Legged robot

A legged robot having a frame with a plurality of links in mechanical communication with plurality of brackets, the frame forming a front, back, top, bottom, and sides, legs in mechanical communication with one or more of the plurality of brackets, each leg having a knee motor, an abduction motor, and a hip motor, a computer module in mechanical communication with one or more of the plurality of brackets and in electrical communication with the legs, and a power module in mechanical communication with one or more of the plurality of brackets and in electrical communication with the legs and the computer module.

BACKGROUND

Due to their electromechanical complexity, legged robots can be difficult to maintain and repair without a highly trained technician present. This may limit functionality and use of such robots, particularly when technicians are not immediately available or in high-stress environments such as military or policing situations where a complex design will increase the time to repair or make onsite repair difficult or impossible. The issue may be further complicated when a robot is desired for operation in harsh environments where componentry may rapidly deteriorate or the robotic device has a high probability of damage during operation. It may be advantageous for a robotic system to have a modular design, such that core components may be interchanged by users with less repair experience or knowledge of the system design. Because robotic systems may be desired for use in environments hostile to human presence, it may also be advantageous for component interchange to be possible without requiring humans to be in physical proximity to the robotic system.

Users of robots, and specifically legged robots, may want to interchange variants of key components for different use cases and environments without purchasing a new robot. For example, an exoskeleton frame may be sized larger to accommodate a larger sensor, battery or robotic actuator and leg, or robotic actuator. Similarly, a leg may be sized in length for a specific application such as subterranean tunnel exploration or for climbing stairs, while different sizes and types of motors may be used for specific tasks and power requirements, such as to move over certain substrates such as sand or mud, swim in water or carry heavier payloads. Such interchangeability increases the usability of the robots for a broader range of use cases and reduce the cost for a user.

Furthermore, it may be desirable to have sealed sub-assemblies individually injected with inert gas to create positive pressure to block external flammable gases, dust and particulate from entering into the sub-assemblies and causing potential fire or explosive discharge, and allowing them to be used in environments such as coal mines, gas manufacturing plants and refineries where equipment must be intrinsically safe for operation.

Finally, it may be desirable to have a sub-assembly design where all electronics are separated and sealed with the mechanicals can be operated without an external cover (skin), reducing weight and supporting faster interchange of specific subassemblies.

SUMMARY OF DISCLOSURE

Some or all of the above needs and/or problems may be addressed by certain embodiments of the disclosure. In one aspect, the present invention may have a legged robot having a frame with a plurality of links in mechanical communication with plurality of brackets, the frame forming a front, back, top, bottom, and sides, legs in mechanical communication with one or more of the plurality of brackets, each leg having a knee motor, an abduction motor, and a hip motor, a computer module in mechanical communication with one or more of the plurality of brackets and in electrical communication with the legs, and a power module in mechanical communication with one or more of the plurality of brackets and in electrical communication with the legs and the computer module.

DETAILED DESCRIPTION

In order that the present invention may be fully understood and readily put into practical effect, there shall now be described by way of non-limiting examples of preferred embodiments of the present invention, the description being with reference to the accompanying illustrative figures.

FIG.1shows an exploded perspective view of Robotic System500according to an aspect of the present disclosure. Robotic System500may have Frame1capable of securing and interfacing with Leg Subassembly2, Computing Box3, Energy Box4, and other components. Frame1may be formed of material suitable for an intended environment, including but not limited to, metals, ceramics, plastics, composites, and wood. In general, the materials typically suitable for many applications may be aluminum, steel, or composites.

Robotic System500may have Sensor Panel5, Sensor Strip6, and Sensor Enclosure7that may support various components and connectors, including, but not limited to, sensors, screens, buttons, interface ports and buses, switches, electrical components capable of transmitting or receiving power to or from an outside source including in the presence of an electromagnetic field.

Non-limiting examples of sensor components may include light sensors such as cameras, photoresistors, phototubes, phototransistors, or photovoltaic cells; sound sensors such as microphones; temperature sensors such as a LM34, LM35, TMP35, or TMP 36 sensors; contact sensors such as push button switches, tactile bumper switches, or capacitive contact sensors such as touch screens; proximity sensors such as infrared (IR) transceivers, ultrasonic sensors, or photoresistors; distance sensors such as laser range sensors including LIDAR, and stereo cameras; pressure sensors such as a barometer; tilt sensors such as an analog mercury-suspension glass bulb sensor; positioning sensors such as global position system (GPS) sensors and digital magnetic compasses; acceleration sensors such as accelerometers; gyroscopes; inertial measurement units; electrical sensors such as voltmeters; radiofrequency sensors; radar; chemical sensors; or any other device capable of receiving or transmitting information or transforming environmental information into an analytically useful signal.

Sensor Panel5may be a panel that holds electrical, sensory and user interface components that may be attached to the front, back, or side of Frame1. Sensor Strip6may be an enclosure or attachment point of electrical and sensory components that may attach to Side Brackets8or Corner Brackets9through various connective techniques including but not limited to, welding, clamping, adhesive, threaded fasteners, interference fit, magnetic, hook and loop, or similar joining technologies. Sensor Enclosure7may be an enclosure of electrical and sensory components that may attach to Computing Box3, Energy Box4, Frame1, or panels attached to Frame1. Attachment of Sensor Enclosure7may be done through various connective techniques including but not limited to, adhesive, threaded fasteners, interference fit, magnetic, hook and loop, or similar connection mechanisms, or it may be embedded directly into another component in or on Robotic System500. In one non-limiting aspect as shown inFIG.1, Sensor Enclosure7may be affixed to Computing Box3, but it is understood that Sensor Enclosure7may be moved to other components within Robotic System500.

Still referencingFIG.1, Frame1may contain Side Brackets8and Corner Brackets9that may provide structural support to Frame1and the components secured thereon. Side Brackets8and Corner Brackets9may be made out of similar material to Frame1depending on the intended use of Robotic System500. In general, Side Brackets8and Corner Brackets9may be designed with the specific function of Robotic System500in mind. For example, if Robotic System500is intended to carry a large payload, then Side Brackets8and Corner Brackets9may be made out of a sturdier material than other components of Frame1to better support the payload against the forces of gravity. In general, common material suitable for many applications includes steel, aluminum and composites.

Still referencingFIG.1, Frame1may be coupled to one or more Leg Subassemblies2. Each Leg Subassembly2may enable robotic movement such that Robotic System500is capable of moving translationally, or rotationally, within an environment in a controlled manner.

Still referencingFIG.1, Robotic System500may include a Computing Box3which may house electrical and computing components assisting the operation and control of Robotic System500. Robotic System500may also include an Energy Box4which may house components capable of storing and supplying electrical power to Robotic System500. AlthoughFIG.1shows Computing Box3and Energy Box4located substantially at the center of Frame1, other configurations are possible depending on intended use of Robotic System500. For example, Energy Box4may be switched to the top, and Computing Box3switched to the bottom; both Energy Box4and Computing Box3may be shifted forward or aft; or they may be rotated in various configurations within, on or about Frame1.

FIG.2is a view of Frame1according to an aspect of the present disclosure. Frame1may be formed of links and brackets, such as Side Links10that may be fastened by or to Side Brackets8, and End Links11that may be fastened by or to Side Links10via Corner Brackets9. In one non-limiting aspect, additional End Links11(not shown) may be fastened perpendicularly to Side Links10via Side Brackets8, and this may add stability to Frame1at increased weight and cost. Fastening may be done by welding, adhesive, clamping, interference fits, or other joining technologies or mechanisms. Side and End Links10&11may be formed of any material suitable for the operating environment, including but not limited to, metals, ceramics, plastics, composites, and wood. In general, common material suitable for many applications includes steel, aluminum and composites. In one non-limiting aspect, Side and End Links10&11may be formed as hollow tubes.

Side and End Links10&11may be able to route electrical power and electronic signals from one component of Robotic System500to other components. This may be done in various ways, including but not limited to, integrated circuitry within Side and End Links10&11, or wire or fiber optics housed within Side and End Links10&11. In some non-limiting examples, power and other signals may be routed via external cables; cables embedded within Side Links10and/or End Links11; and/or embedded connectors that engage when a sensor or sensor head is coupled to Frame1.

Side Brackets8may provide structural support to Frame1and may provide connection points to interior and exterior components, such as Energy Box4and Computing Box3. In some non-limiting examples, Side Brackets8may couple to Energy Box4and Computing Box3with threaded fasteners, clips, adhesives, hook and loops, electromagnetic, interference fit, or other similar connection mechanisms. In some non-limiting examples, Side Brackets8may couple to Sensor Panel5, Sensor Strip6, and Sensor Enclosure7(as shown inFIG.1) with threaded fasteners, clips, adhesives, hook and loops, electromagnetic, interference fit, or other similar connection mechanisms.

Corner Brackets9may provide structural support to Frame1and may provide connection points to interior and exterior components, such as Sensor Panel5, Sensor Strip6, and Sensor Enclosure7(as shown inFIG.1). In some non-limiting examples, Corner Brackets9may couple to Sensor Panel5, Sensor Strip6, and Sensor Enclosure7with threaded fasteners, clips, adhesives, hook and loops, electromagnetic, interference fit, or other similar connection mechanisms.

Although not pictured inFIG.1or2, it is understood that interior or exterior components including Computing Box3, Energy Box4, Sensor Panel5, Sensor Strip6, and Sensor Enclosure7may be affixed either to Side Brackets8, Corner Brackets9or Frame1as called for by the design considering the intended purpose of Robotic System500.

Side Brackets8may also provide a connection to Leg Subassembly2through Alignment Guide12and Alignment Fastener13. Alignment Guide12may be a geometric feature including, but not limited to, a hole, prong, or peg capable of providing alignment and a load bearing connection when attaching to Leg Subassembly2through the use of pins, splines, edge contacts, or similar mechanisms. Alignment Fastener13may be a retention mechanism including, but not limited to, a hole, prong, or peg to align Leg Subassembly2with Frame1through the use of connectors including, but not limited to, threaded fasteners, clips, adhesives, hook and loops, interference fits, electromagnetic, or other fasteners.FIG.2shows one non-limiting aspect wherein Alignment Guide12may be a prong or peg, and Alignment Fastener13may be a hole. Although not pictured inFIG.2, in one non-limiting aspect, Alignment Guide12and Alignment Fastener13may be included on Corner Brackets9thereby enabling connection to Leg Subassembly2via Corner Brackets9. Such a configuration may be advantageous in certain operational circumstances.

Still referencingFIG.2, Frame1may also include Payload Fastener14, which may be a retention mechanism to hold external devices or payloads onto Frame1through the use of threaded fasteners, clips, adhesives, hook and loops, electromagnetic, interference fit, or other similar connectors. AlthoughFIG.2shows Payload Fastener14as part of Side Brackets8and Corner Brackets9, Payload Fastener14may be located anywhere on Frame1and in any configuration desired by the user, such that the payload is fastened and secured according to the unique needs of the user.

Referencing nowFIGS.1and2, Energy Box4may connect to Side Brackets8in a way that such connection is easily and intentionally engaged or disengaged. InFIG.1, Energy Box4may slide into ports located on Side Brackets8through the underside of Frame1. Similarly, Computing Box4may have a similar connection that is easily intentionally engaged or disengaged allowing Computing Box4to slide in through the top of Frame1.

Referencing againFIG.2, panels may be mounted between each Side Brackets8and Corner Brackets9such that the interior of Frame1is an isolated or quasi-isolated environment. These panels may be made out of any material deemed suitable for use by the user depending on the intended purpose. For example, panels may be serve a decorative, support or protective purpose.FIG.1shows an example panel according to one non-limiting aspect wherein Sensor Panel5is mounted to the front of Frame1, via Corner Brackets9. Panels may also be secured to Side and End Links10&11for additional support through connection methods such as snap fits, interference fits, electromagnetic, hook and loops, or similar methods.

FIG.3is a view of the Leg Subassembly2according to an aspect of the present disclosure. Leg Subassembly2may contain Pod15which may contain motor control electronics as well as a subset of motors, mechanical reductions, transmissions, and encoders in a secure and isolated environment. Leg Subassembly2may also include Interface Bracket16which may enable coupling to Frame1through one or more of Alignment Guide12and Alignment Fastener13. Pod15may have an electrical connection to Interface Bracket16such that electrical power and/or electronic signals may be received and directed to the components within Pod15thus supplying power and control to the components of Pod15. Pod15may also contain Pod Connectors18that may provide an additional or alternative interface for providing power and electronic signals to the internal components of Pod15.

Leg Subassembly2may also have Leg Components17including an upper leg hingably coupled to a lower leg that may be made out of materials such as metals, composites, plastics, ceramics, or others if deemed appropriate for the intended use, and may include additional internal electromotive components such as motors, reductions, transmissions, and encoders. Depending on electrical input received by the components of Pod15, Leg Subassembly2may be capable of performing translative or rotational movement with respect to Frame1such that Robotic System500may be capable of independent movement through its environment. The upper leg may be uncoupled from the lower leg thereby enabling interchange of the lower leg component. This may be done to repair a damaged lower leg, or may be done to replace the lower leg with a configuration more suitable to the intended environment, for example, with a component having different geometry. Similarly, a distal end of Leg Components17may include a removable tread suitable for contact with the environment surface, or the ground. The shape of the removable tread may be optimized for the environment and may include a robotic foot, fins, wheels, claws, or others.

FIG.4is a view of Energy Box4according to an aspect of the present disclosure. Energy Box4may have a Protective Housing19wherein electrical and computing components are stored including, but not limited to, chemical batteries, capacitors, fuel cells, internal engines, as well as all necessary computing and control systems. Protective Housing19may be constructed out of materials specifically designed for the environment in which Robotic System500is to be used. For example, if such an environment was near or under water, then Protective Housing19may be made constructed to be watertight out of a material that strongly resists corrosion and has proper buoyancy characteristics.

Energy Box4may include Energy Box Guide20which may guide a user to install Energy Box4within Frame1. In one non-limiting aspect, Energy Box Guide20may be a unique geometric shape or frame that permits installation when Energy Box4is oriented in a specific and correct way, relative to Frame1. Energy Box4may include a disengageable Energy Box Fastener21that may provide additional structural support to Energy Box4. Energy Box Fastener21may be a clamp, adhesive, threaded fasteners, interference fit, magnetic, hook and loop, push pin or “push and click” connectors, or similar disengageable support technologies. In one non-limiting aspect, Energy Box Fastener21may be a hole that mates with Bracket Fastener26located on Side Bracket8.

Energy Box4may also have Electrical Connector22that permits the transmission of electrical power and electronic signals to and from the components within Energy Box4. Electrical Connector22may include any method or mechanism for transmitting electronic signals and electrical power to or from the outside of Energy Box4to or from the components therein, including but not limited to, wire connections, integrated circuits, wireless power transmission, or kinetically induced power generation. In one non-limiting example, Energy Connector22may be an electrically conductive material inlaid within Protective Housing19, capable of transmitting electronic signals and electrical power from the outside of Energy Box4to the components therein upon contact. In one non-limiting example, Energy Connector22may be made out of highly electrically conductive metal, such as silver or copper, or other electrically useful materials.

FIG.5is a perspective view of Computing Box3. Computing Box3may contain a Protective Housing23wherein electrical, computing, and control components are stored. Protective Housing23may be constructed out of materials specifically designed for the environment in which Robotic System500is to be used. For example, if such an environment was near or under water, then Protective Housing23may be made constructed to be watertight out of a material that strongly resists corrosion, and that has proper buoyancy characteristics. In one non-limiting aspect, Sensor Enclosure7may be affixed to or integrated with Protective Housing23as shown inFIG.5.

Computing Box3may include a Computing Box Guide24which may easily guide a user to install Computing Box3within Frame1. In one non-limiting aspect, Computing Box Guide24may be a unique geometric shape or frame that permits installation only when Computing Box3is oriented in a specific and correct way, relative to Frame1. Computing Box3may include a disengageable Computing Box Fastener27that may provide additional structural support to Computing Box3. Computing Box Fastener27may be a clamp, adhesive, threaded fasteners, interference fit, magnetic, hook and loop, push pin or “push and click” connectors, or similar disengageable support technologies. In one non-limiting aspect, Computing Box Fastener27may be a hole that mates with Bracket Fastener26located on Side Bracket8.

FIG.6is a side view of an inside end of Frame1according to one aspect of the present disclosure, showing Side Brackets8and Corner Brackets9inclusive of Alignment Guide12and Alignment Fastener13. Side Brackets8and Corner Brackets9may also include Alignment Guide12and Alignment Fastener13towards the top of Frame1. This may enable Frame1to couple with other motive subassemblies, other than Leg Subassembly2, which may provide controlled motion in other ways. Interface Bracket16may exist on different types of motive subassemblies thereby enabling controlled connection and interfacing with Frame1via Alignment Guide12and Alignment Fastener13. Other subassemblies may utilize wheels, treads, spinning rotors, gyroscopes, fans, turbines, thrust components, or other mechanisms to achieve controlled movement. These assemblies may attach to Frame1via Alignment Guide12and Alignment Fastener13located at either the top or bottom of Side Brackets8and Corner Brackets9.

Alignment Guide12and Alignment Fastener13may optionally transmit electrical signals and power from Frame1to Leg Subassembly2through their connection with Interface Bracket16located on Pod15. In one non limiting aspect, Interface Bracket16may include a peg that mates with Alignment Fastener13wherein both components are electrically conductive. Frame1may route power and electrical signals from Energy Box4and Computing Box3to Alignment Fastener13, which may then transmit power and electrical signals to Interface Bracket16through the peg and to Leg Subassembly2. The interface between Interface Bracket16, Side Bracket8, and Corner Bracket9may be interchangeable, wherein the electrical connection may be established through Alignment Guide12, rather than Alignment Fastener13, and such connection may be achieved through methods other than a peg and hole. For example, there may be an interface bus wherein a connection is established through a wire connection, or electrical power and signals may be transmitted to Leg Subassembly2through wireless remote transmission technology.

Still referencingFIG.6, Side Brackets8may include a Bracket Fastener26that may mate with Energy Box Fastener21and Computing Box Fastener27, thereby providing structural support through ample connection mechanisms including, but are not limited to, threaded fasteners, clips, adhesives, hook and loops, magnets, “push and click” connectors, interference fits, and others. In another non-limiting aspect, Corner Brackets9may also include Bracket Fastener26thereby allowing a similar coupling thereto, though this is not pictured inFIG.6.

FIG.7is a side view of Pod15within Leg Subassembly2according to an aspect of the present disclosure. Pod15may include Interface Bracket16which connects Leg Subassembly2to Frame1. In one non-limiting aspect, Interface Bracket16may include a Pod Fastener31and Pod Guide32that mates with counterparts on Frame1, for example, Alignment Guide12and Alignment Fastener13, respectively.

Pod Guide32may be a geometric feature including, but not limited to, a hole, prong, or peg capable of providing alignment, and a load bearing connection when attaching to Leg Subassembly2to Frame1through the use of pins, splines, edge contacts, or similar mechanisms. Pod Fastener31may be a retention mechanism including, but not limited to, a hole, prong, or peg to correctly align Leg Subassembly2with Frame1through the use of connectors including but not limited to threaded fasteners, clips, adhesives, hook and loops, interference fits, electromagnetic, or other fasteners. In one non-limiting aspect, Pod Guide12may be a prong or peg, and Pod Fastener13may be a hole. Pod Guide32and Pod Fastener31may be able to transmit electrical signals and power from Frame1to Pod15through connection with Alignment Guide12or Alignment Faster13.

FIG.8is a top-down view of Frame1according to an aspect of the present disclosure. Side Brackets8may have Ridge25that may interact with Energy Box Guide20or Computing Box Guide24, thereby preventing an incorrect installation into Frame1. Ridge25may be a unique geometric shape or frame that permits installation only when Energy Box4or Computing Box3is oriented in a specific and correct way, relative to Frame1. Side Brackets8may include a Bracket Fastener26that may, once correct installation is permitted by Ridge25, mate with Energy Box Fastener21and Computing Box Fastener27, thereby providing structural support through ample connection mechanisms including, but are not limited to, threaded fasteners, clips, adhesives, hook and loops, magnets, “push and click” connectors, interference fits, and others. In another non-limiting aspect, Corner Brackets9may also include Ridge25and Bracket Fastener26thereby allowing a similar coupling thereto, although this particular configuration is not shown inFIG.8.

FIG.9is a top view of Pod15and Leg Subassembly2according to an aspect of the present disclosure. Pod15may include an Abduction Motor29that may include a motor and requisite gear train, electrical and control components such as encoders and motor controllers, and kinetic transmission systems designed to actuate rotation of Leg Components17about the abduction axis AA. Pod15may also include a Hip Motor30which may include a motor and requisite gear train, electrical and control components such as encoders and motor controllers, and kinetic transmission systems designed to actuate rotation of Leg Components17about the hip axis HA. Knee Motor28may include a motor and requisite gear train, electrical and control components such as encoders and motor controllers, and kinetic transmission systems designed to actuate rotation of Leg Components17about the knee axis KA. In one non-limiting example, axes HA and KA may be parallel, and axis AA may be perpendicular to axes HA and KA. In one non-limiting example, Knee Motor28may be located close to axis HA to minimize inertia.

In one non-limiting example, Pod15may be mechanically coupled to Frame1. Abduction Motor29may be mechanically coupled to Frame1. The mechanical output of Abduction Motor29may be transmitted to Hip Motor30. The mechanical output of Hip Motor30may be transmitted to Knee Motor28.

Pod15may include a motor controller (not shown) that communicates with Computing Box3and with one or more of Knee Motor28, Abduction Motor29, and Hip Motor30. As a result of the operation of the motor controller at Pod15, there may be a reduced number of wires from Computing Box3to Pod15, such as, in one non-limiting example, two power wires plus four signal wires. In another aspect, Pod15and motors may receive additional or alternative power from Energy Box4.

FIG.10is a front view of Sensor Panel5according to an aspect of the present disclosure. Sensor Panel5may be a panel that supports or provides connections for electrical, sensory and user interface components that may be attached to the front, back, or side of Frame1. Sensor Panel5may support various components and connectors, including, but not limited to, sensors, screens, buttons, interface ports and buses, switches, electrical components capable of transmitting or receiving power to or from an outside source including in the presence of an electromagnetic field. In one non-limiting aspect, Sensor Panel5may have an electrical interface wherein Robotic System500may be electrically charged through connection to an outside power source. In one non-limiting aspect, Sensor Panel9may be affixed to Corner Brackets9through various connective techniques including but not limited to, welding, clamping, adhesive, threaded fasteners, interference fit, magnetic, hook and loop, or similar joining technologies.

The above description presents the best mode contemplated for carrying out the present embodiments, and of the manner and process of practicing them, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which they pertain to practice these embodiments. The present embodiments are, however, susceptible to modifications and alternate constructions from those discussed above that are fully equivalent. Consequently, the present invention is not limited to the particular embodiments disclosed. On the contrary, the present invention covers all modifications and alternate constructions coming within the spirit and scope of the present disclosure. For example, the steps in the processes described herein need not be performed in the same order as they have been presented, and may be performed in any order(s). Further, steps that have been presented as being performed separately may in alternative embodiments be performed concurrently. Likewise, steps that have been presented as being performed concurrently may in alternative embodiments be performed separately.