Abstract:
Corresponding threaded mechanical fasteners are automatically aligned with an alignment guide. The alignment guide includes a tapered cavity defined in a housing. As the threaded mechanical fasteners are moved towards one another to mate, the tapered cavity in the alignment guide causes the threaded mechanical fasteners to align with each other. The mechanical fasteners can connect a modular rechargeable battery to a battery receptacle in a vehicle.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 62/180,680, entitled “Self-Aligning Mechanical Fastener,” filed on Jun. 17, 2015, which is hereby incorporated by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure generally relates to mechanical fasteners for mating physical components of an apparatus. 
       BACKGROUND 
       [0003]    Physical components often need to be mated or joined together to form an apparatus. Such components can be mated or joined together with an adhesive (e.g., glue), a clamp, a nail, a screw, a bolt, or a similar device. Screws and bolts include a head and a threaded shaft that is driven into one or more physical components to mechanically secure the components together. A driving apparatus (screwdriver, wrench, Allen wrench, or similar device) drives the head, which causes the threaded shaft to rotate. A bolt or nut can be attached to a proximal end of the threaded shaft, which can be rotatably tightened to generate a mechanical force between the head and the bolt/nut to secure one or more parts therebetween. 
         [0004]    In order to drive the head, accurate mechanical alignment is required between the driving apparatus and the head. For example, a screw head or bolt head includes a recessed portion to receive a corresponding end of a flathead or Phillips screwdriver. Bolt heads can also have a raised or recessed hexagonal shape that allows the bolts to be engaged by a wrench. In addition, accurate mechanical alignment is required between the threaded shaft and a bolt or nut to drive the threaded shaft into the bolt/nut. 
         [0005]    Although such mechanical alignment can be done manually by a human with relative ease, challenges arise in automated systems. For example, robotic systems need expensive and complex optical devices for guidance and alignment. In addition, robotic systems need to manipulate and keep track of multiple loose/detached components (e.g., screws, bolts, etc.). 
         [0006]    The present disclosure provides improved and lower-cost alignment systems for mechanical fasteners. 
       SUMMARY 
       [0007]    The following description and drawings set forth certain illustrative implementations of the disclosure in detail, which are indicative of several exemplary ways in which the various principles of the disclosure may be carried out. The illustrative examples, however, are not exhaustive of the many possible embodiments of the disclosure. Other objects, advantages and novel features of the disclosure will be set forth in the following detailed description of the disclosure when considered in conjunction with the drawings. 
         [0008]    In an aspect, the invention is directed to a self-aligning mechanical fastener system. The system includes a first apparatus comprising a first threaded fastener disposed at least partially in a first fastener guide hole defined in a first fastener guide housing; and a motor in mechanical communication with said first fastener component. The system also includes a second apparatus comprising a second threaded fastener disposed at least partially in a second fastener hole defined in a second fastener housing, the second fastener configured to mate with the first threaded fastener; a second fastener alignment guide disposed on the second fastener housing, the second fastener alignment guide including a hollow body having a hollow body aperture defined by an internal tapered wall, the hollow body aperture having a first width at a first end of the hollow body and a second width at a second end of the hollow body, the first width greater than the second width, the second width configured to align the first threaded fastener with the second threaded fastener when the first fastener guide housing is disposed in the hollow body aperture of the hollow body aperture of the second fastener alignment guide; and a plate connecting the second end of the second fastener alignment guide to the second fastener guide housing, the plate having a plate hole in alignment with the hollow body aperture and the second fastener hole, the plate hole having a plate hole width less than a width of at least a portion of the second threaded fastener disposed in the second fastener hole, wherein the plate secures at least a portion of the second threaded fastener in the second fastener hole. 
         [0009]    In another aspect, the invention is directed to an apparatus comprising: a housing including a housing hole defined in a housing face of the housing; a threaded fastener including at least a portion of the fastener disposed in the hole, the at least a portion of the fastener having a fastener width; a plate disposed on the housing face, the plate having a plate hole aligned with the housing hole, the plate hole having a width less than the fastener width, wherein the plate retains the at least a portion of the fastener in the housing hole; and an alignment guide including a body having opposing first and second faces, the first face disposed on the plate, the body having a cavity extending from the first face to the second face, the cavity having a first width at the first face and a second width at the second face, the second width greater than the first width, the cavity aligned with the plate hole and the housing hole. 
         [0010]    In another aspect, the invention is directed to a method comprising: with a robot, raising a portable apparatus towards a stationary apparatus, the portable apparatus including an alignment guide including a body having opposing first and second faces, the body having a cavity extending from the first face to the second face, the cavity having a first width at the first face and a second width at the second face, the second width greater than the first width; inserting the stationary apparatus into the cavity on the second face of the portable apparatus; aligning a first threaded fastener at least partially disposed in a first housing of the stationary apparatus with a corresponding second threaded fastener at least partially disposed in a second housing of the portable apparatus, the second housing disposed on the second face of the alignment guide, the first threaded fastener aligned with the cavity in the alignment guide; and rotating the first threaded fastener to engage and secure the first threaded fastener with the corresponding second threaded fastener. 
         [0011]    This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with some aspects of the present invention as set forth in the remainder of the present application with reference to the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    For a fuller understanding of the nature and advantages of the present invention, reference is made to the following detailed description of preferred embodiments and in connection with the accompanying drawings, in which: 
           [0013]      FIG. 1  illustrates a cross section of an exemplary automated system that includes a mechanical fastener; 
           [0014]      FIG. 2  illustrates a perspective view of a cross section of the automated system of  FIG. 1 ; 
           [0015]      FIG. 3  illustrates a side view of an exemplary automated system having an alternative configuration; 
           [0016]      FIG. 4  illustrates the automated system of  FIG. 3  during a first stage of alignment; 
           [0017]      FIG. 5  illustrates the automated system of  FIG. 3  during a second stage of alignment; 
           [0018]      FIG. 6  illustrates the automated system of  FIG. 3  during a third stage of alignment; 
           [0019]      FIG. 7  illustrates the automated system of  FIG. 3  in a fully-aligned state; 
           [0020]      FIG. 8  illustrates an automated system having an alternative configuration; 
           [0021]      FIG. 9  illustrates the automated system of  FIG. 8  during a first stage of alignment; 
           [0022]      FIG. 10  illustrates the automated system of  FIG. 8  during a second stage of alignment; 
           [0023]      FIG. 11  illustrates the automated system of  FIG. 8  during a third stage of alignment; 
           [0024]      FIG. 12  illustrates the automated system of  FIG. 8  in a fully-aligned state; 
           [0025]      FIG. 13  illustrates a perspective view of an automated system including a robotic system and a removable apparatus in a disconnected state; and 
           [0026]      FIG. 14  illustrates a perspective view of the automated system of  FIG. 13  where each removable apparatus is in a secured state. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]      FIG. 1  illustrates a cross section of an exemplary automated system  10  that includes a mechanical fastener. The system includes a robotic system  20  for driving a bolt  30 . The robotic system  20  includes an actuating mechanism  40  (e.g., a motor) having an actuator gear  45  that mechanically communicates with a bolt gear  50 . In some embodiments, a chain connects actuator gear  45  and bolt gear  50 . Alternatively, actuator gear  45  and bolt gear  50  interleave each other. The bolt gear  50  is mechanically coupled to a head  32  of the bolt  30  to provide torque thereto. A shaft  35  of the bolt  30  is disposed in a channel  65  defined in bolt guide  60 . The bolt guide  60  is attached to a support plate  70 , which can be connected to a larger system (e.g., an electric vehicle). A threaded portion  34  of the bolt shaft extends beyond the bolt guide  60  to engage nut  120 . A thrust bearing  80  can be disposed between the head  32  of the bolt  30  and the support plate  70  to reduce friction therebetween. Additional sliding mechanical interfaces, including lubricated or polished metal surfaces, ceramics, polymers, or bearings can facilitate the smooth movement of contacting parts against each other in any of the present embodiments as would suit a particular application. Therefore, the particular configurations of the shown illustrative examples are not intended to be limiting, and those skilled in the art will appreciate equivalent or alternate embodiments and arrangements consistent with the present disclosure, which are also comprehended by the present disclosure and claims. 
         [0028]    The bolt  30  and nut  120  provide a mechanical connection between (a) bolt guide  60  and support plate  70  (and anything connected to support plate  70 ) and (b) removable apparatus  100 . The removable apparatus  100  includes a body  110  having a channel  115  defined therein to hold nut  120 , which is disposed on a spring  130 . The channel  115  can be square, hexagonal, or a similar shape (e.g., an angular shape) in a second cross section orthogonal to the plane defining the side view illustrated in  FIG. 1 . The shape and size of channel  115  are configured to prevent the nut  120  from rotating when it is engaged by the bolt  30 . 
         [0029]    A plate  140  is disposed on the body  110 . The plate  140  can be connected to a larger system, such as a tray that holds multiple modular replaceable electric batteries as described below. The plate  140  includes a hole  145  disposed over the channel  115 . The hole  145  has a smaller diameter than the channel  115  to retain the nut  120  in the channel  115 . A hollow tapered guide  150  is disposed on the plate  140 . The tapered guide  150  includes a tapered portion  152  and a channel portion  154 . The tapered portion  152  tapers from a wide diameter to the narrower diameter of the channel portion  154 . The width of the channel portion  154  is configured to secure the bolt guide  60  so that the threaded portion  34  of bolt  30  is aligned with the nut  120  through hole  145  and channel  115 . In some embodiments, the width of the channel portion  154  is about 0.25″ to about 0.5″ larger than the width of the bolt guide  60 . 
         [0030]    In operation, the removable apparatus  100  is moved (e.g., by a second robotic system) below the automated system  10  for connection thereto. The removable apparatus  100  is positioned so that the nut  120  is in approximate alignment with the bolt  30  (e.g., as illustrated in  FIG. 1 ). The removable apparatus  100  and the automated system  10  are brought closer to one another so that the bolt  30  and nut  120  are in contact with one another. In some embodiments, the removable apparatus  100  is moved towards (e.g., raised, positioned from the side, etc.) the automated system  10  (i.e., towards bolt guide  60 ). In addition, or in the alternative, the automated system  10  including bolt guide  60  can be moved towards (e.g., lowered, positioned from the side, etc.) the removable apparatus  100 . 
         [0031]    If the alignment of the nut  120  and the bolt  30  is offset, the bolt guide  60  touches a sidewall of the tapered portion  152  of the tapered guide  150  as the removable apparatus is raised. The tapered portion  152  causes the bolt guide  60  to align with and pass through the channel portion  154  resulting in alignment of the bolt  30  and nut  120 . 
         [0032]    When the bolt  30  contacts the nut  120 , the spring  130  provides a force to press the nut  120  against the bolt  30  to cause the nut  120  to engage with the bolt  30  as the actuator  40  turns the bolt  30 . The threaded portion  34  is driven into the bolt  30  by the actuator  40  until the bolt guide  60  contacts the plate  140  and a minimum torque level is achieved, resulting in a secure mechanical connection between the removable apparatus  100  and the automated system  10 . The actuator  40  can include a sensor to measure the torque applied to the bolt  30 . When the minimum or predetermined torque level is reached, a feedback circuit can cause the actuator  40  to stop driving the bolt  30 . The minimum/predetermined torque level can be adjusted manually (e.g., by user input from an operator) or automatically (e.g., based on the type of removable apparatus  100 , bolt  30 , nut  120 , etc.). 
         [0033]    Although the automated system  10  has been described as stationary and the removable apparatus  100  is described as moveable, it is recognized that the converse can also apply. In other words, the automated system  10  can be moveable and the removable apparatus  100  can be stationary. Alternatively, both the removable apparatus  100  and the automated system  10  can be moveable. 
         [0034]    In some embodiments, the automated system  10  is disposed in an electric vehicle (e.g., in the bottom of the vehicle). The removable apparatus  100  can include one or more rechargeable batteries (e.g., in the body  110  and/or connected to plate  140 ) to power the electric vehicle. In some embodiments, the body  110  includes or holds one or more modular rechargeable batteries. In some embodiments, the plate  140  is connected to or secures one or more modular rechargeable batteries. When the battery/modular battery is mechanically connected to the automated system (on the vehicle), an electrical connection between the battery and the vehicle can also be formed. The batteries can be part of a removable tray that includes additional components for the vehicle. The batteries can be electrically connected to one another in the tray and the tray can include one or more electrical outputs for electrically connecting the tray to the vehicle. 
         [0035]    As an alternative to recharging the battery of the electric vehicle (e.g., in a rapid charging station or a traditional charging station), the battery (or modular batteries) can be replaced with a fully charged battery, or batteries, (e.g., the removable apparatus  100 ). The battery replacement can be completely automated using modular robots to remove the old batteries from the car and move the new batteries to approximate alignment with the automated system  10 , as described above. An example of a robotic system to replace or recharge batteries (or battery modules) in a vehicle is disclosed in U.S. Provisional Application No. 62/180,686, entitled “Robot Assisted Modular Battery Interchanging System,” filed on Jun. 17, 2015, and its related applications, which are hereby incorporated by reference. 
         [0036]      FIG. 2  illustrates a perspective view of a cross section of the automated system  10  described above. In  FIG. 2 , additional details of the actuator gear  45  and bolt gear  50  are illustrated. The actuator gear  45  is driven by actuating mechanism  40  (e.g., a motor). The actuator gear  45  drives bolt gear  50 , which in turn drives bolt  30  into nut  120 . 
         [0037]    Although the above system has been described with respect to a bolt being driven by a robotic system into a nut disposed in a removable apparatus, it is recognized that the system can have the opposite configuration. That is, a nut can be driven by the robotic system into a bolt disposed in a removable apparatus. 
         [0038]      FIG. 3  illustrates a side view of an exemplary automated system  300  having an alternative configuration. The system  300  includes a robotic system  310  for driving a nut  320  into a bolt  330  disposed in removable apparatus  301 . The nut  320  is disposed in a channel  385  defined in nut guide  380 . Nut guide  380  is attached to a support plate  390 , which can be connected to a larger system (e.g., an electric vehicle) in some embodiments. 
         [0039]    The robotic system  310  includes an actuating mechanism  350  (e.g., a motor) having an actuator gear  360  that mechanically communicates with a bolt gear  370 . The bolt gear  370  is mechanically coupled to nut  320  via shaft  375 . The actuating mechanism  350  drives actuator gear  360 , which drives bolt gear  370 , which in turn drives shaft  375  and nut  320 . 
         [0040]    Removable apparatus  301  includes a body  305  having a channel  315  defined therein to hold bolt  330 , which is disposed on a spring  340 . The channel  315  can be square, hexagonal, or a similar shape (e.g., an angular shape) in a second cross section orthogonal to the plane defining the side view illustrated in  FIG. 3 . The shape and size of channel  315  are configured to prevent the bolt  330  from rotating when it is engaged by the nut  320 . 
         [0041]    A plate  340  is disposed on the body  305 . The plate  305  can be connected to a larger system, such as a tray that holds multiple modular replaceable electric batteries as described below. The plate  305  includes a hole  345  disposed over the channel  315 . The hole  345  has a smaller diameter than the channel  345  to retain the head  332  in the channel  115 . A tapered bolt guide  335  is disposed on the plate  340 . The tapered bolt guide  335  includes a hollow tapered region  337  to receive the nut guide  380 . The tapered portion  337  tapers from a wide diameter to a narrow diameter at base  339 . The width of the base  339  is configured to secure the nut guide  380  so that the bolt  330  is aligned with the nut  320 . In some embodiments, the width of base  339  is about 0.25″ to about 0.5″ larger than the width of nut guide  380 . 
         [0042]    In operation, the removable apparatus  301  is moved (e.g., by a second robotic system) below the automated system  300  for connection thereto. The removable apparatus  301  is positioned so that the bolt  330  is in approximate alignment with the nut  320  (e.g., as illustrated in  FIG. 3 ). The removable apparatus  301  and the automated system  300  are then brought closer to one another so that the bolt  330  and nut  320  are in contact with one another. In some embodiments, the removable apparatus  301  is moved towards (e.g., raised, positioned from the side, etc.) the automated system  300  (i.e., towards nut guide  380 ). In addition, or in the alternative, the automated system  300  including nut guide  380  can be moved towards (e.g., lowered, positioned from the side, etc.) the removable apparatus  301 . 
         [0043]      FIG. 4  illustrates the automated system of  FIG. 3  during a first stage of alignment. If the alignment of the nut guide  380  and bolt guide  335  is offset, the nut guide  380  contacts an outwardly-tapered sidewall  339  of the tapered guide  335  on removable apparatus  301  as the removable apparatus  301  is raised towards the automated system  300  (i.e., towards nut guide  380 ). 
         [0044]      FIG. 5  illustrates the automated system of  FIG. 3  during a second stage of alignment. As illustrated in  FIG. 5 , the tapered sidewall  339  causes the bolt guide  335  to align with the nut guide  380  as the bolt guide  335  (and removable apparatus  301 ) is raised towards the nut guide  380 . Nut guide  380  includes an outwardly-flared hollow portion  385  that extends from nut  320  to the bottom face of nut guide  380 . The hollow portion  385  is configured to receive the tip  334  of the bolt  330  to align nut  320  and bolt  330 . 
         [0045]      FIG. 5  illustrates the automated system of  FIG. 3  during a third stage of alignment. As illustrated in  FIG. 6 , after the tip  334  of bolt  330  passes through hollow portion  385  of nut guide  380 , the nut  320  and bolt  330  are aligned. The hollow portion  385  can also prevent that the complementary threads of nut  320  and bolt  330  are aligned and not cross-threaded. The hollow portion  385  can be about 0.2 inches to about 0.4 inches in length, about 0.25 inches to about 0.35 inches in length, about 0.3 inches in length, or any length or range between any two of the foregoing values. As used herein, “about” means plus or minus 10% of the relevant value. 
         [0046]    In some embodiments, the nut  320  and bolt  330  can include complementary chamfered portions proximal to the respective threads on nut  320  and bolt  330 . For example, nut  330  can include a male chamfered portion and bolt  330  can include a female chamfered portion. Alternatively, nut  320  can include a female chamfered portion and bolt  330  can include a male chamfered portion. 
         [0047]      FIG. 7  illustrates the automated system of  FIG. 3  in a fully-aligned state. As illustrated, the nut  320  and bolt  330  are fully aligned and engaged. 
         [0048]      FIG. 8  illustrates an automated system  800  having an alternative configuration. As illustrated, the automated system  800  includes an actuating mechanism  850  (e.g., a motor) disposed above support plate  890 . Actuating mechanism  850  mechanically communicates and drives nut  820  through bevel gear  855 . Placing actuating mechanism  850  above support plate  890  reduces the density of components disposed below support plate  890 , which can allow for a system having a higher density of removable apparatus  801  (e.g., battery modules). In addition, the actuating mechanism  850  is protected by support plate  890  from inadvertent contact (e.g., by robots), which could damage actuating mechanism  850 . 
         [0049]    Similar to previous figures,  FIG. 8  illustrates a tapered bolt guide  835  and a nut guide  880  including a flared portion, which are both used to align nut  820  and bolt  830 .  FIGS. 9-12  illustrate the alignment and positioning of bolt guide  835 , nut guide  880 , bolt  830 , and nut  820 , similar to the description above with respect to  FIGS. 3-7 . 
         [0050]      FIG. 13  illustrates a perspective view of an automated system  1300  including robotic system  1320  and removable apparatus  1301 A in a disconnected state. The automated system  1300  includes a robotic system  1320  that includes a plurality of actuators  1340  that are each connected to respective bolts and bolt guides (and/or nuts and nut guides, depending on the embodiment), as described above. The removable apparatus  1301 A comprises a tray  1310  that includes a plurality of tapered guides  1350  and respective channels for holding nuts and springs (and/or bolts and springs, depending on the embodiment), as described above. The tray  1310  can include a plurality of modular components (e.g., rechargeable batteries) or a single component. A plurality of removable apparatus  1301 B,  1301 C in a secured state is illustrated adjacent the disconnected removable apparatus  1301 A for reference. 
         [0051]      FIG. 14  illustrates a perspective view of the automated system  1300  of  FIG. 13  where each removable apparatus  1301 A- 1301 C is in a secured state. 
         [0052]    It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. 
         [0053]    Unless otherwise defined, all technical and scientific terms used herein have the same meanings as are commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods are described herein. The present materials, methods, and examples are illustrative only and not intended to be limiting. 
         [0054]    It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.