wheeled or multi-wheeled robots with automatic charging docking. Through precise control of the docking process, the robot generates less impact force when docking with the charging dock, rather than the traditional method of impact followed by stress release. This method significantly reduces the impact during docking, effectively protecting the mechanical structure and charging pads of both the robot and the charging dock, thereby greatly extending the overall lifespan of the equipment and preventing power consumption and motor damage caused by maintaining high torque for extended periods.

[0092] 2. By making reasonable use of the electric drive system, the opposing torque between the motor and the buffer mechanism can be reduced after pile driving is completed. By precisely controlling the motor output, the required torque is minimized, thereby reducing current loss, improving energy utilization efficiency, and reducing unnecessary power consumption.

[0093] 3. After the pile unloading function is activated, the system will monitor the unloading effect in real time, forming a complete closed-loop control system. This design not only ensures that the ideal contact state is achieved every time the pile is aligned, but also allows for timely adjustment of any deviations, ensuring the safety and reliability of the operation.

[0094] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A method of robot charge post force relief, the method comprising: The method comprises the following steps: The robot acquires the pile aligning command and the torque required for aligning the pile; The robot drives to the charging pile according to the positioning navigation and just contacts with the charging sheet of the charging pile; The robot adjusts the torque of the motor to the torque required for aligning the pile and slowly drives to the preset charging contact distance; The torque required for aligning the pile is acquired through the following steps: The elastic coefficient k of the buffer mechanism connected with the charging sheet is acquired; The sensor detects the compression amount x of the buffer mechanism connected with the charging sheet when the robot drives to the preset charging contact distance; The stress F of the buffer mechanism when aligning the pile is acquired through the following formula: F=kx; The torque T required for aligning the pile is acquired through the following formula: T=Fr, wherein r is the tire radius; When slowly driving to the preset charging contact distance, the following steps are further included: The sensor detects the actual stress of the buffer mechanism connected with the charging sheet on the charging pile; It is judged whether the actual stress detected by the sensor is within the tolerance range of ±10% of the stress F of the buffer mechanism when aligning the pile; If not, the robot adjusts the torque of the motor until the actual stress is within the tolerance range of ±10% of the stress F of the buffer mechanism when aligning the pile.

2. The method of claim 1, wherein, The following steps are further included: The sensor judges whether the buffer mechanism connected with the charging sheet on the charging pile is within a reasonable compression range; If yes, the charging pile charges the robot through the charging sheet, and if not, the robot exits the charging pile and aligns the pile again.

3. The method of claim 1, wherein, The sensor is a pressure sensor or a position sensor.

4. The method of claim 2, wherein, When the charging pile charges the robot through the charging sheet, the following steps are further included: The power system of the robot judges whether the charging parameter is abnormal; If yes, the robot exits the charging pile and aligns the pile again.

5. The method of claim 2, wherein, The following steps are further included: The main controller of the robot switches the driving motor to the speed mode through the electric drive system, maintains the speed to be zero, and makes the robot park.

6. The method of claim 3, wherein, The following steps are further included: The main controller of the robot switches the driving motor to the speed mode through the electric drive system, maintains the speed to be zero, and makes the robot park.

7. The method according to claim 5 or 6, characterized in that, The following steps are further included: The robot mechanically brakes and parks.

8. The method of claim 1, wherein, When the robot drives to the charging pile according to the positioning navigation, the following steps are further included: The robot drives to the pile aligning point in front of the charging pile according to the positioning navigation; The main controller of the robot switches the motor to the position mode through the electric drive system and drives to the charging sheet of the charging pile and just contacts with it.

9. The method of claim 1, wherein, The robot is a cleaning robot.

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