US20230150382A1

US20230150382A1 - Pivoting charging mechanism for mobile robots

Info

Publication number: US20230150382A1
Application number: US18/055,535
Authority: US
Inventors: David Debusca; Spencer W. Allen; Joseph S. Beri; David Peduzzi
Original assignee: ST Engineering Aethon Inc
Current assignee: ST Engineering Aethon Inc
Priority date: 2021-11-15
Filing date: 2022-11-15
Publication date: 2023-05-18
Also published as: WO2023086667A3; WO2023086666A1; WO2023086667A2; US20230150321A1; EP4433326A4; AU2022386562A1; WO2023086666A9; EP4433326A1; WO2023086665A3; WO2023086665A2; US20230150139A1; US12515342B2

Abstract

Embodiments relate to a charging dock which allows a mobile robot to self-dock for charging more efficiently and reliably. The charging dock has a pivoting face including a disk fashioned with charging connection points. When a robot encounters the dock, the pivoting face is able to pivot to ensure the charging disk can align with corresponding charging pickup points within the robot's charging receptor. The pivoting face improves efficiency and reliability of the robot's docking procedures.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims the benefit of and priority to U.S. Application No. 63/279,276, filed on Nov. 15, 2022, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the transportation of carts and other loads within, for example, an indoor commercial environment using an autonomous mobile robot. More specifically, the present invention provides for a charging mechanism that allows a mobile robot to efficiently dock and charge through a pivoting charging mechanism.

BACKGROUND OF THE INVENTION

Transporting goods on wheeled carts is labor intensive, repetitive, exhausting and potentially hazardous work. This is particularly true in healthcare, hospitality, warehouse and industrial settings. Thus, the automatic movement of these carts would provide numerous benefits, financially and otherwise, to an organization and its employees.
Autonomous mobile robots are battery operated machines which require recharging. However, in order to maintain their autonomous nature these machines must be able to self-dock to a precise charging location and mechanism.
It is possible to reduce the level of navigation precision required by the robot and improve its efficiency by altering the charging dock to accommodate multiple angles of approach by the robot and still retain a connection for charging to occur.
The present disclosure is directed toward overcoming one or more of the above-mentioned problems, though not necessarily limited to embodiments that do.

SUMMARY OF THE INVENTION

The present invention describes a mechanism for mating a robot with a charging dock for the purposes of charging its onboard battery. The present invention uses a disc with charging contacts attached to a pivoting face on the charging dock. A robot with a receptacle on the traveling side of its frame approaches the dock by virtue of an onboard digital map and localization logic. As the robot approaches the dock, the circular disc on the charging dock enters the receptacle on the robot. As the robot finalizes its docking procedure it is pressed against the pivoting head which then centers the disc into the receptacle on the robot to align the charging contacts.
The present invention allows the robot to self-dock for charging more efficiently and reliably. The charging dock has a pivoting face with a disk fashioned with charging connection points. When a robot encounters the dock, this pivoting face will ensure the charging disk can align with the corresponding charging pickup points within the robot's charging receptor. An advantage of this approach is to improve the efficiency and reliability of the robot's docking procedures.
Additional features, aspects, objects, advantages, and possible applications of the present disclosure will become apparent from a study of the exemplary embodiments and examples described below, in combination with the Figures and the appended claims.
An exemplary embodiment relates to a charging dock. The charging dock includes a charging connector configured to be in electrical connection with an electrical power source, the charging connector comprising electric conductive material. The charging dock includes a pivot mechanism. The charging connector is attached to the pivot mechanism.
In some embodiments, the charging dock includes a casing configured to house the charging connector and the pivot mechanism. The casing is configured to attach to a wall or be part of a stand.
In some embodiments, the casing has a top, a bottom, a front face, a rear face, a first side, and a second side, the rear face configured to attach to a structure. The charging connector has a first end and a second end that extends in a direction from the first side to the second side, the charging connector further extending from the front face. The pivot mechanism is configured to facilitate pivotal motion of the charging connector such that the first and second ends move towards and away from the front face.
In some embodiments, the pivot mechanism includes a member attached to a pivot device.
The charging connector is attached to the member.
In some embodiments, the member is an elongate member having a first end, a second end, and an intermediary point. The member is attached to the pivot device at the intermediary point.
In some embodiments, the charging connector is attached to the member at the intermediary point.
In some embodiments, the charging connector includes a charging contact formed in or on the charging connector.
In some embodiments, the charging connector has a semi-circular disc shape.
In some embodiments, the charging connector has a semi-circular disc shape defined by a straight edge and an arcuate edge. The charging connector straight edge is attached to the pivot mechanism.
In some embodiments, the pivot mechanism is a passive device or an actuated device.
In some embodiments, the pivot mechanism including a biasing mechanism.
In some embodiments, the casing includes a flexible shroud for the pivot mechanism.
In some embodiments, the casing includes a bumper.
An exemplary embodiment relates to a robot charging system. The robot charging system includes a robot having a battery in electrical connection with a charging receptor. The robot charging system includes a charging dock. The charging dock includes a charging connector configured to be in electrical connection with an electrical power source, the charging connector comprising electric conductive material. The charging dock includes a pivot mechanism. The charging connector is attached to the pivot mechanism. The charging connector is configured to insert into the charging receptor and facilitate transfer of electrical power from the electrical power source to the battery.
In some embodiments, the charging receptor includes a guide arm configured to urge the charging connector into a slot formation within the charging receptor.
In some embodiments, the guide arm is beveled.
In some embodiments, the guide arm is attached to a biased pivot mechanism.
An exemplary embodiment relates to a method of operating a robot. The method involves causing a robot to advance towards a charging dock such that a charging connector of the charging dock inserts into a charging receptor of the robot. The method involves further advancing the robot to the charging dock to make physical contact with a pivot mechanism of the charging dock. The method involves causing the pivot mechanism to pivot the charging connector due to the physical contact between the robot and the pivot mechanism.
In some embodiments, the method involves allowing electrical power transfer from the charging connector to the charging receptor.
In some embodiments, the method involves allowing electrical power transfer from the charging receptor to a battery of the robot.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an exemplary robot with an embodiment of a charging receptor in accordance with an embodiment the present invention.

FIG. 2A an isometric view of an embodiment of a pivoting charging dock in accordance with an embodiment the present invention.

FIG. 2B shows an exemplary embodiment of a pivot mechanism.

FIG. 3A is a side view of an exemplary robot docked onto an embodiment of the pivoting charging dock attached to a wall in accordance with an embodiment the present invention.

FIG. 3B is a side view of an exemplary robot docked onto an embodiment of the pivoting charging dock attached to a stand in accordance with an embodiment the present invention.

FIG. 4 is a top view of an exemplary robot docked askew onto an embodiment of the charging dock in accordance with an embodiment the present invention.

FIG. 5 is a block diagram of an exemplary system architecture for an embodiment of the robot.

FIG. 6 shows a close-up view (top) and a cut-away view (bottom) of an exemplary charging receptor.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a front view of an exemplary robot (16) having an embodiment of a charging receptor (13). The robot (16) includes features such as a housing (50), a drive head (51), at least one wheel (52), at least one sensor (14), a computing unit (53), a user interface (15), motors, actuators, servos, encoders, etc. to facilitate it operating as an autonomous robot, semi-autonomous robot, and/or user-controlled robot. The robot (16) includes a drive system, which can comprise the drive head (51) and wheels (52) disposed on a bottom portion of the robot (16). The wheels (52) are configured to contact the ground floor and the drive head (51) is configured to provide mobility for the robot (16). Any of the wheels (52) can be drive wheels or passive wheels. A drive wheel is in electro-mechanical connection with a motor that causes to the wheel to spin. When in contact with the ground floor, the spinning wheel forces the robot (16) to move in a direction dictated by the spin direction of the wheel. A passive wheel is a wheel that spins freely and provides support for the robot's structure. The drive head (51) can be a rotatable mount, rotatable platform, a turret, etc. structure that causes the drive wheels (52) to rotate in unison when the drive head (51) is rotated so as to facilitate steering the robot (16). There is an electrical motor connected to the rotatable mount and one or more electrical motors connected to the drive wheels (52). These electric motors are in communication with the computing unit (53), wherein the computing unit (53) controls electrical power transfer to the motors to control operation of the motors. Alternatively, any of the motors can have their own processors that control their operation, wherein the computing unit (53) transmits a command signal to the processors to control operation of the motors.
The robot (16) includes a user interface (15), which can be a display screen, keypad, touchscreen, etc. configured to display information, receive input, facilitate command and control of one or more functions of the robot (16) or components of the robot (16), etc. The display of the user interface can be textual display, graphical display, audible display, etc. Command inputs can be textual, haptic, audible, etc.
The robot (16) includes a battery (54). The battery (54) can be rechargeable. The battery (54) can be a NiCd (Nickel-Cadmium) battery, a NiMH (Nickel-Metal Hydride) battery, a Li-ion (Lithium Ion) battery, etc. The battery (54) can include components such as transformers, transducers, converters, etc. to facilitate electrical power conversion and transfer. The battery (54) is in electrical connection with other components (e.g., drive head (51), drive wheel (52), sensor (14), computing unit (53), user interface (15), motors, actuators, servos, encoders, etc.) so as to provide electrical power to any one or combination of them for operation. The battery (54) is also in electrical connection with the charging receptor (13) so as to receive electrical power from the charging receptor (13). The charging receptor (13) is an opening formed in the housing (50) and includes at least one electrical contact 75 (see FIG. 6 ) (e.g., electrically conductive lead, pin, plate, etc.) configured to transmit electrical current from an electrical power source. The charging receptor (13) can also include components such as transformers, transducers, converters, etc. to facilitate electrical power conversion and transfer from the electrical power source to the battery (54).
The charging receptor (13) opening is configured to receive a charging connector (18) of a charging dock (17). The charging connector (18) comprises electric conductive material (e.g., it is fabricated of electric conductive material, it includes charging contacts (19) that are fabricated from electric conductive material, etc.). In use, the charging connector (18) is in electrical connection with an electrical power source (e.g., a 120 V or 220 V power line), wherein electrical power in the form of electric current is transferred to the electric conductive material. When the charging connector (18) is inserted into the charging receptor (13) of the robot (16), electrical connection between the charging receptor (13) and the charging connector (18) is made due to the electric conductive material making physical or electric contact with an electrical contact of the charging receptor (13). Electrical power from the electrical power source can then be transferred to the battery (54) of the robot (16) via the connection made between the charging connector (18) and the charging receptor (13).
FIG. 2A illustrates a perspective view of an embodiment of the pivoting charging dock (17) having a disc-shaped charging connector (18) having charging contacts (19), wherein the charging connector (18) is mounted to a pivot mechanism (20). The charging connector (18) is configured to fit into and mate with a charging receptor (13) (see FIG. 3 ) provided on the robot (16).
FIG. 2B shows an exemplary embodiment of a pivot mechanism (20). The charging dock (17) includes a casing (55) configured to mount to a structure (e.g., a wall (21), a stand (22), etc.) and contain the components of the charging dock (17). The charging dock (17) is configured to electrically connect to the electrical power source. The casing (55) can be a square or rectangular shaped container-like structure having a rear face (56), a front face (57), a top (58), a bottom (59), and two sides (60). The rear face (56) abuts the structure, and the front face (57) faces away from the structure. Mounting to the structure can be achieved via welding, use of adhesive, use of fasteners, etc. In an exemplary embodiment, mounting is achieved via use of fasteners inserted through mounting apertures (61) formed in the rear face of the casing (55). The casing (55) is configured to house a pivot mechanism (20). It is contemplated for the pivot mechanism (20) to be contained within a portion of the casing (55) and be in mechanical connection with a charging connector (18) that protrudes through the casing (55). The pivot mechanism (20) is a device that facilitates pivotal or rocker motion in a lateral direction (e.g., pivotal or rocker motion from one side (60) to the other side (60)). For instance, the pivot mechanism (20) includes a member (62) that has a first distal end (63), a second distal end (64), and an intermediary point (65) (e.g., central point). The pivot mechanism (20) is configured to rock about a pivot point (which is located at the intermediary point (65)) such that the first and second distal ends (63, 64) retract/extend to/from the front face (57) of the casing (55) (e.g., the member (62) rocks about the pivot point or rocks about the intermediary point (65)). The charging connector (18) is attached (e.g., via weld, adhesive, fastener, etc.) to the member (62), and thus pivots or rocks in a similar manner as the member (62) pivots or rocks. It is contemplated for the charging connector (18) to be attached to the member (62) at the intermediary point (65).
The member (62), at its intermediary point (65), is attach to a pivot device (66) (e.g., a hinge, a rocker arm, a cam, a wheel, gimbal assembly, etc.). The pivot mechanism (20) can be a passive device (e.g., freely rocks about the pivot device (66)). In the alternative, the pivot mechanism (20) can be an actuated device (e.g., connected to a motor, actuator, servo, etc. so as to facilitate active control the rocking motion). Whether actuated or passive, the pivot mechanism (20) can have a biasing mechanism (74) (e.g., a spring) to cause the pivot mechanism (20) to maintain a predetermined orientation (e.g., bias the member (62) so that it is parallel or substantially parallel with the front face (57) unless a force acts upon it to rock the member (62) to a different orientation).
The portion of the casing (55) containing the pivot mechanism (20) can include a shroud (67). The shroud (67) can be flexible/semi-rigid/deformable (e.g., made from rubber, polymer, silicone, etc.). The flexibility of the shroud (67) maintains confinement and protection for the pivot mechanism (20) but also permits rocking motion of the member (62). The shroud (67) includes a charging connector opening (68) that allows the charging connector (18) to protrude through. It is contemplated for the charging connector (18) to be a semi-circular planar member; however, other shapes can be used. For instance, the charging connector (18) can be a semi-circular disc having a straight edge (69) and an arcuate edge (70). The straight edge (69) is attached to the member (62) and the arcuate edge (70) protrudes through the shroud opening (68). Any portion of the charging connector (18) can be made of electric conducting material (e.g., iron, steel, aluminum, copper, etc.) or have at least one charging contact (19) formed in or on the charging connector (18), the charging contact (19) being made of electric conducting material. Placement and configuration of the charging contact (19) is such that when the charging connector (18) is inserted into the charging receptor (13) of the robot (16), the charging contact (19) makes physical and/or electrical contact with the electrical contact of the charging receptor (13).
In some embodiments, the charging connector (18) is attached directly to the pivot mechanism (20). For instance, the straight edge (69) is attached (e.g., welded, attached via adhesive, attached via fasteners, etc.) to the pivot device (66).
In an exemplary embodiment, the charging dock (17) is mounted to a wall (21) (see FIG. 3A) or a stand (22) (see FIG. 3B) and placed into electrical connection with an electrical power source. Placement of the charging dock (17) is such that the charging connector (18) is at an elevation from the ground floor that matches the elevation from the ground floor of the charging receptor (13) opening, thereby allowing insertion of the charging connector (18) into the charging receptor (13) opening when the robot (16) is upright. The robot (16), via user control, via autonomous control (use of maps stored in memory, use its sensor(s) 17, etc.) by the computing unit (53), or a combination of both, navigates to the charging dock (17). The robot (16) advances toward the charging dock (17) to cause the charging connector (18), or at least a portion thereof, to insert into the charging receptor (13) opening. If the robot's (16) orientation and advance is square with respect to the charging dock (17), then the charging connector (18) inserts into the charging receptor (13) opening fully and a good electrical connection between the charging receptor (13) and the charging connector (18) is made. As noted above, the robot (16) has a housing (50), and the charging receptor (13) opening is formed in the front face (57) of the robot housing (50). A square orientation and advance of the robot (16) towards the charging connector (18) is one in which the housing (50) where the charging receptor (13) opening is formed is parallel or substantially parallel to the shroud (67) where the charging connector opening (68) is formed. Electrical power can then be transferred from the electrical power source to the battery (54).
If the robot's (16) orientation and/or advance is not square, the charging connector (18) may partially insert into the charging receptor (13) opening. As the robot (16) advances further, the housing (50) makes physical contact with the shroud (67). As the robot advances even further, the robot's (16) advance forces the member (62) to pivot about the pivot device (66) such that the member rocks to a canted orientation. The canted orientation allows there to be a square orientation between the charging connector (18) and the charging receptor (13) opening. Further, the robot (16) can still move forward in an otherwise non-square advance but due to the canted orientation the advance is a square advance. The advance continues until the charging connector (18) inserts into the charging receptor (13) opening fully and a good electrical connection between the charging receptor (13) and the charging connector (18) is made. Electrical power can then be transferred from the electrical power source to the battery (54).
When the robot (16) is finished charging the battery (54), the robot (16) retreats from the charging connector (18). If the pivot mechanism (20) is not biased, it will remain in an orientation the robot (16) forced into. If the pivot mechanism (20) is biased, the biasing mechanism (74) forces the member (62) into the biased orientation.
Referring to FIG. 5 , as noted herein, some embodiments of the pivot mechanism (20) can be actuated. The actuation can be via the computing unit (53) (e.g., the computing unit (53) can communicate (e.g., wireless communication) with a processor of the pivot mechanism (20). Orientation of the robot (16) and the robot's (16) advance relative to the charging connector (18) can be determined via sensor (14) data and known data processing techniques. For instance, LIDAR, RADAR, etc. sensors (14) can generate position and orientation information, and the computing unit (53) can receive this information and determine relative position and orientation. The computing unit (53), based on the relative position and orientation determination, can transmit a command signal to the pivot mechanism (20) to cause it to rock the member (62) to an orientation that will allow for a square orientation and advance based on the robot's (16) orientation and advance. In addition, or in the alternative, the computing unit (53) can cause the robot (16) to rotate or turn to provide for a square orientation and advance.
Sensors (14) such as inductance, capacitance, or resistance sensors, for example, can be used to determine whether a good connection between the charging receptor (13) and charging connector (18) is made. For instance, inductance, capacitance, or resistance can be measured based on the electrical current flowing from the charging connector (18) to the charging receptor (13). This measurement can be compared to a threshold value. If the measurement is at or above the threshold value, then it can be determined that a good connection is made. If it is below the threshold value, it can be determined that a bad connection is made. If a bad connection is made, the computing unit (53) can: 1) cause the robot (16) to rotate or turn to provide for a square orientation and advance; 2) cause the pivot device (66) to rock to provide for a square orientation and advance; and/or 3) cause the robot (16) to back away from the charging dock (17), reposition, and advance towards the charging dock (17) at an angle that differs from a previous angle.
In some embodiments, the casing (55) can include a bumper (71). The bumper (71) can be a structure to absorb or deflect impact. For instance, the bumper (71) can be a rubber member, a spring, a roller, etc. In an exemplary embodiment, the casing includes a bumper (71) at each corner of the shroud (67).
As noted herein, the robot (16) includes a computing unit (53). The computing unit (53) can be a controller, a control module, etc. The computing unit includes a processor (72) and associated memory (73). Other components of the robot (16) or system controlling the robot may also have a processor. Any of the processors disclosed herein can be part of or in communication with a machine (e.g., a computer device, a logic device, a circuit, an operating module (hardware, software, and/or firmware), etc.). The processor can be hardware (e.g., processor, integrated circuit, central processing unit, microprocessor, core processor, computer device, etc.), firmware, software, etc. configured to perform operations by execution of instructions embodied in computer program code, algorithms, program logic, control, logic, data processing program logic, artificial intelligence programming, machine learning programming, artificial neural network programming, automated reasoning programming, etc. The processor can receive, process, and/or store data related to operations of the robot (16) or a component of the robot (16).
Any of the processors disclosed herein can be a scalable processor, a parallelizable processor, a multi-thread processing processor, etc. The processor can be a computer in which the processing power is selected as a function of anticipated network traffic (e.g., data flow). The processor can include any integrated circuit or other electronic device (or collection of devices) capable of performing an operation on at least one instruction, which can include a Reduced Instruction Set Core (RISC) processor, a CISC microprocessor, a Microcontroller Unit (MCU), a CISC-based Central Processing Unit (CPU), a Digital Signal Processor (DSP), a Graphics Processing Unit (GPU), a Field Programmable Gate Array (FPGA), etc. The hardware of such devices may be integrated onto a single substrate (e.g., silicon “die”), or distributed among two or more substrates. Various functional aspects of the processor may be implemented solely as software or firmware associated with the processor.
The processor can include one or more processing or operating modules. A processing or operating module can be a software or firmware operating module configured to implement any of the functions disclosed herein. The processing or operating module can be embodied as software and stored in a memory, the memory being operatively associated with the processor. A processing module can be embodied as a web application, a desktop application, a console application, etc.
The processor can include or be associated with a computer or machine readable medium. The computer or machine readable medium can include memory. Any of the memory discussed herein can be computer readable memory configured to store data. The memory can include a volatile or non-volatile, transitory or non-transitory memory, and be embodied as an in-memory, an active memory, a cloud memory, etc. Examples of memory can include flash memory, Random Access Memory (RAM), Read Only Memory (ROM), Programmable Read only Memory (PROM), Erasable Programmable Read only Memory (EPROM), Electronically Erasable Programmable Read only Memory (EEPROM), FLASH-EPROM, Compact Disc (CD)-ROM, Digital Optical Disc DVD), optical storage, optical medium, a carrier wave, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by the processor.
The memory can be a non-transitory computer-readable medium. The term “computer-readable medium” (or “machine-readable medium”) as used herein is an extensible term that refers to any medium or any memory, that participates in providing instructions to the processor for execution, or any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). Such a medium may store computer-executable instructions to be executed by a processing element and/or control logic, and data which is manipulated by a processing element and/or control logic, and may take many forms, including but not limited to, non-volatile medium, volatile medium, transmission media, etc. The computer or machine readable medium can be configured to store one or more instructions thereon. The instructions can be in the form of algorithms, program logic, etc. that cause the processor to execute any of the functions disclosed herein.
Embodiments of the memory can include a processor module and other circuitry to allow for the transfer of data to and from the memory, which can include to and from other components of a communication system. This transfer can be via hardwire or wireless transmission. The communication system can include transceivers, which can be used in combination with switches, receivers, transmitters, routers, gateways, wave-guides, etc. to facilitate communications via a communication approach or protocol for controlled and coordinated signal transmission and processing to any other component or combination of components of the communication system. The transmission can be via a communication link. The communication link can be electronic-based, optical-based, opto-electronic-based, quantum-based, etc. Communications can be via Bluetooth, near field communications, cellular communications, telemetry communications, Internet communications, etc.
Transmission of data and signals can be via transmission media. Transmission media can include coaxial cables, copper wire, fiber optics, etc. Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infrared data communications, or other form of propagated signals (e.g., carrier waves, digital signals, etc.).
Any of the processors can be in communication with other processors of other devices (e.g., a computer device, a computer system, a laptop computer, a desktop computer, etc.). Any of the processors can have transceivers or other communication devices/circuitry to facilitate transmission and reception of wireless signals. Any of the processors can include an Application Programming Interface (API) as a software intermediary that allows two or more applications to talk to each other. Use of an API can allow software of the processor of one device/component to communicate with software of the processor of the other device(s)/component(s).
It is contemplated for the computing unit (53) to be in communication with other components of the robot (16) (e.g., a drive head (51), drive wheel (52), sensor (14), user interface (15), motors, actuators, servos, encoders, etc.) or component of the pivot mechanism (20). Any one or combination of these components may or may not have a processor. The computing unit (53) can send command signals to the processor of these components or control electrical power transmission to these components to operate them directly. In addition, any of the components of the robot (16) can be in communication with another component. The communication can include the transmission of information data, operational data, command signals, etc. In other words, any component of the robot (16) can talk to other components of the system. This talking can be via direct communication between each component, or it can be via indirect communication via the computing unit (53).
FIGS. 3A and 3B are side views of an exemplary robot (16) docked onto an embodiment of the charging dock (17). The charging dock (17) is attached to an exemplary wall (21) (see FIG. 3A) via screws or other attachment mechanisms or is part of a stand (22) (see FIG. 3B). Typically, the charging dock (17) is mounted to the wall (21), or the stand (22) is configured, so that the height of the charging connector (18) is at a height corresponding with the charging receptor (13) on the robot (16). The robot (16) will drive up to the charging dock (17) and align itself so that the disc-shaped charging connector (18) is inserted into the robot's charging receptor (13). The robot (16) will move toward the wall (21) or stand (22) until a complete connection is effectuated (e.g., a good electrical connection is made).
FIG. 4 illustrates a top view of the robot (16) docked askew onto the charging dock (17) mounted on the exemplary wall (21). As illustrated in FIG. 4 , the pivot mechanism (20) is configured to pivot about a centralized point of the member (62) and self-adjust so that the disc shaped charging connector (18) makes contact inside of the robot's charging receptor (13) even if the robot (16) attempts to dock at an angle relative to the charging area. This helps ensure a good charging connection is made even if the robot (16) does not, or cannot, engage the charging dock (17) in perfect alignment.
Referring to FIG. 6 , as noted above, the charging receptor (13) is an opening formed in the housing (50) and includes at least one electrical contact 75 (e.g., electrically conductive lead, pin, plate, etc.) configured to transmit electrical current from an electrical power source. The charging receptor (13) can also include components such as transformers, transducers, converters, etc. to facilitate electrical power conversion and transfer from the electrical power source to the battery (54). The charging receptor (13) can also include at least one guide arm (76) configured to guide the charging connector (18) as it is advanced into the charging receptor (13). For instance, the charge receptor (13) opening can be provided with beveled arms (76) that act as ramps to urge the charging connector (18) into a slot (77) where the electrical contact(s) 75 is/are located. There can be arms (76) located at the top and bottom of the opening so that when the charging connector (18) is inserted it follows an increasingly narrower path to force it into the slot (77) such that its charging contact (19) makes physical or electrical contact with the electrical contact 75 of the charging receptor (13). Once fully inserted, the straight portions of the beveled arms (76) can sandwich the charging connector (18) and hold it in place. In some embodiments, any one or combination of the arms (76) is/are connected to a biased pivot mechanism (78) (e.g., a pivot arm (79) with a tension spring (80). The biased pivot mechanism (78) can allow the arm(s) (76) to open so as to widen the path for the charging connector (18) but are biased to a closed or more narrow position. Thus, when the charging connector (18) is inserted, the beveled portion(s) of the arm(s) (76) urge it towards the straight portion(s) of the arm(s) (76) but due to the thickness of the charging connector (18), the arm(s) is/are pivoted open as the charging connector (18) continues its advance. Yet, the pivot mechanism (78) biases the arm(s) (76) to a closed or more narrow position so as to sandwich the charging connector (18). This biasing force assists in keeping the charging connector (18) seated within the charging receptor (13) and maintaining good contact between the electrical contact 75 of the charging receptor (13) and the charging contact (19) of the charging connector (18).
It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teachings of the disclosure. The disclosed examples and embodiments are presented for purposes of illustration only. Other alternate embodiments may include some or all of the features disclosed herein. Therefore, it is the intent to cover all such modifications and alternate embodiments as may come within the true scope of this invention, which is to be given the full breadth thereof. Additionally, the disclosure of a range of values is a disclosure of every numerical value within that range, including the end points.

Claims

1. A charging dock, comprising:

a charging connector configured to be in electrical connection with an electrical power source, the charging connector comprising electric conductive material; and

a pivot mechanism;

wherein the charging connector is attached to the pivot mechanism.

2. The charging dock of claim 1, further comprising:

a casing configured to house the charging connector and the pivot mechanism; and

wherein the casing is configured to attach to a wall or be part of a stand.

3. The charging dock of claim 2, wherein:

the casing has a top, a bottom, a front face, a rear face, a first side, and a second side, the rear face configured to attach to a structure;

the charging connector has a first end and a second end that extends in a direction from the first side to the second side, the charging connector further extending from the front face;

the pivot mechanism is configured to facilitate pivotal motion of the charging connector such that the first and second ends move towards and away from the front face.

4. The charging dock of claim 1, wherein:

the pivot mechanism includes a member attached to a pivot device; and

the charging connector is attached to the member.

5. The charging dock of claim 4, wherein:

the member is an elongate member having a first end, a second end, and an intermediary point; and

the member is attached to the pivot device at the intermediary point.

6. The charging dock of claim 5, wherein:

the charging connector is attached to the member at the intermediary point.

7. The charging dock of claim 1, wherein:

the charging connector includes a charging contact formed in or on the charging connector.

8. The charging dock of claim 1, wherein:

the charging connector has a semi-circular disc shape.

9. The charging dock of claim 1, wherein:

the charging connector has a semi-circular disc shape defined by a straight edge and an arcuate edge; and

the charging connector straight edge is attached to the pivot mechanism.

10. The charging dock of claim 1, wherein:

the pivot mechanism is a passive device or an actuated device.

11. The charging dock of claim 1, wherein:

the pivot mechanism including a biasing mechanism.

12. The charging dock of claim 2, wherein:

the casing includes a flexible shroud for the pivot mechanism.

13. The charging dock of claim 2, wherein:

the casing includes a bumper.

14. A robot charging system, comprising:

a robot having a battery in electrical connection with a charging receptor;

a charging dock, comprising:

a pivot mechanism;

wherein the charging connector is attached to the pivot mechanism;

wherein the charging connector is configured to insert into the charging receptor and facilitate transfer of electrical power from the electrical power source to the battery.

15. The robot charging system of claim 14, wherein:

the charging receptor includes a guide arm configured to urge the charging connector into a slot formation within the charging receptor.

16. The robot charging system of claim 15, wherein:

the guide arm is beveled.

17. The robot charging system of claim 15, wherein:

the guide arm is attached to a biased pivot mechanism.

18. A method of operating a robot, the method comprising:

causing a robot to advance towards a charging dock such that a charging connector of the charging dock inserts into a charging receptor of the robot;

further advancing the robot to the charging dock to make physical contact with a pivot mechanism of the charging dock; and

causing the pivot mechanism to pivot the charging connector due to the physical contact between the robot and the pivot mechanism.

19. The method of claim 18, further comprising:

allowing electrical power transfer from the charging connector to the charging receptor.

20. The method of claim 18, further comprising:

allowing electrical power transfer from the charging receptor to a battery of the robot.