Robot Wireless Charging Pads With Multi-Directional Alignment Tolerance
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Solution Overview
Problem
Existing autonomous robots require human intervention for charging, which is time-consuming and poses safety risks, especially in outdoor settings, and existing hot-swappable battery solutions are costly and unsafe.
Innovation Solution
A wireless charging system for autonomous robots, comprising a stationary charging unit, mobile charging pad, and mobile charging unit, enabling contactless and multi-directional charging with alignment tolerances up to 40 mm air gap and 30 mm lateral displacement, using electromagnetic induction and a Battery Management System for safe and efficient charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual charging plug is used, then charging can be performed, but human intervention is required which is time-consuming and expensive
Solution Approach 1:
The autonomous robot performs charging operations independently without human assistance. The robot autonomously navigates to the charging station, aligns its mobile charging pad with the stationary charging pad, and completes the wireless energy transfer process, thereby eliminating the need for manual plugging and reducing charging time loss.
Solution Approach 2:
The patent replaces the mechanical plug-and-socket charging system with a wireless electromagnetic induction charging system. The mobile charging pad on the robot communicates with the stationary charging unit to transfer energy wirelessly, substituting mechanical contact with electromagnetic field-based energy transfer, which improves automation and reduces time loss.
2Productivity
If hot-swappable battery is used, then robot can continue functioning, but safety risks and higher costs are incurred
Solution Approach 1:
The patent replaces the hot-swappable mechanical battery system with a wireless electromagnetic induction charging system. This substitution eliminates the physical battery swapping operation and associated safety risks such as electrical hazards, sparks, and fires, while maintaining continuous operation capability through seamless wireless energy transfer.
Solution Approach 2:
The wireless charging system introduces an electromagnetic field as an intermediary for energy transfer between the stationary charging unit and the mobile charging pad. This intermediary mechanism eliminates direct physical contact and potential electrical hazards associated with hot-swappable batteries, thereby improving safety while maintaining productivity.
3Productivity
If precise alignment is required for charging, then charging efficiency is improved, but system complexity and difficulty of operation increase
Solution Approach 1:
The patent employs dynamic alignment mechanisms where the mobile charging pad and stationary charging unit continuously adjust their positions and orientations during the charging process. The system uses real-time communication and feedback to maintain optimal alignment, allowing for operational flexibility and ease of use while preserving charging efficiency through adaptive positioning.
Solution Approach 2:
The wireless charging system incorporates feedback mechanisms where the mobile charging unit communicates with the stationary charging unit to monitor alignment status and adjust positioning accordingly. This feedback loop ensures efficient energy transfer while simplifying operation, as the system automatically corrects misalignment without requiring precise manual positioning by the user.
4Ease of operation
If wireless charging with air gap tolerance is implemented, then ease of operation is improved, but charging efficiency may be reduced
Solution Approach 1:
The patent implements a dynamic wireless charging system that adapts to varying air gap distances between the mobile charging pad and stationary charging unit. The system continuously adjusts transmission power and frequency to maintain efficient energy transfer across different gap tolerances, thereby preserving charging efficiency while providing operational ease through tolerance to misalignment.
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
Enables autonomous, efficient, and versatile charging without human intervention, reducing downtime and safety hazards, allowing robots to quickly recharge from various angles and positions, enhancing operational efficiency and safety.
Implementation Method 1
A wireless charging system for autonomous robots, comprising a stationary charging unit, mobile charging pad, and mobile charging unit, enabling contactless and multi-directional charging with alignment tolerances up to 40 mm air gap and 30 mm lateral displacement, using electromagnetic induction
Data Source
AI summary
A wireless charging system and method is described for an outdoor autonomous robot. The system comprises a stationary charging unit, a stationary charging pad connected to the stationary charging unit, a mobile charging pad attached to the autonomous robot for capturing wireless energy transferred from the stationary charging pad, and a mobile charging unit connected to the mobile charging pad for translating the wireless energy for a battery of the autonomous robot. The mobile charging unit is adapted to communicate with the stationary charging unit for contactless and wireless charging of the autonomous robot from more than one direction of alignment in between the stationary charging pad and the mobile charging pad.