Compliant Charge Connector for Robotic Drive Units
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Solution Overview
Problem
Charging stations for robotic mobile drive units face challenges in accommodating navigational tolerances and elevation variances, leading to increased wear and downtime due to rigid connector designs.
Innovation Solution
The implementation of a charging station with a compliant charge connector system, utilizing springs for positional compliance along multiple directions, allowing mobile drive units to dock at various angles and orientations, reducing wear and enhancing compatibility with uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid charge connector design is used, then structural stability is improved, but wear and damage increase due to navigational tolerances and elevation variances
Solution Approach 1:
The charge connector is designed with compliant mechanisms that allow dynamic movement and adjustment. The connector can move laterally, vertically, and rotationally to accommodate navigational tolerances and elevation variances, transforming the rigid structure into a dynamic one that adapts to positioning variations without causing wear or damage.
Solution Approach 2:
The connector's positional parameters are made variable through compliant mechanisms. Instead of fixed position, the connector can change its lateral position, vertical position, and rotational angle to match the mobile drive unit's docking position, resolving the contradiction between structural stability and wear reduction.
2Ease of manufacture
If a rigid charge connector design is used, then manufacturing simplicity is improved, but compatibility with navigational tolerances deteriorates
Solution Approach 1:
The connector incorporates compliant mechanisms that provide lateral compliance, vertical compliance, and rotational compliance. These dynamic capabilities enable the connector to accommodate navigational tolerances and floor elevation variances while maintaining relatively simple manufacturing through modular compliant mechanism design.
3Adaptability or versatility
If a compliant charge connector with multi-directional movement is implemented, then compatibility with navigational tolerances and elevation variances is improved, but device complexity increases
Solution Approach 1:
The compliant charge connector uses compliant mechanisms that provide lateral, vertical, and rotational movement capabilities. These mechanisms achieve multi-directional compliance through integrated flexible structures rather than multiple independent actuators, managing device complexity while maintaining high adaptability to navigational and elevation variations.
4Productivity
If frequent connector replacement is performed to handle wear, then operational continuity is maintained, but downtime and operational costs increase
Solution Approach 1:
The compliant connector design with multi-directional movement capability significantly reduces wear and damage from improper docking. This extends connector service life and reduces replacement frequency, maintaining operational continuity while minimizing downtime and operational costs associated with connector maintenance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution extends the service life of both charging station and mobile drive unit connectors, reduces operational costs, and improves charging efficiency by accommodating a wider range of navigational and elevation variations.
Implementation Method 1
The charge connector is connected to the mount by at least one spring that is configured to provide the charge connector with positional compliance at least along a lateral direction
Implementation Method 2
The charge connector is connected to the mount by at least one spring that is configured to provide the charge connector with positional compliance
Data Source
AI summary
An electric charging station for a mobile drive unit includes a frame that defines an interior volume of space. The frame is configured to carry an electrical charging unit positioned above the interior volume of space. The station includes a station charge connector that is configured to be in electrical communication with the electrical charging unit and is also configured for mating with a corresponding charge connector of the mobile drive unit. The station charge connector extends forward within the interior volume of space along a longitudinal direction that is substantially perpendicular to the vertical direction. The station charge connector is connected to the frame by at least one compliant mechanism that is configured to provide the station charge connector with positional compliance with respect to the frame.