Automated Battery Station for Mobile Robot Swapping and Charging

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Solution Overview

Problem

The existing methods for swapping and charging batteries in mobile robots and electric vehicles are inefficient, as they require manual handling of heavy batteries, which can lead to physical harm and interruptions in operation, and often result in batteries being left uncharged, causing operational delays.

Innovation Solution

A battery station that integrates battery swapping and charging capabilities, featuring a battery charging unit, a battery handling mechanism, and localization elements to detect and align batteries with high precision, allowing for automated swapping and charging without human intervention, and the ability to store and charge multiple batteries simultaneously.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual battery handling is used, then the operator can swap batteries, but the operator may suffer physical harm and operation is interrupted

Engineering Contradiction:

Improvebattery swapping operationVSAvoidphysical harm to operator

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The battery station performs battery swapping automatically without human intervention. The system detects when a robot needs battery service, autonomously exchanges batteries using robotic grippers, and manages charging operations, thereby eliminating physical harm risks to operators while maintaining operational continuity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical battery handling with an automated robotic system. The battery station uses robotic grippers controlled by sensors and processors to detect, grasp, exchange, and position batteries, substituting human physical operations with automated mechanical systems that eliminate operator exposure to heavy lifting hazards

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If manual battery charging is used, then batteries can be charged, but operational delays occur due to waiting time

Engineering Contradiction:

Improvebattery chargingVSAvoidoperational interruption time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The battery station maintains a fleet of pre-charged batteries ready for immediate exchange. When a robot's battery is depleted, a fully charged battery is already available at the station, allowing instant swap without waiting for charging. The system proactively manages battery charging cycles in the background to ensure continuous availability of charged batteries

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The automated battery station enables continuous operation by eliminating idle waiting time. While one battery is being used by a robot, another battery is being charged or is ready for exchange. The system orchestrates multiple batteries in different states (charging, ready, in-use) to ensure that a charged battery is always available for immediate swap, maintaining uninterrupted robot operation

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If automated battery swapping is implemented, then operational efficiency improves, but device complexity increases

Engineering Contradiction:

Improvebattery swapping efficiencyVSAvoidbattery station structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The battery station is designed as a multi-functional integrated system that combines battery storage, charging, detection, and automated swapping operations in a single device. The system can serve multiple mobile robots simultaneously, perform both charging and swapping functions, and adapt to different battery types, thereby achieving high productivity through consolidated multi-functionality rather than separate specialized devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The battery station acts as an intermediary between mobile robots and the power grid. It buffers the complexity of charging operations by managing battery charging in the background while providing simple, quick swap operations to robots. The station's control system mediates between detection sensors, robotic grippers, charging circuits, and communication interfaces, organizing these complex components into a coordinated automated system that appears simple from the robot's perspective

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11420531B2Device, method and system for swapping and/or charging a battery of a mobile robot

Publication Date: 2022.08.23 STARSHIP TECH OU

AI summary

A battery station, for use by at least one mobile robot, includes a battery charging unit configured to perform at least one of: holding at least one battery, and charging at least one battery. A battery load/unload position is configured to facilitate loading and unloading of a battery to and from a mobile robot. A battery handling mechanism is configured to operate on a reaching range, comprising at least one of the following: (i) the battery of the mobile robot positioned in the battery load/unload position, and (ii) the battery charging unit. A localization element is configured to at least one of detect and locate at least one of: at least one battery of the mobile robot, wherein the mobile robot is positioned in the battery load/unload position, and/or at least one battery positioned in the battery charging unit.