Robotic charging system, robotic system and charging station for statically stable charging of the robotic system

Abstract

A robotic charging system is described comprising a charging station and a robotic system configured to dock with the charging station. The charging station includes a base and a structural tab extending from the base. The robotic system includes a receptacle dimensioned to receive the structural tab. During docking, the structural tab mechanically engages with the receptacle to support at least a portion of the weight of the robotic system while simultaneously establishing electrical connectivity. The charging station further includes electrical contacts disposed along the structural tab that mate with corresponding contacts within the receptacle, the contacts configured to facilitate transfer of charging current and data communication between the charging station and the robotic system. The structural arrangement facilitates the robotic system to remain in a statically stable docked orientation, thereby enabling recharging, data transfer, or calibration while one or more actuators of the robotic system are powered down.

Description

P03008-1NWO (128729-1902) PATENTSYSTEMS AND METHODS FOR STATICALLY STABLE CHARGING OFROBOTIC SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 690,250, filed September 3, 2024, which is incorporated by reference in its entirety.TECHNICAL FIELD

[0002] This application relates generally to charging systems for autonomous humanoid robots.BACKGROUND

[0003] Humanoid robots are increasingly designed to perform autonomous tasks in industrial and consumer environments. A common requirement for such robots is autonomous charging, which allows the robot to restore energy reserves without human intervention. Traditional robotic charging systems typically involve the robot returning to a fixed charging station. In these cases, the robot remains statically stable when powered off, and therefore does not require external mechanical support during charging.

[0004] Humanoid robots present a challenge for autonomous charging. Unlike statically stable mobile robots, humanoid robots may require active control of joints and actuators to remain upright and balanced. When power to the actuators is removed, the joints can become limp and unstable, causing the humanoid robot to collapse under its own weight. As a result, conventional charging docks designed for statically stable robots are not suitable for humanoid robot applications.

[0005] Additional requirements arise when humanoid robots undergo software updates, motor calibration, or safety checks. In various situations, these operations are performed while the robot is connected to a reliable power source, yet the robot may need to remain powered off or with motors disengaged during such procedures. Without mechanical support from an external structure, the robot may be unable to safely maintain balance in these scenarios.SUMMARY

[0006] For the aforementioned reasons, there is a need for improved methods and systems for a charging system that facilitates autonomous docking of a humanoid robot and, in4936-6722-8771.1 - 1 -P03008-1NWO (128729-1902) PATENT some embodiments, also provides structural support so that the robot can disengage its motors while remaining upright. It is understood that the implementations of the systems and methods described herein may satisfy more, fewer, or different needs than those improvements described above without departing from the scope of the descriptions herein.

[0007] In some aspects, the techniques described herein relate to a robotic charging system including: a charging station including: a base; and a structural tab coupled to the base of the charging station angled upward relative to the base of the charging station; and a robotic system including: a receptacle dimensioned to slidably receive the structural tab along a first direction, wherein, in a docked position, the structural tab supports at least a portion of a weight of the robotic system in a cantilevered orientation and maintains alignment between the charging station and the receptacle to permit electrical contact for charging.

[0008] In some aspects, the techniques described herein relate to a robotic charging system, wherein the structural tab is disposed at an angle greater than 25 degrees and less than 65 degrees relative to a first face of the base of the charging station.

[0009] In some aspects, the techniques described herein relate to a robotic charging system, wherein the charging station further includes one or more arms configured to provide coarse alignment of the robotic system in a lateral direction prior to engagement with the structural tab.

[0010] In some aspects, the techniques described herein relate to a robotic charging system, wherein the structural tab includes: a steel core extending within the structural tab from a first end toward a second end; and a polymer overmold surrounding at least a portion of the steel core.

[0011] In some aspects, the techniques described herein relate to a robotic charging system, wherein the structural tab includes a tapered end tapering from a first end to a second end and configured to provide fine alignment in a lateral direction during engagement of the receptacle with the structural tab.

[0012] In some aspects, the techniques described herein relate to a robotic charging system, wherein the charging station further includes a set of electrical contacts positioned between a first end of the structural tab and a second end of the structural tab, the set of electrical contacts including: at least two power contacts configured to carry a charging current and engage with corresponding power contacts within the receptacle; and at least two4936-6722-8771.1 - 2 -P03008-1NWO (128729-1902) PATENT communication contacts configured to carry data signals and engage with corresponding communication contacts within the receptacle, wherein the at least two communication contacts are positioned such that the at least two communication contacts disengage from the corresponding communication contacts prior to the at least two power contacts disengaging from the corresponding power contacts.

[0013] In some aspects, the techniques described herein relate to a robotic charging system, wherein the at least two power contacts extend farther toward the second end than the at least two communication contacts such that, during undocking, the at least two communication contacts are disengaged from the corresponding communication contacts prior to disconnection of the at least two power contacts such that communication is terminated prior to disconnection of the at least two power contacts.

[0014] In some aspects, the techniques described herein relate to a robotic charging system, wherein the charging station includes one or more high-contrast visual markers configured to be detected by a rear-facing camera of the robotic system.|0015[ In some aspects, the techniques described herein relate to a robotic charging system, wherein the receptacle is positioned between two or more shoulder structures of the robotic system.

[0016] In some aspects, the techniques described herein relate to a robotic charging system, wherein the charging station and the receptacle are configured to support docking procedures in which the robotic system performs a backward walking motion followed by a squatting motion to fully engage the structural tab.

[0017] In some aspects, the techniques described herein relate to a robotic charging system, wherein the structural tab is dynamically coupled to the base of the charging station, wherein the base of the charging station is statically coupled to a support surface.

[0018] In some aspects, the techniques described herein relate to a robotic charging system, further including: a mating tab coupled to the robotic system; wherein the structural tab includes: a first apex; a second apex; and a mating channel positioned between the first apex and the second apex, and having a profile corresponding to the mating tab such that the mating tab is received within the mating channel in the docked position.

[0019] In some aspects, the techniques described herein relate to a robotic charging system, wherein the mating tab and the mating channel are positioned such that in the docked4936-6722-8771.1 - 3 -P03008-1NWO (128729-1902) PATENT position, at least one contact of the charging station is electrically coupled to a corresponding contact the robotic system.

[0020] In some aspects, the techniques described herein relate to a robotic system including: a receptacle disposed on a back portion of the robotic system, the receptacle being dimensioned to slidably receive a structural tab of a charging station along a docking path; and at least one electrical contact positioned within the receptacle and configured to engage a corresponding electrical contact of the structural tab in a docked position; wherein, in the docked position, the receptacle cooperates with the structural tab to mechanically support at least a portion of a weight of the robotic system in a cantilevered orientation while maintaining electrical connectivity such that robotic system remains statically stable when one or more actuators of the robotic system are powered down.

[0021] In some aspects, the techniques described herein relate to a robotic system, wherein the robotic system includes a rear-facing camera configured to detect visual features on the charging station to facilitate autonomous docking.

[0022] In some aspects, the techniques described herein relate to a robotic system, wherein the robotic system includes one or more load sensors disposed in legs of the robotic system, the one or more load sensors configured to measure a proportion of a weight of the robotic system supported by the structural tab during docking.

[0023] In some aspects, the techniques described herein relate to a robotic system, wherein the robotic system is configured to perform a calibration routine while docked, the calibration routine including maintaining a partial weight distribution on the structural tab while recalibrating a kinematic chain including a rear-facing camera of the robotic system.

[0024] In some aspects, the techniques described herein relate to a charging station for providing electrical power to a humanoid robotic system including: a base; an arm extending from the base of the charging station in a first direction; and a structural tab angled upward relative to the base of the charging station; wherein, in a docked position, the structural tab supports at least a portion of a weight of the humanoid robotic system in a cantilevered orientation and maintains alignment between the charging station and a receptacle of the humanoid robotic system to permit electrical contact for charging and communication.4936-6722-8771.1 - 4 -P03008-1NWO (128729-1902) PATENT

[0025] In some aspects, the techniques described herein relate to a charging station, wherein the arm includes a tapered end configured for directing the humanoid robotic system toward a mounting position.10026] In some aspects, the techniques described herein relate to a charging station, the structural tab is slidably coupled to the base such that the structural tab extends in the first direction when engaging with the humanoid robotic system.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Non-limiting embodiments of the present disclosure are described by way of example with reference to the accompanying figures, which are schematic and are not intended to be drawn to scale. Unless indicated as representing the background art, the figures represent aspects of the disclosure.

[0028] FIG. 1 illustrates a robotic charging system including a robotic system and a charging station, according to an embodiment.

[0029] FIG. 2 illustrates a cross-sectional view of a structural tab engaged with a receptacle, according to an embodiment.

[0030] FIG. 3 illustrates a receptacle with electrical contacts, according to an embodiment.

[0031] FIG. 4 illustrates a perspective view of a structural tab with electrical contact regions, according to an embodiment.

[0032] FIG. 5 illustrates a side view of a robotic system approaching a charging station along a docking path, according to an embodiment.

[0033] FIG. 6 illustrates a perspective view of a robotic system with a mating tab configured for docking, according to an embodiment.

[0034] FIG. 7 illustrates a perspective view of a robotic system including a mating tab, according to an embodiment.

[0035] FIG. 8 illustrates a perspective view of a charging station including a mating channel, according to an embodiment.

[0036] FIG. 9A illustrates a side view of a robotic system aligning a mating tab with a mating channel, according to an embodiment.4936-6722-8771.1 - 5 -P03008-1NWO (128729-1902) PATENT

[0037] FIG. 9B illustrates a top view of the robotic system and charging station of FIG. 9A, according to an embodiment.

[0038] FIG. 10A illustrates a side view of a robotic system lowering a mating tab into a mating channel, according to an embodiment.

[0039] FIG. 10B illustrates a top view of the robotic system and charging station of FIG. 10A, according to an embodiment.

[0040] FIG. 11A illustrates a perspective view of a robotic system fully docked with a charging station, according to an embodiment.

[0041] FIG. 11B illustrates a top view of the robotic system and charging station of FIG. 11 A, according to an embodiment.DETAILED DESCRIPTION

[0042] Reference will now be made to some embodiments illustrated in the drawings, and specific language will be used here to describe the same. It will nevertheless be understood that no limitation of the scope of the embodiments of the methods and systems described herein is thereby intended. Alterations and further modifications of the features illustrated here, and additional applications of the principles of the embodiments of the methods and systems described herein, as illustrated here, which would occur to a person skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the embodiments, methods, and / or systems described herein.

[0043] The embodiments described herein relate to docking systems for humanoid and other robotic systems. The disclosed charging system includes a charging station with a structural tab with integrated power and / or communication connectors and a corresponding receptacle disposed on / within the robotic system. The receptacle is dimensioned to receive the structural tab along a docking path such that, in a docked position, the structural tab supports at least a portion of the weight of the robotic system (e.g., a humanoid robotic system) in a cantilevered orientation. This structural engagement allows the robotic system to remain statically stable while one or more actuators of the robotic system are powered down, thereby facilitating safe charging, software updates, and / or calibration procedures without requiring continuous motor actuation. In certain embodiments, the charging station further incorporates alignment features such as funnel arms, planar hardstops, and / or tapered geometries to guide the docking motion of the robotic system to a mounting position relative to the charging station4936-6722-8771.1 - 6 -P03008-1NWO (128729-1902) PATENT during docking. Electrical contacts positioned within the structural tab and the receptacle provide both power transfer and data communication, facilitating reliable charging while maintaining mechanical support.

[0044] FIG. 1 illustrates a robotic charging system 100 (e.g., a humanoid robotic system). The robotic charging system 100 is configured to provide mechanical support and electrical power transfer to a robotic system during docking of the robotic system, such as autonomous and / or semi-autonomous docking. The robotic charging system 100 includes a charging station 102 and a robotic system 103 that cooperates with the charging station 102 to achieve a docked / mounting position suitable for charging, communication, and statically stable support.

[0045] The robotic system 103 may be implemented as a humanoid robot or other robotic platform configured to perform autonomous and / or semi-autonomous tasks. In various embodiments, the robotic system 103 can be employed for industrial automation, warehouse logistics, manufacturing support, or consumer service applications. A humanoid form factor may be particularly advantageous for environments designed around human ergonomics, enabling the robotic system 103 to interact with tools, machinery, or infrastructure originally designed for human operation. In such embodiments, the robotic system 103 can perform tasks such as transporting goods, operating equipment, conducting inspections, and / or assisting human workers. The robotic system 103 may further include one or more sensors, cameras, or control modules to support autonomous navigation, perception, and interaction with its environment.(0046] The robotic system 103 can further include an electrical storage system configured to store energy for powering one or more actuators, sensors, and control modules of the robotic system 103. The electrical storage system may comprise one or more rechargeable battery packs integrated within the robotic system 103 (e.g., the torso portion of the robotic system 103). During docking of the robotic system 103 to the charging station 102, the electrical storage system is electrically coupled to the charging station 102 through electrical contacts, enabling the electrical storage system to receive charging current from the charging station 102. In this manner, the robotic system 103 can autonomously replenish its stored energy reserves to support extended operation without manual intervention.(0047] In some embodiments, it may be beneficial for the robotic system 103 to be charged while standing upright (e.g., in a standing position), or in another statically unstable4936-6722-8771.1 - 7 -P03008-1NWO (128729-1902) PATENT position (e.g., not balanced), with one or more actuators powered down. Unlike statically stable robots such as wheeled platforms, humanoid robots (e.g., the robotic system 103) may, in some embodiments, require continuous motor actuation to maintain balance when not externally supported. This results in significant idle power consumption, diverting available energy away from battery charging.(0048] The charging station 102 may be configured with one or more support members to mechanically support the robotic system 103 when docked to the charging station 102. By mechanically supporting the robotic system 103 in the docked position, the robotic charging system 100 allows the robotic system 103 to disengage its actuators while remaining upright and mechanically stable, as the robotic system 103 is supported above its center of gravity by the charging station 102. This configuration reduces unnecessary power draw, increases the rate of battery charging, and decreases wear on motors and joints. In addition, allowing the robotic system 103 to remain in the standing (or semi-standing) position while powered down enables software updates, calibration, or diagnostic routines to be performed safely with a reliable external power connection.(0049] The robotic system 103 includes a receptacle 106 dimensioned to receive a structural charging tab (e.g., a structural tab 104) of the charging station 102. The receptacle 106 may be formed within a body portion of the robotic system 103 and is configured to establish both mechanical engagement and electrical connectivity when mated with the structural tab 104, as described herein. In some embodiments, the receptacle 106 is positioned on an upper back portion of the robotic system 103 between a pair of shoulder structures (e.g., two or more shoulder structures). Locating the receptacle 106 in this position can provide mechanical protection during unintended events such as a fall or a collision with proximate objects (e.g., a wall, door, machine, or vehicle). For example, in a humanoid implementation of the robotic system 103, two or more shoulder structures may include outwardly extending protrusions that mimic the anatomical profile of human shoulder blades. These protrusions extend beyond the receptacle 106 such that, if the robotic system 103 falls onto its back, the shoulder structures contact the support surface before the receptacle 106. This arrangement prevents the receptacle 106 from sustaining direct impact forces, thereby reducing the risk of structural damage or misalignment of electrical contacts. In other embodiments, the receptacle 106 may be recessed into a cavity defined in the back surface of the robotic system 103, further reducing exposure and providing a smooth exterior profile while still allowing engagement with the structural tab 104 during charge docking. Although the example embodiments may4936-6722-8771.1P03008-1NWO (128729-1902) PATENT describe the location of the receptacle on the back portion of the robotic system, it is intended that there are other configurations consistent with this disclosure where the receptacle can be located on a front portion.

[0050] The robotic charging system 100 includes the charging station 102. The charging station 102 is configured to provide structural support and electrical connectivity to the robotic system 103 during docking. The charging station 102 includes a base 120 that may be mounted to or rest upon a support surface and a docking interface (e.g., the structural tab 104) dimensioned to mate with the receptacle 106 of the robotic system 103. In a docked position, the charging station 102 supports at least a portion of the weight of the robotic system 103 while also establishing electrical contact to permit charging and communication. By combining mechanical support with electrical functionality, the charging station 102 facilitates the robotic system 103 to be charged while standing and with one or more actuators powered down, thereby improving energy efficiency and providing a statically stable positioning for software updates.

[0051] The robotic charging system 100 includes the base 120. The base 120 provides structural stability for the charging station 102 and is configured to support engagement between the structural tab 104 and the receptacle 106 of the robotic system 103. In some embodiments, the base 120 is statically mounted to a support surface such as a floor, wall, or equipment frame, thereby forming a rigid base capable of bearing loads transferred from the robotic system 103 during docking. In other embodiments, the base 120 may be dynamically coupled to a support surface, for example, through a sliding track, hinge, or adjustable bracket, to allow repositioning of the charging station 102 relative to the robotic system 103. The base 120 may be formed from rigid materials such as steel (e.g., a steel core), aluminum, or reinforced composites and may further include mounting apertures, flanges, or other securing features to fix the charging station 102 in place. In some embodiments, the base 120 comprises mounting apertures spaced 16-24 inches laterally along the base such that mounting fasteners may be coupled to structural components (e.g., studs) and thereby couple to the mounting apertures and provide structurally secure mounting for the charging station 102.

[0052] The base 120 may include one or more alignment arms, shown as an alignment arm 108. The alignment arm 108 extends outward from the base 120 and is configured to facilitate coarse alignment of the robotic system 103 relative to the charging station 102 during docking toward a mounting position. Structurally, the alignment arm 108 may comprise a rigid4936-6722-8771.1 - 9 -P03008-1NWO (128729-1902) PATENT member formed from metal, polymer, or a composite material, and may define a tapered or funnel-like geometry that narrows toward a central axis of the charging station 102 and / or the structural tab 104. The alignment arm 108 provides one or more guiding surfaces that engage with a corresponding portion of the robotic system 103 as the robotic system 103 approaches the charging station 102. This guiding interaction reduces lateral misalignment and directs the receptacle 106 of the robotic system 103 toward the structural tab 104. In some embodiments, the alignment arm 108 may be spring-loaded or otherwise compliant to absorb minor docking impacts and to accommodate positional tolerances.[00531 The alignment arm 108 is configured to facilitate positional adjustments of the robotic system 103 relative to the charging station 102 as the robotic system 103 approaches docking. In some embodiments, the alignment arm 108 is shaped to accommodate lateral adjustments of the robotic system 103 in the range of several millimeters to several centimeters, thereby compensating for errors in approach trajectory or sensor localization. The alignment arm 108 may further allow minor angular adjustments about a vertical or yaw axis, facilitating that the receptacle 106 of the robotic system 103 is properly oriented with the structural tab 104 prior to engagement.

[0054] During docking, the alignment arm 108 engages with an exterior portion of the robotic system 103, such as a side surface (e.g., a torso region) or rear housing region adjacent to the receptacle 106. As the robotic system 103 moves into position, the alignment arm 108 guides the robotic system 103 into a narrowed region proximate the structural tab 104, thereby fixing the lateral position of the robotic system 103 relative to the charging station 102. Once fully docked, the robotic system 103 is held adjacent to or in contact with the alignment arm 108 such that the robotic system 103 is positionally constrained in a lateral direction. In this configuration, the alignment arm 108 cooperates with the base 120 and structural tab 104 to maintain the robotic system 103 in a stable, repeatable orientation suitable for both mechanical support and electrical connectivity.

[0055] In some embodiments, a portion of the base 120, such as the alignment arm 108, may be slidably coupled to the structural tab 104. In such configurations, the alignment arm 108 is mounted on a sliding mechanism, track, or compliant linkage that allows the alignment arm 108 to translate rearward as the robotic system 103 physically engages with the charging station 102. During docking, the robotic system 103 initially contacts the alignment arm 108, which provides coarse positional guidance. As forward force is applied by the robotic system4936-6722-8771.1 - 10 -P03008-1NWO (128729-1902) PATENT103, the alignment arm 108 retracts or slides relative to the structural tab 104, thereby exposing the structural tab 104 for engagement with the receptacle 106. Once the structural tab 104 is received within the receptacle 106, the alignment arm 108 may return to its initial position or remain in a retracted state, depending on the embodiment. This sliding configuration permits the alignment arm 108 to serve a dual purpose of guiding the robotic system 103 into proper alignment while also preventing obstruction of the structural tab 104 during final engagement. In some embodiments, the alignment arm provides for lateral adjustments from 5-100 mm of misalignment during docking. The structural tab 104 provides for further fine adjustment during the final stages of docking.

[0056] As described, the charging station 102 includes the structural tab 104. The structural tab 104 is configured to facilitate both mechanical support and electrical connectivity between the charging station 102 and the robotic system 103. Structurally, the structural tab 104 extends upward and outward from the base 120 along a central axis and is dimensioned to be slidably received within the receptacle 106 of the robotic system 103. In some embodiments, the structural tab 104 is oriented at an upward angle relative to the base 120 (e.g., at 45°), such that the robotic system 103 is supported in a cantilevered orientation when docked. The angled orientation prevents unintentional slip-off of the robotic system 103 while still permitting autonomous undocking when commanded.

[0057] The structural tab 104 may include a tapered leading end that narrows toward the distal tip of the tab. This taper provides a guiding geometry that facilitates fine alignment of the receptacle 106 during the final stages of docking, complementing, in some embodiments, the coarse alignment functions of the alignment arm 108. The tapered geometry also reduces the binding or jamming during engagement.

[0058] In some embodiments, the structural tab 104 comprises a rigid core, such as a steel core or aluminum insert, surrounded by a polymer overmolded shell. The rigid core provides the necessary load-bearing capacity to support at least a portion of the weight of the robotic system 103 (e.g., 100-300 lbs.), while the polymer shell reduces wear, distributes contact forces, and provides electrical insulation around the core. Other embodiments may utilize composite laminates, reinforced plastics, or multi-material structures to achieve similar performance.

[0059] The structural tab 104 may be oriented at an angle greater than 25 degrees and less than 65 degrees relative to the base 120. Positioning the structural tab 104 within this4936-6722-8771.1 - 11 -P03008-1NWO (128729-1902) PATENT angular range allows the robotic system 103 to be reliably retained in the docked position without slipping under its own weight, while also facilitating autonomous undocking of the robotic system.|0060| The structural tab 104 further defines a surface region for electrical contacts positioned along one or more sides of the tab (as further described herein). These electrical contacts are configured to engage corresponding contacts positioned within the receptacle 106 when the robotic system 103 is docked. In some implementations, the contacts on the structural tab 104 include elongated conductive pads or bus bars, while the receptacle 106 includes compliant spring contacts that deflect against the pads to establish a reliable electrical connection. The positioning of the contacts along the structural tab 104 allows for simultaneous engagement of mechanical and electrical features during docking.

[0061] The robotic system 103 further includes a robot body 118 that houses actuators, electronics, and / or an electrical storage system of the robotic system. The receptacle 106 may be disposed within the robot body 118 such that it structurally integrates with the load-bearing frame of the robotic system while maintaining accessibility for engagement with the structural tab 104. Positioning the receptacle 106 within the robot body 118 in this manner provides structural rigidity while also protecting the receptacle from damage.

[0062] The structural tab 104 includes a first taper 110 defined along a forward-facing portion of the tab. The first taper 110 narrows the distal end of the structural tab and provides a guiding surface that facilitates initial insertion of the tab into the receptacle 106. The first taper 110 directs the receptacle 106 toward the mounting axis 112, thereby compensating for minor misalignments during the approach and reducing the likelihood of jamming.

[0063] The structural tab 104 may further include a second taper 116 defined along a lateral or side portion of the tab. The second taper 116 provides an additional guiding geometry that permits the receptacle 106 to self-align laterally during docking. By allowing lateral displacement and correction as the receptacle descends, the second taper 116 reduces binding and enhances the repeatability of autonomous docking procedures.

[0064] The structural tab 104 is oriented relative to a mounting axis 112 that extends upward from the base 120. When docked, the robotic system 103 defines a central axis 114 that extends through the robot body 118. In some embodiments, the structural tab 104 is disposed at an angular offset relative to the central axis 114. This angular relationship biases the robotic system 103 into a stable, self-locking orientation when docked, such that gravity urges the4936-6722-8771.1 - 12 -P03008-1NWO (128729-1902) PATENT receptacle 106 downward along the structural tab 104. By maintaining this angular offset, the robotic charging system 100 prevents unintended slip-off and facilitates stable autonomous docking and undocking of the robotic system 103.

[0065] In some embodiments, the first taper 110, the second taper 116, and the angular offset defined between the mounting axis 112 and the central axis 114 cooperate with docking motions of the robotic system, such as a backward walking motion and a squatting motion. The backward walking motion aligns the receptacle 106 generally with the tapered leading end of the structural tab 104, while the squatting motion lowers the receptacle along the tapers until it seats fully over the tab. The tapers thereby guide the final engagement path, and the angular offset secures the robotic system in a gravity-assisted, self-locking orientation. Together, these features facilitate autonomous docking procedures without requiring precise actuator control during the final stages of engagement.

[0066] Turning now to FIG. 2, a system 200 is shown with a cross-section of a structural tab 204 inserted into a receptacle 206. Like parts shown in FIG. 2 may be substantially similar to like parts shown in FIG. 1. For example, the structural tab 204 may be substantially similar to the structural tab 104 described above with respect to FIG. 1, and the receptacle 206 may be substantially similar to the receptacle 106 described above with respect to FIG. 1. As shown, FIG. 2 illustrates additional detail of the internal configuration of the structural tab 204 and its engagement with the receptacle 206.

[0067] The structural tab 204 may include a rigid core (shown as a core 216) that extends along at least a portion of a length of the tab and provides structural strength sufficient to support some or all of the weight of the robotic system. Surrounding the core 216, the structural tab 204 may further include a polymer overmold layer (shown as shell 214) that provides electrical insulation, distributes contact forces, and reduces wear during repeated docking cycles. The receptacle 206 defines a cavity that is dimensioned to slidably receive the structural tab 204 and to retain the structural tab 204 in a cantilevered orientation (e.g., an angled cantilevered orientation) when the robotic system is docked.

[0068] In some embodiments, the structural tab 204 includes multiple sets of electrical contacts, such as power contacts and communication contacts, positioned along one or more sides of the structural tab 204. The power contacts may be configured as wide conductive pads or bus bars sized to carry higher current suitable for charging the electrical storage system of4936-6722-8771.1 - 13 -P03008-1NWO (128729-1902) PATENT the robotic system. The communication contacts may be configured as narrower conductive pads or terminals positioned adjacent to, but electrically isolated from, the power contacts.

[0069] The receptacle 206 includes corresponding compliant contacts, such as spring- loaded pins or leaf springs, that are configured to deflect against the power contacts and communication contacts of the structural tab 204. In some implementations, the power contacts on the structural tab 204 extend farther toward the distal end of the structural tab 204 than the communication contacts. In this embodiment, during undocking, the communication contacts disengage first, thereby terminating data communication prior to disconnection of the power contacts. Such staggered sequencing reduces the risk of arcing or data corruption when the robotic system disconnects from the charging station. Similarly, during docking, the communication contacts may be configured to engage after initial contact between the power contacts, ensuring that stable power delivery is established before initiation of data exchange. It is understood that in other embodiments, the power contacts and the communication contacts may be positionally disposed such that communication is initiated prior to power (e.g., the communication contact is positioned farther toward the distal end of the structural tab 204 than the power contact).

[0070] As further illustrated in FIG. 2, the receptacle 206 and / or the structural tab 204 defines a depth 224 corresponding to the insertion length of the structural tab 204 when the robotic system is in the docked position. The depth 224 may be about 5-100 millimeters. This depth provides sufficient overlap between the structural tab 204 and the receptacle 206 to maintain stable mechanical support while distributing cantilevered forces along the interior walls of the receptacle 206.

[0071] The structural tab 204 defines a depth 210 measured between opposing faces of the tab. The depth 210 at the electrical contact point may be about 5-100 millimeters, while a distance 218 at the receptacle 206 opening may be about 5-100 millimeters. These dimensions facilitate insertion of the structural tab 204 into the receptacle 206 while maintaining a compact overall profile.

[0072] The structural tab 204 is oriented at an angle 208 relative to the base 120 of the charging station. The angle 208 may be about 45° (±2 degrees) from vertical. In other embodiments, the angle 208 may be between 35-75°. At this angle, gravitational forces acting on the robotic system are directed into the receptacle 206, preventing the robotic system from4936-6722-8771.1 - 14 -P03008-1NWO (128729-1902) PATENT slipping off the structural tab 204 under its own weight, while still allowing controlled disengagement. The structural tab 204 may include a draft of about 5-10°.

[0073] The structural tab 204 further includes one or more electrical contacts disposed along its surface. These electrical contacts may be configured as conductive bus bars extending longitudinally along the structural tab 204. Correspondingly, the receptacle 206 includes compliant electrical contacts, such as spring-biased contact elements, positioned within the cavity. As the structural tab 204 is received within the receptacle 206, the compliant contacts of the receptacle 206 deflect against the conductive bus bars of the structural tab 204, thereby establishing a secure electrical connection. This arrangement allows for simultaneous mechanical and electrical engagement when the robotic system is docked to the charging station.

[0074] The robotic system, shown as robotic system 203, may include one or more conductors, shown as conductor 220, 222. The conductor 220, 222 may provide an electrical conduit from the power / communication contacts of the structural tab 204 to an energy storage device and / or controller of the robotic system 203. In some embodiments, the conductor 220 is a leaf spring or other compliant material that provides a biasing force against the communication / power contacts of the structural tab 204.

[0075] Turning now to FIG. 3, a perspective view of a receptacle 306 of a robotic system 303 is shown. Like parts shown in FIG. 3 may be substantially similar to like parts shown in FIGS. 1-2. For example, the receptacle 306 may be substantially similar to the receptacle 106, 206 described above with respect to FIGS. 1-2. Similarly, the robotic system 303 may be substantially similar to the robotic system 103, 203 described above with respect to FIGS. 1-2

[0076] As shown, the receptacle 306 defines an opening 318 bounded by an opening edge 316. The opening 318 is dimensioned to slidably receive a structural tab (e.g., structural tab 104, 204) along a docking axis 312. In some embodiments, the docking axis 312 may be oriented at an angle 314 relative to a vertical datum of the robotic system 303. The angled orientation provides clearance during insertion, and gravitational forces acting on the robotic system 303 are directed into the receptacle 306 to maintain statically stable support in the docked position.

[0077] The receptacle 306 further includes one or more electrical contacts, shown as contacts 308, 310. These contacts are disposed along interior surfaces of the receptacle 306 and4936-6722-8771.1 - 15 -P03008-1NWO (128729-1902) PATENT are positioned to engage corresponding power contacts and / or communication contacts disposed along a bottom surface of a structural tab. In some embodiments, the contacts 308, 310 are formed as spring-biased conductive pads, leaf springs, or pogo-pin style connectors that deflect upon insertion of the structural tab to establish a reliable electrical interface. The contacts 308, 310 may be arranged in pairs, with power contacts positioned toward lateral sides of the receptacle 306 and communication contacts positioned centrally, thereby ensuring electrical isolation while maintaining compact spacing.10078] The receptacle 306 may be recessed into a body portion of the robotic system 303 such that the opening edge 316 is flush or nearly flush with the surrounding body surface. This recessed configuration protects the receptacle 306 from incidental contact during normal operation and provides a smooth profile when the robotic system 303 is not docked. In some embodiments, the receptacle 306 is further reinforced by structural ribs or a surrounding frame integrated into the housing of the robotic system 303, allowing the receptacle 306 to absorb cantilevered loads transmitted through the structural tab without deformation or misalignment.

[0079] The receptacle 306 may also include draft angles (e.g., angle 314) along the interior surfaces adjacent to the opening 318 to facilitate smooth insertion of the structural tab and to reduce binding during docking. In certain embodiments, the draft angle may be between about 2° and about 10°, and in one embodiment, is approximately 5°. This geometry, combined with the tapered distal end of the structural tab, ensures that docking is repeatable and tolerant of minor misalignment.

[0080] Turning now to FIG. 4, a perspective view of a structural tab 404 of a charging station is shown. Like parts shown in FIG. 4 may be substantially similar to like parts shown in FIGS. 1-3. For example, the structural tab 404 may be substantially similar to the structural tab 104, 204 described above, and is dimensioned to be received within a corresponding receptacle (e.g., receptacle 106, 206, 306) of the robotic system.

[0081] The structural tab 404 extends between a first end 420 and a second end 407. The first end 420 is proximate to a base of the charging station, while the second end 407 defines a distal portion configured to be inserted into the receptacle. The structural tab 404 includes a tapered end 414 that narrows toward the second end 407. The tapered end 414 provides a guiding geometry that facilitates insertion into the receptacle and reduces the likelihood of binding during docking.4936-6722-8771.1 - 16 -P03008-1NWO (128729-1902) PATENT

[0082] The structural tab 404 defines opposing side surfaces, including a first side 418 and a second side 424, as well as one or more exterior surfaces, shown as surface 410 and surface 422 extending between the first end 420 and second end 407. Disposed along these surfaces are a set of electrical contacts, including the power contacts 408, 412, and at least two communication contacts, shown as communication contacts 426, 428. The power contacts 408, 412 are configured to carry a charging current sufficient to replenish an electrical storage system of the robotic system. The communication contacts 426, 428 are configured to carry data signals between the robotic system and the charging station.

[0083] The communication contacts of the structural tab 404 and receptacle are configured to transmit data signals between the robotic system and the charging station. In some embodiments, the data signals may include digital communication protocols such as Ethernet, CAN bus, RS-485, or USB, allowing for exchange of operational data, diagnostic information, or software updates. In other embodiments, the data signals may include low- voltage analog signals used for sensing, alignment verification, or safety interlocks.

[0084] Structurally, the communication contacts may be plated copper pads or bus bars configured to carry data signals at voltages typically less than 12 volts and at currents less than 1 ampere. The corresponding receptacle-side contacts may be compliant spring pins or conductive pads with contact resistance less than 50 milliohms, ensuring signal integrity during docking and undocking. The communication contacts may be electrically isolated from the power contacts by insulating polymer overmold material and by maintaining spacing of at least 4-6 millimeters between adjacent power and communication lines.

[0085] The communication contacts can facilitate bidirectional exchange of information between the robotic system and the charging station. For example, the robotic system may transmit state-of-charge data from its onboard electrical storage system, thermal management status, or actuator condition. The charging station may transmit control signals such as charging voltage, current levels, or error conditions. In some embodiments, the data signals may be encrypted or otherwise secured to prevent unauthorized access to robotic system firmware or operational data.

[0086] In some embodiments, the communication contacts 426, 428 of the structural tab 404 and the corresponding communication contacts within the receptacle may be used to provide firmware and software updates to the robotic system. When the robotic system is in the docked position, the communication pathway established through the contacts enables4936-6722-8771.1 - 17 -P03008-1NWO (128729-1902) PATENT direct data transfer from the charging station to onboard memory and control modules of the robotic system. This configuration allows for periodic updates of operating firmware, bug fixes, security patches, and deployment of new functionality without requiring removal of the electrical storage system or manual connection of external data cables.

[0087] The communication contacts may further be used for calibration routines. For example, the robotic system may include one or more cameras (e.g., a rear-facing camera) or positional sensors that require periodic calibration to maintain accuracy. While the robotic system is mechanically stabilized in the docked position, a portion of the weight of the robotic system may be supported by the structural tab of the charging station, while the remainder of the weight is supported by the robot’s own actuators. This partial weight distribution facilitates calibration of a kinematic chain of the robotic system, as the actuators may be commanded through controlled motions while the structural tab maintains positional stability.

[0088] In one embodiment, the calibration routine includes recalibration of a kinematic chain associated with the rear-facing camera of the robotic system. The charging station 102 may present high-contrast fiducial markers or reference patterns disposed on its exterior surface, which are imaged by the rear-facing camera during docking. By analyzing the position and orientation of these visual features relative to the known geometry of the charging station, the robotic system can recalibrate the kinematic relationship between the camera and other joints or sensors in the kinematic chain. This recalibration may correct for positional drift, lens distortion, or joint misalignment accumulated during operation.

[0089] In some embodiments, the rear-facing camera may be further configured to detect visual features on or around the charging station to facilitate autonomous docking prior to calibration. Once docked, the same visual features may be used as calibration references to update the robotic system’s internal coordinate system.

[0090] The communication pathway established through communication contacts 426, 428 may also be used for uploading calibration results, diagnostic routines, or data logging. For example, calibration parameters, diagnostic error codes, or system logs collected by the robotic system can be transmitted to the charging station 102 for review or remote upload. Conversely, configuration files or updated calibration parameters can be transmitted from the charging station 102 into the robotic system. By combining mechanical stabilization, partial weight support, and a communication pathway during a single docking event, the robotic4936-6722-8771.1 - 18 -P03008-1NWO (128729-1902) PATENT charging system facilitates both recharging and operational recalibration of the robotic system with minimal manual intervention.

[0091] The communication contacts 426, 428 are positioned between the power contacts 408, 412 along the surface 410 of the structural tab 404. In some embodiments, the communication contacts 426, 428 are recessed relative to the power contacts 408, 412 along the docking axis, ensuring that during undocking, the communication contacts disengage prior to the power contacts. Conversely, during docking, the power contacts engage first, followed by the communication contacts. This sequential arrangement provides stable charging prior to initiation of data transfer to facilitate data communication termination before power disconnection, thereby reducing the risk of arcing or data loss.

[0092] The structural tab 404 further includes a depth stop 416 positioned between the first side 418 and the body of the tab. The depth stop 416 limits the insertion of the structural tab 404 into the receptacle, facilitating consistent seating depth and repeatable engagement of the electrical contacts. In some embodiments, the depth stop 416 may also provide structural support by transferring load from the structural tab 404 into the surrounding structure of the charging station.

[0093] Turning now to FIG. 5, a side view of a robotic system 503 approaching a charging station 502 is shown. Like parts shown in FIG. 5 may be substantially similar to like parts shown in FIGS. 1-4. For example, the robotic system 503 may be substantially similar to the robotic system 103, 203, 303, described above, and the charging station 502 may be substantially similar to the charging station 102 described above.

[0094] As shown, the robotic system 503 moves in a direction 508 toward the charging station 502 such that a receptacle 506 of the robotic system 503 is positioned to receive a corresponding structural tab, shown as a structural tab 504, of the charging station 502. Initial alignment may be facilitated by alignment features of the charging station (e.g., alignment arms), after which the receptacle 506 transitions into engagement with the structural tab 504.{0095] A direction 508 (shown in FIG. 5) defines the travel of the receptacle 506 from initial engagement with the structural tab 504 to full engagement of the receptacle 506 around the structural tab 504. The direction 508 facilitates a gradual transition into a fully seated docking position, during which both mechanical alignment and electrical contact formation occur. In some embodiments, the travel distance of the receptacle 506 may be between about4936-6722-8771.1 - 19 -P03008-1NWO (128729-1902) PATENT20 millimeters and about 80 millimeters, and in one embodiment is approximately 50 millimeters.

[0096] A distance 510 defines the amount by which the robotic system 503 lowers (e.g., by bending its knees) relative to the charging station 502 during docking. This downward travel facilitates the seated engagement of the structural tab 504 into the receptacle 506 and provides a vertical locking component that resists unintentional withdrawal. In some embodiments, the distance 510 may be between about 10 millimeters and about 40 millimeters, and in one embodiment is approximately 25 millimeters.

[0097] The docking process may thus include an initial approach of the robotic system 503 in direction 508, followed by vertical lowering, which directs the robotic system 503 along a direction 512, such that the receptacle 506 of the robotic system 503 transitions into full engagement with the structural tab 504 along junction 514. By combining lateral travel and vertical lowering, the charging station 502 facilitates a secure cantilevered support of the robotic system 503 while also bringing the electrical contacts of the structural tab 504 into mating engagement with the corresponding contacts of the receptacle 506. Upon complete docking to the structural tab 504, the robotic system 503 can reduce or terminate power transmission to one or more actuators aiding in the balancing of the robotic system 503.

[0098] In some embodiments, the charging station 502 and the structural tab 504 may be configured to dynamically move relative to one another during docking. For example, the charging station 502 may include a sliding carriage or linkage that supports the structural tab 504, permitting the structural tab 504 to translate or retract relative to the base as the receptacle 506 of the robotic system 503 advances into engagement. In this arrangement, an alignment feature of the charging station 502 (e.g., a funnel arm or alignment surface) may initially engage with the robotic system 503 to provide coarse alignment. As docking progresses, the alignment feature slides rearward or downward relative to the charging station 502, thereby exposing the structural tab 504 for final insertion into the receptacle 506.

[0099] In other embodiments, the structural tab 504 itself may be mounted on a sliding, pivoting, or telescoping mechanism relative to the charging station 502. In this configuration, the structural tab 504 may remain recessed or partially covered during the initial approach of the robotic system 503. Once the robotic system 503 is positioned proximate the charging station 502, the structural tab 504 extends or pivots into alignment with the receptacle 506,4936-6722-8771.1 - 20 -P03008-1NWO (128729-1902) PATENT facilitating docking while reducing the likelihood of accidental interference or damage to the structural tab 504 during approach.

[0100] By allowing the charging station 502 and / or the structural tab 504 to dynamically move relative to one another, the charging station facilitates both improved alignment and protection of the structural tab 504. This dynamic motion further permits staged engagement, wherein alignment features provide coarse positioning during early docking, while exposure of the structural tab 504 facilitates fine alignment and electrical contact formation during final docking.10101 ] Docking procedures for a robotic system and charging station, such as described herein, may include a sequence of coordinated motions that facilitate both mechanical engagement and electrical connection. In one embodiment, the docking procedure begins with the robotic system executing a backward walking motion toward the charging station. The backward walking motion positions the robotic system in proximity to the charging station along a defined approach path, while coarse alignment features of the charging station facilitate positional guidance during the initial approach. In some embodiments, the robotic system may further include a rear-facing camera configured to detect one or more visual features on or around the charging station. These visual features may include fiducial markers, high-contrast geometric patterns, or distinctive surface geometries that facilitate autonomous docking by providing visual cues for approach trajectory, lateral alignment, and docking orientation.

[0102] Following the backward walking motion, the docking procedure may include a squatting motion of the robotic system. The squatting motion lowers a receptacle or mating tab of the robotic system onto a corresponding structural tab or channel of the charging station, thereby transitioning from initial engagement to a fully seated docking position. This combination of translational approach and vertical lowering facilitates stable engagement while reducing the likelihood of misalignment or incomplete insertion. The rear-facing camera may continue to monitor the charging station during this motion to facilitate fine adjustment, such as correcting minor yaw, pitch, or roll misalignment as the robotic system descends.

[0103] During the docking procedure, the robotic system may be equipped with one or more load sensors disposed in its legs. These load sensors are configured to measure ground reaction forces during docking and, by extension, determine the proportion of the robot’s weight that is supported by the structural tab of the charging station as opposed to the robot’s legs. For example, as the squatting motion lowers the robotic system into engagement, the load4936-6722-8771.1 - 21 -P03008-1NWO (128729-1902) PATENT sensors may detect a reduction in force borne by the legs as more of the weight is transferred to the structural tab. This measurement facilitates control algorithms that regulate how much load is carried by the structural tab versus the legs, enabling precise calibration of the docking process and preventing overstress on either the robotic system’s joints or the charging station interface.

[0104] During the docking procedure, the squatting motion also facilitates staged engagement of electrical contacts between the robotic system and the charging station. The arrangement of contacts may be configured such that power contacts engage first to establish a stable charging current, followed by communication contacts that engage to provide data exchange. Conversely, during undocking, the communication contacts disengage prior to the power contacts, terminating data transfer before power is disconnected. In alternative embodiments, the positioning of the power contacts and the communication contacts are reversed.|0105| In some implementations, docking procedures may also include dynamic adjustment of charging station components. For example, alignment arms or docking guides may retract as the robotic system advances, exposing a structural tab for final engagement. In other embodiments, the rear-facing camera of the robotic system may facilitate calibration routines during docking, such as capturing images of high-contrast visual markers disposed on the charging station. These markers facilitate calibration of onboard cameras, positional sensors, or navigation systems of the robotic system. Once the backward walking motion and squatting motion are complete, the robotic system is mechanically supported in a statically stable orientation with actuators powered down. At this stage, the load sensors in the legs may confirm that a desired proportion of the robotic system’s weight is supported by the structural tab, while electrical coupling facilitates both recharging of onboard energy storage and data communication for diagnostics, calibration, or software updates.

[0106] Undocking procedures may likewise include a sequence of coordinated motions that facilitate disengagement of both mechanical and electrical connections between the robotic system and the charging station. In one embodiment, the undocking procedure begins with the robotic system executing a rising motion that is the reverse of the squatting motion performed during docking. By rising from the squatting motion, the robotic system lifts its receptacle vertically relative to the structural tab of the charging station, thereby disengaging the vertical4936-6722-8771.1 - 22 -P03008-1NWO (128729-1902) PATENT locking component of the docking interface. This upward motion facilitates clearance of the structural tab while maintaining alignment to prevent binding or contact damage.

[0107] Following the rising motion, the undocking procedure may include a forward walking motion that carries the robotic system away from the charging station along the same approach path used during docking, but in the opposite direction. As the robotic system advances forward, the structural tab of the charging station is withdrawn from the receptacle of the robotic system, completing mechanical separation.

[0108] During this sequence, disengagement of the electrical contacts occurs in a controlled order. The communication contacts are configured to disengage first, thereby terminating data transfer prior to loss of power. The power contacts then disengage, safely interrupting charging current after communication has already ceased. This sequencing facilitates reliable and repeatable undocking while reducing the risk of arcing or data corruption.

[0109] In some embodiments, undocking procedures may further include dynamic repositioning of charging station components. For example, retractable alignment arms may extend outward after the robotic system begins its forward walking motion to provide clearance and to facilitate subsequent docking procedures. In other embodiments, the rear-facing camera may capture images of visual features on or around the charging station during undocking to facilitate trajectory verification or recalibration prior to resuming mobility. Once the rising motion and forward walking motion are complete, the robotic system resumes free mobility with stored energy replenished and operational data updated.

[0110] Turning now to FIG. 6, a perspective view of a robotic charging system 600 is shown. Like parts shown in FIG. 6 may be substantially similar to like parts described above with respect to FIGS. 1-5. For example, the robotic charging system 600 includes a robotic system 603 and a charging station 602. The charging station 602 includes a structural tab 604 dimensioned to receive or be received in a corresponding mating tab, shown as mating tab 606, disposed on the back portion of the robotic system 603.

[0111] As illustrated, the mating tab is integrated into an upper back region of the robotic system 603 and is dimensioned positionally mate with the structural tab 604 along a docking path. During docking, the robotic system 603 may perform a backward walking motion toward the charging station 602 followed by a squatting motion to lower the mating tab 6064936-6722-8771.1 - 23 -P03008-1NWO (128729-1902) PATENT onto the structural tab 604, thereby facilitating mechanical engagement and electrical connectivity.

[0112] The structural tab 604 may comprise a rigid insert, such as a steel or aluminum core, overmolded with a polymer shell to facilitate both load-bearing support and electrical insulation. Electrical contacts may be disposed along one or more surfaces of the structural tab 604 and may be configured to mate with corresponding electrical contacts positioned within the mating tab 606. In some embodiments, the electrical contacts include both power contacts configured to carry a charging current and communication contacts configured to transmit data signals between the robotic system 603 and the charging station 602.

[0113] FIG. 7 illustrates a perspective view of a portion of a robotic system 703 configured for docking with a charging station. In this embodiment, the robotic system 703 includes a mating tab 706 extending outward from a back portion of the robot. Unlike other embodiments in which the robotic system includes a receptacle, the embodiments shown in FIGS. 6-1 IB utilize the mating tab 706 as a projecting interface feature of the robotic system. The mating tab 706 is dimensioned to be received within a corresponding mating channel (e.g., a mating channel 810 of FIG. 8) defined in the charging station.

[0114] Structurally, the mating tab 706 extends outward in a cantilevered fashion from the back surface of the robotic system 703. The mating tab 706 may define a generally rectangular profile with planar sidewalls and a tapered leading edge that narrows toward its distal end. The taper facilitates guided insertion into the mating channel during docking, reducing the likelihood of misalignment or binding. The mating tab 706 may further include chamfered or radiused edges along its distal tip to assist with smooth insertion into the mating channel.10115] The mating tab 706 includes electrical contacts, shown as contacts 708, disposed along one or more surfaces of the tab. These contacts 708 are configured to engage corresponding electrical contacts positioned upon the charging station. In some embodiments, the contacts 708 include power contacts configured to carry charging current and communication contacts configured to transmit data signals between the robotic system 703 and the charging station. The positioning of the contacts along the tab permits both mechanical capture of the mating tab and electrical engagement to occur simultaneously as the robotic system is docked.4936-6722-8771.1 - 24 -P03008-1NWO (128729-1902) PATENT

[0116] The body of the mating tab 706 may be formed from a rigid material such as steel, aluminum, or a composite structure. In some embodiments, the mating tab includes a metallic load-bearing core with a polymer overmolded shell that provides electrical insulation, distributes contact forces, and protects the embedded electrical contacts. This structural arrangement allows the mating tab 706 to transfer cantilevered loads from the robotic system 703 to the charging station while also facilitating electrical connectivity.

[0117] FIG. 8 illustrates a perspective view of a charging station configured to receive a robotic system mating tab (e.g., the mating tab 706 of FIG. 7). The charging station includes a structural tab 804 that defines a mating channel 810 dimensioned to capture and retain the mating tab of the robotic system during docking.

[0118] The mating channel 810 is recessed into the structural tab 804 and extends between a first apex 806 and a second apex 808. The channel defines a receiving cavity with sidewalls and a base surface configured to engage corresponding surfaces of the mating tab 706. In some embodiments, the mating channel 810 defines a generally U-shaped or rectangular cross-section, with planar opposing sidewalls that closely conform to the width of the mating tab. The spacing between the sidewalls may be dimensioned to provide minimal clearance (e.g., on the order of 1-50 millimeters per side) to facilitate insertion of the mating tab while also providing sufficient lateral constraint to resist side-to-side motion once fully docked.|01l9| The mating channel 810 may further include a tapered lead-in geometry adjacent to the first apex 806, which flares outward to guide the mating tab 706 into the channel during the initial stages of docking. This tapered geometry facilitates smooth insertion even if minor lateral misalignment is present as the robotic system approaches. The channel may also extend at an upward angle relative to the base of the charging station body 802, such that when the robotic system performs a squatting motion, the mating tab 706 is urged downward and seated securely against the base of the channel.

[0120] Electrical contacts, such as contacts 812, are disposed along a mating surface of the structural tab 804. These contacts 812 are positioned to engage corresponding contacts disposed on the mating tab 706 when the tab is fully inserted into the channel. In some embodiments, the contacts 812 comprise spring-loaded conductive pins, leaf springs, or elastically deflectable bus bars that press against the conductive pads of the mating tab. This compliant arrangement facilitates reliable electrical engagement under repeated docking cycles and accommodates manufacturing tolerances or minor angular misalignments.4936-6722-8771.1 - 25 -P03008-1NWO (128729-1902) PATENT

[0121] In some embodiments, the contacts 812 are positioned below the mating channel 810 such that when the robotic system (e.g., the robotic system 603) is mated with the structural tab 804 of the by the mating channel 810, the corresponding contacts of the mating tab 606 of the robotic system 603 are firmly pressed into the contacts 812, thereby creating an electrical connection between the corresponding contacts.[0122| FIGS. 9A-11B illustrate a method of electrically and mechanically coupling a robotic system to a charging station. FIGS. 9A and 9B illustrate side and top views, respectively, of a robotic system 903 approaching a charging station 902 during docking. In this embodiment, the robotic system 903 includes a mating tab 906 extending outward from its back portion, and the charging station 902 includes a corresponding mating channel, shown as a mating channel 904, configured to receive and capture the mating tab 906.

[0123] As shown in FIG. 9A, a system 900 is shown, including the robotic system 903 positioned proximate the charging station 902 with the mating tab 906 aligned with the opening of the mating channel 904. The mating channel 904 is recessed into the structural body of the charging station and defines a cavity sized and shaped to capture the mating tab 906. During docking, the robotic system 903 may execute a backward walking motion along a direction 908 toward the charging station 902, aligning the mating tab 906 with the channel opening.

[0124] FIG. 9B, which is a top view of FIG. 9A, further illustrates the robotic system 903 moving in a docking direction toward the charging station 902. As the mating tab 906 advances into the mating channel 904, the tapered leading edge of the mating tab interacts with corresponding tapered surfaces of the channel to facilitate smooth insertion and reduce the likelihood of binding. Once inserted, the sidewalls of the mating channel 904 constrain lateral movement of the mating tab 906, while the base surface of the channel constrains vertical movement, thereby mechanically fixing the robotic system relative to the charging station.|0125| Electrical contacts may be disposed along the surfaces of the mating tab 906 and within the mating channel 904 such that insertion of the mating tab establishes electrical engagement. In some embodiments, the contacts are arranged so that power connections are established prior to data connections during docking and are disengaged after the data connections during undocking. This sequential engagement facilitates stable charging and reliable communication.

[0126] The cooperation of the mating tab 906 and the mating channel 904 provides both mechanical support and electrical connectivity. When fully docked, the mating tab 906 is4936-6722-8771.1 - 26 -P03008-1NWO (128729-1902) PATENT securely captured within the mating channel 904, supporting a portion of the weight of the robotic system 903 in a cantilevered orientation and maintaining stable electrical contact throughout the charging cycle.101271 FIGS. 10A and 10B illustrate side and top views of a system 1000, respectively, of a robotic system 1003 docking with a charging station 1002. In this embodiment, the robotic system 1003 includes a mating tab 1006 projecting rearward from its back portion, and the charging station 1002 includes a mating channel 1004 dimensioned to receive and capture the mating tab 1006.101281 As shown in FIG. 10A, the robotic system 1003 approaches the charging station 1002 in a position where the mating tab 1006 is aligned with the opening of the mating channel 1004. The robotic system may execute a backward walking motion to achieve this alignment. At this stage, the mating tab 1006 is positioned adjacent to the channel opening but has not yet been lowered into the channel. A clearance distance may be present between the bottom of the mating tab 1006 and the base of the mating channel 1004.|0129| The robotic system 1003 may further include one or more sensors, shown as sensor 1001, disposed in or associated with the leg actuators of the robotic system. Sensor 1001 is configured to measure the weight of the robotic system 1003 being sustained by the leg actuators during docking. By monitoring load distribution in real time, sensor 1001 provides data indicating how much of the weight of the robotic system 1003 has been transferred from the legs to the charging station 1002. This data may be processed by the robotic system’s control system to determine whether the robotic system is fully seated within the mating channel 1004 and structurally supported by the charging station 1002. In some embodiments, docking is confirmed when sensor 1001 detects that a threshold proportion of the robotic system’s weight has shifted from the legs onto the charging station, thereby verifying that the robotic system is mechanically captured and properly held in the docked position.

[0130] FIG. 10B, which is a top view of FIG. 10A, illustrates the next stage of the docking sequence. The robotic system 1003 performs a squatting motion, lowering the mating tab 1006 downward into the mating channel 1004 along a vertical docking path. This motion reduces the clearance distance until the mating tab 1006 is seated within the mating channel 1004. The downward travel facilitates a secure mechanical capture of the mating tab within the channel, resisting unintentional withdrawal and providing a statically stable docking orientation.4936-6722-8771.1 - 27 -P03008-1NWO (128729-1902) PATENT

[0131] In FIG. 10A and FIG. 10B, electrical contacts disposed along the mating tab 1006 are brought into engagement with corresponding contacts disposed within the mating channel 1004. The staged docking motion facilitates sequential engagement of the electrical contacts, such that power contacts engage prior to communication contacts. This sequence provides stable charging current before data exchange begins. Conversely, during undocking, the squatting motion is reversed by a rising motion, which lifts the mating tab 1006 out of the mating channel 1004, causing the communication contacts to disengage before the power contacts.[01321 FIGS. 11A and 11B illustrate perspective and top views or a system 1100, respectively, of a robotic system 1103 in a fully docked position with a charging station 1102. The robotic system 1103 includes a mating tab 1106 extending rearward from its body, and the charging station 1102 includes a mating channel 1104 configured to receive and capture the mating tab 1106.

[0133] As shown, the mating tab 1106 is seated within the mating channel 1104 such that the sidewalls of the channel laterally constrain the tab and the base surface of the channel vertically supports it. This seating arrangement provides structural support to the robotic system 1103, allowing at least a portion of the system’ s weight to be transferred to the charging station 1102. The cantilevered orientation achieved in this docked position facilitates statically stable support, enabling one or more actuators of the robotic system 1103 to be powered down while docked.

[0134] Electrical contacts disposed along the mating tab 1106 engage with corresponding contacts positioned within the mating channel 1104. The contact arrangement provides simultaneous charging and communication functions. In some embodiments, the power contacts are positioned to engage first during docking and disengage last during undocking, while the communication contacts are recessed or offset such that they engage after the power contacts and disengage before them. This sequencing facilitates reliable charging current delivery while also providing a safe termination of data transfer during undocking.

[0135] FIG. 11B, which is a top view of FIG. 11 A, further illustrates the seating depth of the mating tab 1106 within the mating channel 1104. The tab is lowered into the channel by a squatting motion of the robotic system, which facilitates vertical locking and prevents unintentional withdrawal. The load-bearing engagement between the mating tab and the4936-6722-8771.1 - 28 -P03008-1NWO (128729-1902) PATENT channel provides both mechanical stability and repeatable alignment of the electrical contacts across multiple docking cycles.

[0136] As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean + / - 10% of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0137] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0138] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0139] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the figures. It4936-6722-8771.1 - 29 -P03008-1NWO (128729-1902) PATENT should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.4936-6722-8771.1 - 30 -

Claims

P03008-1NWO (128729-1902) PATENTCLAIMSWhat is claimed is:

1. A robotic charging system comprising: a charging station comprising: a base; and a structural tab coupled to the base of the charging station, the structural tab angled upward relative to the base of the charging station; and a robotic system comprising: a receptacle dimensioned to slidably receive the structural tab along a first direction, wherein, in a docked position, the structural tab supports at least a portion of a weight of the robotic system in a cantilevered orientation and maintains alignment between the charging station and the receptacle to permit electrical contact for charging.

2. The robotic charging system of claim 1, wherein the structural tab is disposed at an angle greater than 25 degrees and less than 65 degrees relative to a first face of the base of the charging station.

3. The robotic charging system of claim 1, wherein the charging station further comprises one or more arms extending from a base of the charging station, the one or more arms configured to provide coarse alignment of the robotic system in a lateral direction prior to engagement with the structural tab.

4. The robotic charging system of claim 1, wherein the structural tab comprises: a steel core extending within the structural tab from a first end toward a second end; and a polymer overmold surrounding at least a portion of the steel core.

5. The robotic charging system of claim 1, wherein the structural tab comprises a tapered end tapering from a first end to a second end and configured to provide fine alignment in a lateral direction during engagement of the receptacle with the structural tab.

6. The robotic charging system of claim 1, wherein the charging station further comprises a set of electrical contacts positioned between a first end of the structural tab and a second end of the structural tab, the set of electrical contacts comprising:4936-6722-8771.1 - 31 -P03008-1NWO (128729-1902) PATENT at least two power contacts configured to carry a charging current and engage with corresponding power contacts within the receptacle; and at least two communication contacts configured to carry data signals and engage with corresponding communication contacts within the receptacle, wherein the at least two communication contacts are positioned such that the at least two communication contacts disengage from the corresponding communication contacts prior to the at least two power contacts disengaging from the corresponding power contacts.

7. The robotic charging system of claim 6, wherein the at least two power contacts extend farther toward the second end than the at least two communication contacts such that, during undocking, the at least two communication contacts are disengaged from the corresponding communication contacts prior to disconnection of the at least two power contacts such that communication is terminated prior to disconnection of the at least two power contacts.

8. The robotic charging system of claim 1, wherein the charging station comprises one or more high-contrast visual markers configured to be detected by a rear-facing camera of the robotic system.

9. The robotic charging system of claim 1, wherein the receptacle is positioned between two or more shoulder structures of the robotic system.

10. The robotic charging system of claim 1, wherein the charging station and the receptacle are configured to support docking procedures in which the robotic system performs a backward walking motion followed by a squatting motion to fully engage the structural tab.

11. The robotic charging system of claim 1, wherein the structural tab is dynamically coupled to the base of the charging station, wherein the base of the charging station is statically coupled to a support surface.

12. The robotic charging system of claim 1, further comprising: a mating tab coupled to the robotic system; wherein the structural tab comprises: a first apex; a second apex; and4936-6722-8771.1 - 32 -P03008-1NWO (128729-1902) PATENT a mating channel positioned between the first apex and the second apex, and having a profile corresponding to the mating tab such that the mating tab is received within the mating channel in the docked position.

13. The robotic charging system of claim 12, wherein the mating tab and the mating channel are positioned such that in the docked position, at least one contact of the charging station is electrically coupled to a corresponding contact of the robotic system.

14. A robotic system comprising: a receptacle disposed on a back portion of the robotic system, the receptacle being dimensioned to slidably receive a structural tab of a charging station along a docking path; and at least one electrical contact positioned within the receptacle and configured to engage a corresponding electrical contact of the structural tab in a docked position; wherein, in the docked position, the receptacle cooperates with the structural tab to mechanically support at least a portion of a weight of the robotic system in a cantilevered orientation while maintaining electrical connectivity such that robotic system remains statically stable when one or more actuators of the robotic system are powered down.

15. The robotic system of claim 14, wherein the robotic system comprises a rear-facing camera configured to detect visual features on the charging station to facilitate autonomous docking.

16. The robotic system of claim 14, wherein the robotic system comprises one or more load sensors disposed in legs of the robotic system, the one or more load sensors configured to measure a proportion of a weight of the robotic system supported by the structural tab during docking.

17. The robotic system of claim 14, wherein the robotic system is configured to perform a calibration routine while docked, the calibration routine comprising maintaining a partial weight distribution on the structural tab while recalibrating a kinematic chain including a rearfacing camera of the robotic system.

18. A charging station for providing electrical power to a humanoid robotic system comprising: a base; an arm extending from the base of the charging station in a first direction; and4936-6722-8771.1 - 33 -P03008-1NWO (128729-1902) PATENT a structural tab angled upward relative to the base of the charging station; wherein, in a docked position, the structural tab supports at least a portion of a weight of the humanoid robotic system in a cantilevered orientation and maintains alignment between the charging station and a receptacle of the humanoid robotic system to permit electrical contact for charging and communication.

19. The charging station of claim 18, wherein the arm comprises a tapered end configured to direct the humanoid robotic system toward a mounting position.

20. The charging station of claim 18, the structural tab is slidably coupled to the base such that the structural tab extends in the first direction when engaging with the humanoid robotic system.4936-6722-8771.1 - 34 -

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