Autonomous robot charging stations and methods

• US 8,442,682 B2
• Filed: 05/28/2010
• Issued: 05/14/2013
• Est. Priority Date: 05/28/2010
• Status: Active Grant

• Current Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Original Assignee: Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Wagner, David J.
• Primary Examiner(s): Tran, Khoi
• Assistant Examiner(s): HOLLOWAY, JASON R
• Application Number:
  US12/790,021
• Publication Number:
  US 20110295420A1
• Time in Patent Office: 1,082 Days
• Field of Search: 700/245, 700/258, 700/259, 320/109, 320/DIG.35, 901/1
• US Class Current: 700/258
• CPC Class Codes: A47L 2201/022 Recharging of batteries
• CPC Class Codes: G05D 1/0225 involving docking at a fixed facility, e.g. base station or loading bay parking aids B62D15/027
• CPC Class Codes: G05D 1/024 in combination with a laser lasers per se H01S
• CPC Class Codes: G05D 1/0274 using mapping information stored in a memory device navigation using map-matching G01C21/30
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A method of charging a robotic device using a charging station is provided. The method includes signaling a controller of the charging station to actuate a moveable barrier of the charging station from a closed configuration to an open configuration. The charging station is recessed into a wall, ceiling and/or floor. The moveable barrier is actuated from the closed configuration to the open configuration thereby exposing an electrical contact of the charging station configured to engage a charging contact of the robotic device for a charging operation.

Claims

1. A method of charging a robotic device using a charging station, the method comprising:

signaling a controller of the charging station configured to control actuation a moveable barrier of the charging station from a closed configuration to an open configuration, the charging station being recessed into a wall, ceiling and/or floor; and

actuating the moveable barrier from the closed configuration to the open configuration thereby exposing an electrical contact of the charging station configured to engage a charging contact of the robotic device for a charging operation;

and detecting a presence of an obstacle using an obstacle sensor, the obstacle sensor providing an indication to the controller of the charging station if an obstacle is detected.

2. The method of claim 1 comprising detecting presence of the obstacle prior to actuating the moveable barrier using a non-contact sensor.

3. The method of claim 1 comprising detecting presence of the obstacle when the moveable barrier contacts the obstacle using a contact sensor.

4. The method of claim 1, wherein the step of actuating the moveable barrier includes pivoting the moveable barrier.

5. The method of claim 1, wherein the step of actuating the moveable barrier includes sliding the moveable barrier.

6. The method of claim 1 further comprising the robotic device engaging the electrical contact of the charging station with the charging contact carried by the robotic device.

7. The method of claim 6, wherein the electrical contact of the charging station is located on an interior surface of the moveable barrier.

8. The method of claim 1, wherein the charging station comprises a housing having a depth that is recessed into the wall, ceiling and/or floor about 50 percent or more.

9. A robotic system, comprising:

a robotic device including a controller and a charging contact; and

a charging station comprising;

a housing configured to be recessed into a wall, floor and/or ceiling;

a mounting structure for mounting the housing to the wall, floor and/or ceiling;

a moveable barrier having a closed configuration where an electrical contact of the charging station is at least partially enclosed within the housing preventing access to the electrical contact by the robotic device and an open configuration allowing access to the electrical contact by the robotic device;

a station controller that actuates the moveable barrier from the closed configuration to the open configuration; and

an obstacle sensor that provides an indication to the station controller if an obstacle is detected.

10. The robotic system of claim 9, wherein the controller of the robotic system is configured to signal the station controller of the charging station to initiate a barrier actuation sequence.

11. The robotic system of claim 9, wherein the electrical contact is located on an interior surface of the moveable barrier.

12. A method of assembling a charging station for a robotic device, the method comprising:

mounting a moveable barrier to a housing of the charging station;

operatively connecting an actuator to the moveable barrier to move the moveable barrier from a closed configuration where an electrical contact for a robotic device charging operation is at least partially enclosed within the housing and an open configuration where the electrical contact is exposed for engaging a charging contact of the robotic device and

providing the charging station with an obstacle sensor configured to detect the presence of an obstacle, the obstacle sensor providing an indication to a controller of the charging station if an obstacle is detected.

13. The method of claim 12, wherein the obstacle sensor is a non-contact sensor for detecting presence of the obstacle prior to actuating the moveable barrier.

14. The method of claim 12, wherein the obstacle sensor is a contact sensor for detecting presence of the obstacle when the moveable barrier contacts the obstacle.

15. The method of claim 12, wherein the actuator pivots the moveable barrier between the open and closed configurations.

16. The method of claim 12, wherein the actuator slides the moveable barrier between the open and closed configurations.

17. The method of claim 12, wherein the electrical contact of the charging station is located on an interior surface of the moveable barrier.