Autonomous docking and battery swapping system for unmanned aerial vehicles

Abstract

7. ABSTRACT The present invention relates to a autonomous docking and battery swapping system (100) for drones, designed for precision landing, automated battery replacement, and intelligent operation management. The system (100) comprises a main frame (102), a canopy frame assembly (104), a drone assembly (106), a drone alignment assembly (108), a lifting mechanism assembly (110), a battery swapping assembly (112), a battery storage and charging module, a control system, and a network interface. The lifting mechanism (110) and battery swapping assembly (112) operate through direct linear actuation to remove and insert batteries without rotating carousels. The control system monitors battery health, validates successful swaps, and enables mission-aware decision-making. The invention integrates autonomous landing, precise docking, battery exchange, and data-driven control into a modular, scalable, and low-maintenance docking platform for multi-drone operations. The figure associated with abstract is Fig. 1

Description

Technical Field of the inventionThe present invention relates to unmanned aerial vehicles (UAVs) and autonomouspower management systems. More particularly, the invention relates to an automateddocking and battery swapping system for drones, enabling persistent operationsthrough intelligent precision landing, modular charging, and mission-aware decisionmaking.Background of the inventionIn recent years, unmanned aerial vehicles (UAVs) or drones have seen widespreadadoption for surveillance, inspection, logistics, and monitoring applications. A criticallimitation in prolonged UAV operations is the finite battery capacity, whichnecessitates frequent returns to a base station for recharging or battery replacement. Toaddress this constraint, several prior art systems have proposed automated docking andbattery exchange solutions.KR102563407B1 discloses a drone battery automatic replacement device in which thebattery is integrated into the landing skid of the drone. The system employs a connectorunit for electrical and mechanical engagement and a sliding mechanism to remove thedepleted battery and insert a charged one. The focus is primarily on mechanicalsimplicity, minimizing interference with payloads, and unmanned replacement ofonboard batteries.CA3082217A1 describes a battery exchange and charging system utilizing dualrotating carousels with multiple battery slots. A push-through mechanism ejects adepleted battery while inserting a charged one. Drone landing is guided by lasers orbeacons. While it enables continuous operation, the reliance on carousel mechanismsintroduces high mechanical complexity and maintenance overhead.KR20230057058A discloses a station system with a dome-shaped accommodationspace for drones, a position alignment unit with mechanical guides, and a batteryexchange unit employing multi-axis movement. The system emphasizes rotatingbattery storage and mechanical alignment, but it depends heavily on multi-axis motioncomponents.WO2017119803A1 discloses a drone landing and battery replacement system thatemploys mechanical rails, clamping devices, and lifting mechanisms. Landing isguided by LED, infrared, and image signals, followed by a ground-controlled batterydetaching and insertion process. This system requires significant mechanicalinfrastructure and operator involvement.CN113246790A discloses a docking station using an XY platform, gravity sensors,clamping chucks, and turntables for automatic battery replacement and charging. Thedesign relies heavily on hydraulics, servo motors, and mechanical linkages, increasingsystem complexity and cost.Limitations of the Prior Art: While these prior art systems demonstrate the feasibilityof automated UAV battery replacement, they generally exhibit one or more of thefollowing drawbacks:- Dependence on carousel, multi-axis, or hydraulically actuated systems thatintroduce excessive mechanical complexity and higher maintenancerequirements.- Use of proprietary battery formats, limiting flexibility and supply-chainefficiency.- Reliance on external mechanical alignment or heavy ground infrastructure,restricting scalability.- Absence of integrated health diagnostics, swap validation, or intelligentmission-aware decision-making.- Limited ability to support distributed deployment across multiple docking siteswith secure, networked coordination.Need for the Invention: Accordingly, there exists a need for a docking and batteryswapping system that employs simplified mechanisms, supports commercial off-the10shelf batteries, ensures precision docking with minimal hardware complexity,integrates real-time diagnostics and mission-aware operational logic, and enablesscalable deployment across multiple distributed UAV operations. The presentinvention fulfills these needs while overcoming the deficiencies of the prior art.Objects of the inventionThe primary object of the present invention is to provide an autonomous docking andbattery swapping system for unmanned aerial vehicles (UAVs) that enables rapid,reliable, and intelligent power replenishment, thereby extending flight endurance andminimizing human intervention.Another object of the invention is to provide a docking station equipped with precisionlanding capability using fiducial markers and mechanical alignment mechanisms,ensuring accurate UAV positioning even in the presence of navigation errors.Another object of the invention is to provide a drone locking mechanism that securesthe UAV during the battery exchange process, thereby improving operational safetyand stability.Another object of the invention is to provide a direct linear actuator-based batteryswapping mechanism that replaces depleted batteries with charged ones without usingcomplex carousel or robotic systems.Another object of the invention is to provide a modular battery storage and chargingunit capable of holding multiple commercial off-the-shelf batteries, each with anindependent charging port for simultaneous charging, ensuring flexibility and costefficiency.Another object of the invention is to provide a control system that monitors batteryhealth parameters such as state of charge, temperature, and cycle count, validatessuccessful swaps, detects faults, and generates operator alerts in case of operationalanomalies.Another object of the invention is to provide mission-aware logic that automaticallydetermines whether the UAV should redeploy, remain docked, or suspend operationsbased on system diagnostics and mission priorities.Another object of the invention is to provide a secure network interface that enablesencrypted communication among the UAV, docking station, ground control unit, andcloud servers for coordinated and scalable fleet operations.Another object of the invention is to provide a low-maintenance, modular, and scalabledocking solution integrating autonomous landing, intelligent battery exchange,diagnostic monitoring, and multi-drone networking into a unified system.Brief Summary of the inventionThe following presents a simplified summary of the disclosure in order to provide abasic understanding to the reader. This summary is not an extensive overview of thedisclosure, and it does not identify key / critical elements of the invention or delineatethe scope of the invention. Its sole purpose is to present some concepts disclosed hereinin a simplified form as a prelude to the more detailed description that is presented later.The present invention relates to a autonomous docking and battery swapping systemfor drones, designed to enable rapid, reliable, and intelligent power replenishment,thereby extending UAV operational endurance while minimizing human intervention.In accordance with an embodiment of the present invention, the system comprises amain frame configured to provide structural support and act as a base platform fordocking and battery swapping operations. Mounted on the main frame is a canopyframe assembly, which includes a back cover, main cover, left and right cover plates,telescopic rails, a back cover plate, and a linear actuator, the canopy being configuredto provide environmental protection and controlled enclosure opening and closingduring drone docking and battery swapping.The system comprises a drone assembly, which includes a drone body having a batterycompartment and a battery pack assembly configured for autonomous flight, landing,and communication with the docking station. A drone alignment assembly is provided,including an X-alignment tube, X-alignment mechanism link, Y-alignment tube, Yalignmentmechanism, landing platform, and X-alignment mechanism assembly. Thisalignment assembly ensures precise positioning of the drone on the landing platformusing fiducial markers and mechanical alignment components and corrects residuallanding errors through mechanical alignment bars.A lifting mechanism assembly is integrated, comprising a top support plate, bottomsupport plate, side support assembly, and linear actuator, configured to raise or lowerthe battery swapping assembly. The battery swapping assembly includes a batterycompartment assembly, Y-axis battery swapping assembly, and linear-actuator-drivenswapping mechanism, which is capable of removing depleted batteries from the droneand inserting fully charged batteries without employing rotating or carousel-basedsystems, thereby enabling hot-swappable battery exchange. The system also includesa battery storage and charging module with modular racks and interchangeablehousings, capable of storing multiple commercial off-the-shelf batteries andsimultaneously charging them through individual ports.A control system is provided to monitor and log battery health parameters, includingstate-of-charge, cycle count, and temperature; validate successful battery swaps byconfirming electrical contact engagement and proper seating of the new battery; detectfaults; generate operator alerts in case of mis landing or swap failures; and recordoperational data for predictive maintenance.Finally, the system comprises a network interface to enable secure, encryptedcommunication between the docking station, the drone, ground control units, and cloudservers, thereby supporting scalable deployment, real-time monitoring, diagnostics,and coordinated fleet operations. The invention integrates autonomous landing,precision alignment, lifting-based battery swapping, battery health diagnostics, andmission-aware decision-making into a modular, scalable, low-maintenance dockingplatform, providing a robust solution for automated UAV operations.Brief summary of DrawingsThe invention will be better understood from the following description taken inconjunction with the accompanying drawings, in which like reference numerals denotesimilar elements throughout.Fig. 1 illustrates a autonomous docking and battery swapping system (100) for drones,in accordance with the exemplary embodiment of the present invention;Fig. 2 illustrates the canopy frame assembly (200) of the autonomous docking andbattery swapping system, in accordance with the exemplary embodiment of the presentinvention;Fig. 3 illustrates the drone assembly (106), showing the battery pack replacementmechanism, in accordance with the exemplary embodiment of the present invention;FIG. 4 illustrates the Drone Alignment Assembly (108) of the autonomous docking andbattery swapping system (100), in accordance with the exemplary embodiment of thepresent invention;FIG. 5 illustrates the Lifting Mechanism Assembly (110) of the autonomous dockingand battery swapping system, in accordance with the exemplary embodiment of thepresent invention;FIG. 6 illustrates the battery swapping assembly (112) of the autonomous docking andbattery swapping system, in accordance with the exemplary embodiment of the presentinvention;Detailed Description of the inventionIt is to be understood that the present disclosure is not limited in its application to thedetails of construction and the arrangement of components set forth in the followingdescription or illustrated in the drawings. The present disclosure is capable of otherembodiments and of being practiced or of being carried out in various ways. Inaddition, it is to be understood that the phraseology and terminology used herein is forthe purpose of description and should not be regarded as limiting.The use of "including", "comprising" or "having" and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereof as well asadditional items. The terms "a" and "an" herein do not denote a limitation of quantitybut rather denote the presence of at least one of the referenced items. The use of terms"first", "second", and "third", and the like, herein do not denote any order, quantity, orimportance, but rather are used to distinguish one element from another.According to an exemplary embodiment of the present invention, a autonomousdocking and battery swapping system for drones, which enables rapid, reliable, andintelligent power replenishment, thereby extending UAV operational endurance andminimizing human intervention.In accordance with an embodiment of the present invention, wherein the main frameconfigured to provide structural support and serve as a base platform for all dockingand battery swapping operations. The main frame forms the foundation for mountingall other assemblies of the system.In accordance with an embodiment of the present invention, wherein the a canopyframe assembly mounted over the main frame. The canopy frame assembly includes aback cover, main cover, left and right cover plates, back cover plate, telescopic rails,and a linear actuator. The canopy frame assembly is configured to provideenvironmental protection and controlled enclosure opening and closing during dronedocking and battery swapping operations.In accordance with an embodiment of the present invention, wherein the droneassembly, which includes a drone body having a battery compartment and a batterypack assembly. The drone assembly is configured for autonomous flight, precisionlanding, and communication with the docking station.In accordance with an embodiment of the present invention, wherein the dronealignment assembly including an X-alignment tube, X-alignment mechanism link, Yalignmenttube, Y-alignment mechanism, landing platform, and X-alignmentmechanism assembly. The alignment assembly ensures precise positioning of the droneon the landing platform using fiducial markers and mechanical alignment components.It corrects residual landing errors through mechanical alignment bars and generatesalerts in case of misalignment.In accordance with an embodiment of the present invention, wherein the liftingmechanism assembly, which includes a top support plate, bottom support plate, sidesupport assembly, and linear actuator. The lifting mechanism assembly is configuredto raise or lower the battery swapping assembly to ensure precise alignment with thedrone battery compartment during docking operations.In accordance with an embodiment of the present invention, wherein the batteryswapping assembly including a battery compartment assembly, Y-axis batteryswapping assembly, and a linear-actuator-based mechanism. The battery swappingassembly is configured to remove depleted batteries from the drone and insert fullycharged batteries without employing rotating or carousel-based mechanisms, enablinghot-swappable battery exchange.In accordance with an embodiment of the present invention, wherein the battery storageand charging module configured to store multiple commercial off-the-shelf batteries inmodular racks with interchangeable housings. The module enables simultaneouscharging of multiple batteries through individual charging ports, providing flexibilityand cost efficiency.In accordance with an embodiment of the present invention, wherein the control systemconfigured to monitor and log battery health parameters including state-of-charge,cycle count, and temperature; validate successful battery swaps by confirming properelectrical contact and seating; detect faults; and generate operator alerts in case ofmislanding or swap failure. The control system records operational metrics andactuator movement data for predictive maintenance.In accordance with an embodiment of the present invention, wherein the networkinterface configured for secure, encrypted communication between the docking station,the drone, ground control units, and cloud servers. The network interface enables real-timemonitoring, diagnostics, and coordinated deployment across multiple distributeddocking sites.In accordance with an embodiment of the present invention, the system integratesautonomous landing, precision alignment, lifting-based battery swapping, batteryhealth diagnostics, mission-aware decision-making, and networked operation into amodular, scalable, and low-maintenance docking platform, providing a robust solutionfor automated UAV operations.In references to the Fig's, Fig. 1 illustrates a autonomous docking and battery swappingsystem (100) for drones, comprising a main frame (102) configured to providestructural support and serve as the base platform for all docking and battery swappingoperations. Mounted over the main frame (102) is a canopy frame assembly (104),which includes a back cover, main cover, left cover plate, right cover plate, back coverplate, telescopic rails, and a linear actuator, the canopy being configured to provideenvironmental protection and controlled enclosure opening and closing during dronedocking and battery swapping. The system includes a drone assembly (106),comprising a drone body with a battery compartment and a battery pack assemblyconfigured for autonomous flight, landing, and communication with the dockingstation. A drone alignment assembly (108) is provided, comprising an X-alignmenttube, X-alignment mechanism link, Y-alignment tube, Y-alignment mechanism,landing platform, and X-alignment mechanism assembly, configured to ensure precisepositioning of the drone on the landing platform using fiducial markers and mechanicalalignment components.A lifting mechanism assembly (110) comprising a top support plate, bottom supportplate, side support assembly, and linear actuator, which raises or lowers the batteryswapping unit (112) relative to the drone during docking operations. The batteryswapping assembly (112) comprises a battery compartment assembly, Y-axis batteryswapping assembly, and linear-actuator-based mechanism, configured to remove adepleted battery from the drone and insert a fully charged battery without employingrotating carousels. The system comprises a battery storage and charging module forstoring multiple commercial off-the-shelf batteries in modular housings andsimultaneously charging them through individual ports. A control system monitors andlogs battery health parameters, validates successful battery swaps, detects faults, andalerts an operator in case of mis landing or swap failure. Finally, a network interfaceenables communication between the drone, docking station, ground control units, andcloud systems, thereby supporting scalable deployment across multiple distributeddocking sites.Fig. 2 illustrates the canopy frame assembly (104) of the autonomous docking andbattery swapping system, showing an exploded view of its components mounted overthe main frame (102). The assembly includes a back cover (120), main cover (122), leftcover plate (124), right cover plate (126), back cover plate (128), telescopic rails (130),and a linear actuator (132). The back cover (120) and main cover (122) form the topenclosure of the canopy, while the left (124) and right cover plates (126), along withthe back cover plate (128), provide side and rear protection. The telescopic rails (130)facilitate smooth sliding of the canopy components during opening and closingoperations, and the linear actuator (132) is configured to automate the movement of thecanopy, enabling controlled exposure or protection of the docking and batteryswapping components. The exploded view depicts the spatial arrangement andinterconnection of all these components within the canopy frame assembly (104)highlighting their functional integration for environmental protection and precisemechanical operation.Fig. 3 illustrates the drone assembly (106), showing the battery pack replacementmechanism. The drone (106) includes a battery compartment (134) configured toreceive a removable battery pack assembly (136). The battery compartment (134) ispositioned beneath the drone's main body to allow easy insertion and removal of thebattery pack assembly (136) for rapid power replenishment. The exploded viewhighlights the alignment of the battery pack assembly (136) with the batterycompartment (134) to ensuring secure electrical and mechanical connection duringoperation, while facilitating quick swapping during autonomous docking and chargingprocedures.FIG. 4 illustrates the Drone Alignment Assembly (108) of the autonomous docking andbattery swapping system (100). In accordance with an embodiment of the presentinvention, the alignment assembly (108) comprises an X-alignment tube (138) and aY-alignment tube (140) configured to guide the drone (106) into a precise position onthe landing platform (148). The X-alignment mechanism link (142) and Y-alignmentmechanism (144) are connected to their respective alignment tubes and are adapted tocorrect residual positional errors using mechanical movements. The X-alignmentmechanism assembly (146) provides structural support and facilitates motiontransmission along the X-axis for precise correction. Fiducial markers positioned onthe platform and drone enable visual or sensor-based verification of alignment. Theassembly (108) ensures accurate positioning of the drone (106) by compensating forminor landing deviations and generating alerts in case of misalignment, therebysupporting reliable and repeatable battery swapping operations.FIG. 5 illustrates the lifting mechanism assembly (110) of the autonomous docking andbattery swapping system (100). In accordance with an embodiment of the presentinvention, the lifting mechanism assembly (110) comprises a top support plate (150)and a bottom support plate (152) configured to provide structural rigidity and securemounting points for the battery swapping assembly (112). A side support assembly(154) connects the top and bottom plates and guides the vertical motion of theassembly. A linear actuator (156) is operatively coupled to the support plates and sideassembly, the actuator being configured to raise or lower the battery swappingassembly (112) precisely relative to the drone (106) during docking operations. Thelifting mechanism assembly (110) ensures accurate vertical alignment for batteryinsertion and removal, compensates for minor height variations during landing, andenables controlled, repeatable battery swapping operations.FIG. 6 illustrates the battery swapping assembly (112) of the autonomous docking andbattery swapping system (100). In accordance with an embodiment of the presentinvention, the battery swapping assembly (112) comprises a battery compartmentassembly (158) configured to securely hold the drone's battery during exchangeoperations. The assembly includes a Y-axis battery swapping unit (160) and a linearactuator-driven battery insertion / removal mechanism (162), the mechanism beingconfigured to remove a depleted battery from the drone's battery compartment (106)and insert a fully charged battery without employing rotating or carousel-based systemsto align precisely with the drone's battery compartment, ensure electrical contactengagement, and verify proper seating of the battery before redeployment. The batteryswapping assembly (112) thus enables rapid, hot-swappable battery exchange whilemaintaining reliability and repeatability in autonomous docking operations.Key specifications:The Docking and Battery Swapping Station (DBSS) serve as the critical groundinfrastructure that enhances the operational endurance of the drone system. Designedfor harsh environments and demanding applications, the DBSS enables continuousaerial monitoring without human intervention, thereby transforming the approach tosecuring and observing critical areas. The system supports automated missionexecution with waypoint planning and dynamic in-flight updates, hot-swappablebattery technology to maintain uninterrupted operations, precision landing using GPScombined with fiducial-marker guidance, and mesh-network communications betweenthe drone, DBSS, ground control station, and cloud systems with AES-128 / 256encryption. The DBSS incorporates failsafe and redundancy mechanisms to ensureoperational reliability.Applications: The Docking and Battery Swapping Station (DBSS) is capable ofsimultaneously charging three batteries using a smart Battery Management System(BMS), ensuring that multiple UAVs can be maintained in operational readiness forcontinuous surveillance missions.Convoy Escort and Patrol: The system supports convoy escort and patrol operations,providing persistent aerial monitoring to safeguard convoys and critical transportroutes.Forward Operating Base (FOB) Perimeter Security: The DBSS enables forwardoperating base perimeter security by delivering real-time surveillance and threatdetection around military or strategic installations.Remote Border Outpost Reconnaissance: The system is suitable for remote borderoutpost reconnaissance, allowing persistent monitoring of difficult-to-access or highriskborder areas without requiring personnel to be physically present.Critical Infrastructure Monitoring: Additionally, the DBSS facilitates criticalinfrastructure monitoring, supporting inspection and security of power plants,pipelines, telecommunication towers, and other sensitive facilities, thereby enhancingsituational awareness and operational safety.Advantages:The autonomous docking and battery swapping system provides continuous aerialmonitoring without human intervention, enabling truly persistent 24 / 7 surveillance inharsh or remote environments.Hot-Swappable Battery Technology: The system supports rapid replacement ofdepleted batteries in under 90 seconds, ensuring uninterrupted UAV operations andmaximizing mission endurance.Precision Landing: GPS combined with fiducial-marker guidance provides high-accuracylanding, reducing reliance on complex mechanical alignment systems andensuring safe docking even in challenging conditions.Secure Communications: Mesh-network communications with AES-128 / 256encryption enable secure, real-time coordination between drones, docking stations,ground control, and cloud systems for scalable deployment.Reliability and Fault Management: Built-in failsafe mechanisms, redundancy, andonboard diagnostics enable proactive fault detection, ensuring drones are alwaysmission-ready.Modular and Scalable Design: The docking station and battery storage system aremodular, allowing easy scalability and maintenance while accommodating multiplecommercial off-the-shelf batteries, avoiding dependence on proprietary formats orcomplex carousel systems.Mission-Aware Logic Integrated mission-aware logic ensures drones areautonomously redeployed, held in dock, or alerted for operator intervention based onoperational priorities, optimizing continuous surveillance and operational efficiency.

Claims

1. An autonomous docking and battery swapping system (100) for drones, comprising: a main frame (102) configured to provide structural support and act as the base platform for docking and battery swapping operations; characterized inthat a canopy frame assembly (104) mounted over the main frame, comprising a back cover (120), main cover (122), left cover plate (124), right cover plate (126), telescopic rails (130), back cover plate (128), and a linear actuator (132), the canopy frame assembly (104) being configured to provide environmental protection and controlled enclosure opening and closing during drone docking and battery swapping; a drone assembly (106) comprising a drone body having a battery compartment (134) and a battery pack assembly (136) configured for autonomous flight, landing, and communication with the docking station; a drone alignment assembly (108) comprising an X-alignment tube (138), Xalignment mechanism link (142), Y-alignment tube (140), Y-alignment mechanism (144), landing platform, and X-alignment mechanism assembly, wherein the alignment assembly is configured to ensure precise positioning of the drone on the landing platform using fiducial markers and mechanical alignment components; a lifting mechanism assembly (110) comprising a top support plate (150), bottom support plate (152), side support assembly (154), and linear actuator, (156), is configured to raise or lower the battery swapping unit relative to the drone during docking operations; a battery swapping assembly (112) comprising a battery compartment assembly (158), Y-axis battery swapping assembly (160), and battery swapping assembly (162) configured to remove a depleted battery from the drone's battery compartment and insert a fully charged battery using a direct linear actuator mechanism without employing rotating carousels; a battery storage and charging module configured to store multiple commercial off-the-shelf batteries in modular housings and simultaneously charge them through individual charging ports; a control system configured to monitor and log battery health parameters including state-of-charge, cycle count, and temperature, verify successful battery swap, detect faults, alert an operator in case of mis landing or swap failure; a network interface configured for communication between the drone, docking station, ground control unit, and cloud system, enabling scalable deployment across multiple distributed docking sites.

2. The system (100) as claimed in claim 1, wherein the drone alignment assembly (108) is configured to correct residual landing errors through mechanical alignment bars and generate alerts in case of misalignment.

3. The system (100) as claimed in claim 1, wherein the lifting mechanism assembly (110) employs a direct linear actuator to raise or lower the battery swapping assembly (112) for precise alignment with the drone (106) battery compartment.

4. The system (100) as claimed in claim 1, wherein the battery swapping assembly (112) is configured to perform hot-swappable battery exchange using a linear actuator without rotating or carousel-based mechanisms.

5. The system (100) as claimed in claim 1, wherein the canopy frame assembly (104) includes telescopic rails and a linear actuator configured to automate enclosure movement to protect the docking components from environmental exposure.

6. The system (100) as claimed in claim 1, wherein the control system is configured to validate successful battery swap by confirming electrical contact engagement and proper seating of the new battery before redeployment.

7. The system (100) as claimed in claim 1, wherein the control system is configured to record operation logs, battery usage metrics, and actuator movement data for predictive maintenance.

8. The system (100) as claimed in claim 1, wherein the network interface supports secure, encrypted communication between the docking station (100), drone (106), and remote operator console for real-time monitoring and diagnostics.

9. The system (100) as claimed in claim 1, wherein the battery storage and charging module includes modular racks with interchangeable battery housings to accommodate multiple drone models.

10. The system (100) as claimed in claim 1, wherein the system (100) integrates autonomous landing, precision alignment, lifting-based battery swapping, battery health diagnostics, and mission-aware decision-making into a modular, scalable, and low-maintenance docking platform.