Autonomous Rover Charging System with Hot-Pluggable Modules
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Solution Overview
Problem
Automated vehicles in material handling systems require frequent charging, and existing charging systems are often limited to specific locations, disrupting the continuous operation of these vehicles during material transfer and storage processes.
Innovation Solution
A charging system that includes a network of alternating current (AC) distribution, multiple charging supplies with communication ports, and 'hot pluggable' charging modules capable of switching between constant current, voltage, and power modes, allowing autonomous rovers to charge at any location within the storage and retrieval system, including during material transfer, using a control system that allocates power based on the charge level of each rover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If charging is limited to specific locations, then charging infrastructure complexity is reduced, but autonomous rover operational continuity is disrupted
Solution Approach 1:
The charging system is segmented into multiple independent charging supplies distributed throughout the warehouse, each capable of operating autonomously. This allows rovers to access charging at any location without requiring a centralized complex charging infrastructure, thus maintaining operational continuity while managing system complexity through modular distribution.
Solution Approach 2:
Charging supplies are designed with universal functionality to serve multiple purposes: they can charge different rover types, operate in various locations, and provide both constant current and constant voltage charging modes. This multi-functionality eliminates the need for location-specific charging solutions, maintaining operational flexibility without proportionally increasing overall system complexity.
2Use of energy by moving object
If rovers must stop to charge, then energy storage units are recharged, but material transfer productivity is reduced
Solution Approach 1:
The system enables continuous charging operations where rovers can charge during material transfer activities without stopping their productive work. The hot-pluggable charging modules allow power transfer to occur simultaneously with rover movement and material handling, eliminating idle charging time and maintaining continuous productivity.
Solution Approach 2:
The charging system transitions from static location-based charging to dynamic on-the-move charging. Rovers can establish charging connections while in motion or during material transfer operations, allowing energy replenishment to occur dynamically without interrupting the productive workflow, thus maintaining productivity while ensuring energy supply.
3Reliability
If charging modules are fixed, then system reliability is improved, but adaptability to different rover charge levels is reduced
Solution Approach 1:
Charging supplies are designed with dynamic switching capability between constant current and constant voltage modes, allowing automatic adaptation to different rover battery states. This dynamic operation maintains system reliability through controlled power delivery while providing versatility to handle various charge levels and rover types without requiring multiple fixed charging solutions.
Solution Approach 2:
The charging system changes operational parameters (current and voltage levels) based on the rover's charge state and requirements. By dynamically adjusting these electrical parameters, the system maintains reliable operation across different conditions while adapting to various rover energy storage unit states, eliminating the need for fixed single-mode charging configurations.
4Ease of operation
If multiple charging supplies are distributed throughout the system, then rover charging accessibility is improved, but system complexity increases
Solution Approach 1:
The charging system is divided into multiple independent, modular charging supplies distributed throughout the warehouse. Each module operates autonomously with standardized interfaces, providing easy accessibility to rovers at any location while managing complexity through modular design that allows independent installation, maintenance, and operation of each charging unit.
Data Source
AI summary
A charging system for an autonomous rover includes a charging interface with contacts that interface with the autonomous rover, a rover power source for the autonomous rover, and circuitry operated by the autonomous rover for controlling charging of the rover power source.