Mobile Robot Battery Pack for Hot-Swap Power Continuity
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Solution Overview
Problem
Large robotic systems, such as humanoid robots and robotic vehicles, often require extended battery life and reduced downtime for recharging due to their high power demands, leading to inefficiencies in battery exchange and maintenance, particularly in environments like logistics facilities where downtime is costly.
Innovation Solution
A field replaceable battery system with a main body containing at least one battery cell, enabling movement, a charging interface, and a blind mate connector for easy connection to a battery-powered device, along with a backup battery for continuous operation, and a lift counterbalance system to reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual battery replacement is used, then battery exchange can be performed, but significant human effort is required due to battery weight exceeding 50 pounds
Solution Approach 1:
The battery pack is designed with self-lifting capability through angled connection means that utilize the insertion force to automatically lift the battery into the engaged position, eliminating the need for external lifting mechanisms or significant human effort to overcome gravity during battery replacement
Solution Approach 2:
The angled connection means create a mechanical advantage system where the horizontal insertion force is converted into vertical lifting force, effectively counteracting the battery weight during the engagement process without requiring additional power sources or complex mechanisms
2Ease of operation
If automated conveyance systems are used for battery swapping, then human workers are relieved from handling heavy batteries, but additional expense is imposed for purchasing and maintaining the battery exchange robot
Solution Approach 1:
The battery pack autonomously performs its own installation by converting horizontal insertion force into vertical lifting motion through the angled connection means, eliminating the need for external automated conveyance systems or battery exchange robots while maintaining ease of operation
Solution Approach 2:
The lifting function is extracted from the battery pack body and integrated into the connection means mechanism, allowing the connection interface itself to perform the lifting action during engagement, thereby simplifying the overall system by removing separate lifting mechanisms
3Duration of action of moving object
If larger batteries are used to extend operational time, then service time on single charge is extended, but power requirements and battery weight increase
Solution Approach 1:
The battery system is segmented into replaceable battery packs that can be quickly exchanged, allowing the robot to maintain extended operational capability through rapid swapping rather than relying on single large-capacity batteries, thereby reducing weight while maintaining duration through multiple smaller units
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 allows for hot-swapping of batteries without robot downtime, reduces energy requirements, and extends the operational life of mobile robots by enabling efficient battery management and power conservation.
Implementation Method 1
a lift counterbalance system to reduce energy consumption
Data Source
AI summary
Systems and methods for improved power supply and use in a battery powered device, such as a mobile manipulation robot, are disclosed. These systems include field replaceable batteries that may be hot-swapped with no robot downtime, methods for automating battery replacement messaging and robot operation when battery power is low, and improved mechanical systems having lower energy requirements, and thus extending the lifetime of the battery operated mobile manipulation robot.