Magnetic Robot Charging Dock for Precise Contact Alignment
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Solution Overview
Problem
Existing charging systems for autonomous robots often result in loose connections, slow charging, and other hazards due to manual intervention requirements and inefficiencies in robotic navigation and charging alignment.
Innovation Solution
A magnetic robot charging station with a modular charging mechanism, wireless connector, and cloud connect system that enables autonomous robot navigation, precise alignment, and efficient charging through magnetic connections and cloud-managed communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual intervention is used for robot charging, then ease of operation is improved, but reliability deteriorates due to loose connections and charging errors
Solution Approach 1:
The patent replaces manual mechanical intervention with an automated electromagnet-based system. The electromagnet automatically attracts the robot to the charging station, aligns it precisely, and maintains secure contact during charging, eliminating loose connections and manual operation errors while ensuring reliable charging connectivity.
Solution Approach 2:
The charging system enables robots to autonomously navigate to the charging station and self-align using electromagnetic attraction. The robot independently completes the charging process without human intervention, with the electromagnet automatically securing the connection and the system monitoring charging status, thereby improving both reliability and operational autonomy.
2Device complexity
If traditional charging alignment is used, then device complexity is reduced, but manufacturing precision deteriorates resulting in misalignment and slow charging
Solution Approach 1:
The patent replaces complex mechanical alignment mechanisms with an electromagnetic field-based alignment system. The electromagnet creates an attractive force that automatically pulls the robot into precise alignment with the charging contacts, achieving high manufacturing precision without complex mechanical guide structures or adjustment mechanisms.
Solution Approach 2:
The system uses electromagnetic field parameters (strength, distribution, and polarity) to control alignment precision. By adjusting the electromagnet's field characteristics, the system achieves precise robot positioning and charging contact alignment dynamically, rather than relying on fixed mechanical tolerances.
3Productivity
If autonomous navigation is implemented, then productivity is improved, but difficulty of detecting and measuring increases due to navigation errors
Solution Approach 1:
The charging station incorporates sensors that detect the robot's approach, position, and alignment status. This feedback information is used by the electromagnet to adjust the magnetic field in real-time, correcting navigation deviations and ensuring precise alignment before charging begins, thereby maintaining high productivity while reducing navigation errors.
Solution Approach 2:
The electromagnet serves as an intermediary between the robot's navigation system and the charging contacts. It provides a controllable attractive force that guides the robot into the correct position, acting as a mediator that compensates for navigation inaccuracies and ensures precise charging alignment without requiring perfect autonomous navigation.
4Speed
If electromagnetic attraction is used for alignment, then speed is improved, but force increases which may damage the robot
Solution Approach 1:
The electromagnet's magnetic field strength is dynamically adjusted during the alignment process. Initially, a stronger force rapidly attracts the robot to the charging station for quick alignment. As the robot approaches the target position, the field strength is reduced to a gentler level for precise positioning and secure contact, achieving both high speed and safe force levels.
Solution Approach 2:
The electromagnet operates in periodic cycles: activating to attract the robot, deactivating or reducing strength upon approach to allow gentle contact, then reactivating to maintain secure charging connection. This periodic control prevents continuous high-force exposure while maintaining alignment speed and charging reliability.
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
The solution provides a reliable, efficient, and safe charging process for autonomous robots, minimizing errors and hazards while maximizing charging speed and automation.
Implementation Method 1
the robot may activate an electromagnet positioned above the central metal plate. This will adjust the robot and fasten it in place properly above the modular charging mechanism
Implementation Method 2
the robot may activate an electromagnet positioned above the central metal plate
Implementation Method 3
has magnets designed to contact metal plates on the robot to further ensure the robot is properly aligned
Implementation Method 4
it may activate a hall effect sensor to detect the magnet field produce by the magnets that are positioned within the modular charging mechanism
Data Source
AI summary
A magnetic charging station and method of use is disclosed herein. The magnetic charging station is adapted to receive a robot and connect to the robot to charge a power source on the robot. The magnetic charging station is designed to improve the consistency and safety of charging by offering multiple mechanism to ensure proper alignment of the charging contacts. Having a tread receptacle that begins wide and narrows towards the end makes it easy for a robot entering the station to reach the correct position, and magnets assist in aligning and holding the robot to a charging contact. The charging contact on the charging station may be biased with a spring, allowing the charging contact to smoothly connect to a charging point on the robot. A method of use is further disclosed to describe the process of monitoring battery levels, managing multiple charging station in a network, and issuing instructions to the components of the system using a cloud connect software system.