Mechanical Docking Station for Precise Robot Wheel Alignment

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Solution Overview

Problem

Existing docking systems for autonomous robotic platforms face challenges in achieving precise mechanical alignment for charging, especially in outdoor environments where environmental factors can disrupt localization sensors, leading to inaccurate docking.

Innovation Solution

A mechanical docking station comprising a base pad, a correlator, and a backstop, which aligns the wheels of the robotic platform in a forward direction, allowing for reliable engagement with charging contacts without the need for powered components or precise electronic positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If localization sensors (GPS, imaging, LiDAR, SONAR) and complex software are used for docking, then the robotic platform can initiate a docking sequence, but the docking precision deteriorates due to varying levels of precision and environmental factors

Engineering Contradiction:

Improvedocking initiation capabilityVSAvoiddocking precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces electronic localization sensors and software-based docking systems with a purely mechanical alignment system. The mechanical correlator and alignment members physically guide the robotic platform's wheels into the correct docking position, eliminating reliance on imprecise electronic sensors that are affected by environmental factors like mud, snow, and rain.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces mechanical intermediaries (alignment members, correlator, and base pad) between the robotic platform and the charging system. These mechanical components serve as a mediator that ensures precise alignment and engagement, bridging the gap between the platform's movement and the charging contacts without relying on electronic positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Extent of automation

If electronic localization systems are used for docking, then the docking sequence can be initiated, but the system becomes vulnerable to electromagnetic interference and power outages

Engineering Contradiction:

Improveautonomous docking capabilityVSAvoidsystem reliability under environmental stress

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent replaces electronic and electromagnetic systems with a mechanical alignment and docking system. The mechanical correlator, alignment members, and base pad provide a passive, reliable system that does not depend on power or electromagnetic signals, making it immune to electromagnetic interference and functional during power outages.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical alignment system operates autonomously without requiring external power or electronic control. The physical structure of the correlator and alignment members automatically guides the robotic platform into the correct position through mechanical constraints, providing a self-service docking mechanism that is inherently reliable.

Inventive Principle:

Principle #25Self-service

3Extent of automation

If complex electronic docking systems are used, then the robotic platform can perform autonomous docking, but maintenance costs increase due to sensor calibration and electronic component failures

Engineering Contradiction:

Improveautonomous docking functionVSAvoidmaintenance cost and complexity

Core Design Contradiction:

Extent of automationVSEase of repair

Solution Approach 1:

The patent replaces complex electronic components (sensors, processors, software) with simple mechanical structures (correlator, alignment members, base pad). This mechanical system has fewer failure points, requires no calibration, and is much easier to maintain and repair, directly reducing maintenance costs while preserving autonomous docking functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical alignment system uses simple, inexpensive components that are easier and cheaper to replace than electronic sensors and processors. If wear or damage occurs, the mechanical parts can be quickly swapped without requiring specialized calibration or electronic diagnostics, reducing both maintenance time and cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUSRE50363E1Docking station for the mechanical alignment of an autonomous robotic platform

Publication Date: 2025.04.08 FLORIDA POWER & LIGHT CO

AI summary

Various embodiments are directed to a docking station for the mechanical alignment of an autonomous robotic platform. A correlator may receive the wheels of a moving autonomous robotic platform. A first set of rollers in the correlator may align the wheels, in a substantially linear direction, into a space created by a second set of rollers attached to a frame of a backstop. The second set of rollers may continue to align the wheels of the moving autonomous robotic platform until the wheels come in contact with a stopping roller coupled to the backstop. The stopping roller may be vertically oriented at a height above a wheel radius of the autonomous robotic platform. The stopping roller provides a force to prevent further forward travel. Upon being stopped by the stopping roller, the autonomous robotic platform is positioned for mating with charging contacts in the docking station.