BACKGROUND OF THE INVENTIONThis invention is in the field of portable computers and docking stations for portable computers.
Portable computers are known. Indeed, they comprise the fastest growing segment of the computer market, as more and more people, having come to rely on the capabilities of their desktop computer to increase their productivity, desire the same capabilities when they travel as they do when they are at work.
Although the capabilities of many portable computers closely match those of larger desktop machines, the expense of purchasing a second computer in addition to a desktop machine is difficult for many people to justify. Indeed, there is something inherently wasteful in having two different machines, each functionally nearly identical. In particular, most owners use only one of the machines at any given time. The other machine sits idle. In effect, the user owns two central processing units ("CPU"s), only one of which is operating at a time.
The dilemma posed to a consumer who desires the portability of a notebook computer and the full functionality of a desktop computer without the need of purchasing two separate systems has been recognized by the computer industry. One known solution is to offer a fully capable portable notebook computer which can be coupled to a separate stationary unit, the stationary unit frequently having additional data storage such as disk drives and additional display capabilities. These stationary units are commonly known as "docking stations".
Although the concept of a portable computer/docking station is an excellent one, as it eliminates the duplication of the CPU and greatly increases the ease with which data can be transferred from the portable computer to the desktop environment and vice versa, known embodiments of this concept have suffered from very poor implementation.
In some known portable computer/docking station systems, the method of coupling the portable computer to the docking station uses an extremely clumsy mechanical system which relies on user knowledge and skill to mate the computer and docking station successfully. Examples include latch systems where the computer owner must carefully align the connectors before mating the computer to the docking station. Even after the machines have been coupled together, the security of the latching mechanism is suspect. Also, these systems do not appear to be sufficiently durable to last for an acceptable period of time.
The manner that screen displays integrate with known docking stations is also less than ideal. Typically the screen must remain separate from the docking station, as the portable computer itself forms the top surface of the two units when they are docked together. This increase in the "footprint" of the system is certainly undesirable.
Most importantly, the electrical interface between the docking station and the portable computer is usually very crude. Unless the user follows a carefully prescribed set of instructions, the system crashes during either docking or undocking, resulting in a loss of data and possible damage to the components of either the docking station, the computer, or both. Even if the user carefully follows the instructions and completes a successful docking, the units must still be coupled to all external networks, peripherals and a power supply. Completing such connections is time consuming and prone to error.
In these systems, if undocking is commanded while in an application, the undocking occurs, but the system crashes and data is lost.
There thus remains a need for a fully functional portable computer that can be easily coupled to a docking station, the docking station offering increased data storage and increased video capabilities. The docking process itself should be completely transparent to the system's user, allowing docking and undocking to proceed with a minimum of user input and with many safeguards protecting the data and components in both units from accidental or even intentional misuse. It should also be possible for owners of a portable computer/docking station to use their portable computer with other docking stations without the need for extensive system reconfiguration.
SUMMARY OF THE INVENTIONIn its first embodiment, the present invention comprises a portable computer with a liquid crystal display ("LCD"), hard disk drive storage, CPU and other supporting electronics and a docking station to which the portable computer can be coupled. Docking is accomplished by an electromechanical mating system which ensures reliable interconnection through a plurality of mechanical and electrical interlocks which prevent docking or undocking if certain conditions do not exist and which insure that docking will be accomplished in a simple and repeatable fashion if these prerequisites do exist.
The docking station is configured so that a large CRT display may be rested thereon without damaging the docking station or in any way impeding its functioning. The docking station initially comprises at least additional video-memory and a floppy disk drive, as well as such input/output ("I/O") resources as video, sound, SCSI, etc. Providing these resources in the docking station allows the construction of a very small and lightweight portable computer. A floating point arithmetic co-processor can also be added to the docking station. Additional subsystems such as I/O bus subsystems compatible with the NUBUS® bus architecture and protocol established by Texas instruments. (NUBUS is a registered trademark owned by Texas Instruments) cards having a plurality of different functions and a hard disk drive storage unit can be added.
As the docking station is usually kept in one location, it remains coupled to local area networks, the telephone system, peripherals and an AC power source. As soon as docking is complete, the user can instantly access any of these resources without additional user configuration or effort.
Security systems are provided which permit the user to lock the portable computer in or out of the docking station and to lock the docking station in place.
The present invention will now be described in detail with reference to the figures which are listed and described below.
BRIEF DESCRIPTION OF THE ILLUSTRATIONSFIG. 1 is a front perspective of the portable computer;
FIG. 2 is a back perspective of the portable computer, with its docking connector covered and feet in the open position;
FIG. 3 is a back perspective of the portable computer, showing the portable computer in a closed position with its feet in their closed position and with the docking connector uncovered;
FIG. 4 is a block diagram of the circuitry of the portable computer;
FIG. 5 is a front perspective of the docking station;
FIG. 6 is a perspective drawing of the underside of the top case of the docking station;
FIG. 7 is an exploded isometric drawing of the docking station;
FIG. 8 is an exploded isometric drawing of the base of the docking station;
FIG. 9 is a perspective of the skeleton of the docking station;
FIG. 10 is an exploded isometric drawing showing the top side of the skeleton;
FIG. 11 is an exploded isometric drawing of the bottom side of the skeleton;
FIG. 12 is a perspective drawing of the assembled frying pan;
FIG. 13 is an exploded isometric drawing showing the construction of the frying pan;
FIG. 14 is a top perspective drawing of the docking motor assembly;
FIG. 15 is a bottom perspective drawing of the docking motor assembly;
FIG. 16 is an exploded isometric drawing of the docking motor assembly;
FIG. 17 is an exploded isometric drawing of the docking motor assembly, viewed from beneath the assembly;
FIG. 18 is a schematic of the braking circuit used with the docking motor assembly;
FIG. 19 is a state table diagram illustrating the operation of the docking motor assembly;
FIG. 20 is an exploded isometric drawing of the frying pan/skeleton; and
FIG. 21 is a block diagram of the docking station's electronics.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTA first preferred embodiment of the present invention comprises at least aportable computer 100 and a docking station 500. These will first be described separately in detail. Then those aspects of both the computer and docking station which relate to their operating as a unit will be described.
PORTABLE COMPUTERPortable computer 100 is shown in a front perspective in FIG. 1 and in a rear perspective in FIGS. 2 and 3. In this embodiment,computer 100 comprisesdisplay assembly 110 andbase assembly 120.Display assembly 110 further comprises liquid crystal display ("LCD")panel 112, brightness controls 111 and contrast controls 113, andspeaker 115.Latch 117 along the upper edge ofdisplay assembly 110, activated bylatch button 118, is used to lockcomputer 100 in its closed position. Additionally, whendisplay assembly 110 is in its closed position, latch 117 triggers a clamshell switch 101 (see FIG. 4) on the internal circuitry ofcomputer 100, the switch signal indicating to the computer that it should place itself in a sleep state.Hinge assembly 119 allowsdisplay assembly 110 to open and close, as well as holding the display assembly open to the position chosen by the user.
Base assembly 120 contains the logic circuitry and memory ofcomputer 100. Its exterior is comprised ofkeyboard assembly 123, power switch 121,trackball 125,select switches 127 andpalmrest areas 129. Latchingslot 126 receiveslatch 117 and permits access toclamshell switch 101 triggered bylatch 117.
The front edge ofbase assembly 120 is partially comprised ofbattery compartment door 151. By pressingbattery door button 153, the panel can be moved sideways, allowing the removal ofcomputer 100's battery pack (not shown),door 151 being mechanically attached to the battery pack.
Rear panel 130 ofcomputer 100 is shown in FIGS. 2 and 3.Connector door 131 is in the center of the rear panel and covers 152-pin connector 160.Door 131 opens upwards along a hinge line and retracts into the interior ofcomputer 100. In so doing,panel cutout 137 is exposed. Whendoor 131 is closed,cutout 137 is filled withdoor tab 135. Also exposed by openingdoor 131 areguide holes 162 andhook openings 164. The function of these will be described later.Rear panel 130 also has an serial (modem/printer/network)port 139, apower port 141, amodem port 143 and on/offbutton 144.Feet 145 are shown in their open position in FIG. 2 and in their closed position in FIG. 3. It should be noted that in their closed position, one of the legs coversserial port 139 and the othercovers modem port 143.
The internal mechanical construction ofportable computer 100 is shown and discussed in a related pending patent application entitled "Structural Frame for Portable Computer", filed Jun. 5, 1992, Ser. No. 07/893,853, now U.S. Pat. No. 5,237,486. That disclosure is incorporated herein for all purposes. With reference to the internal frame that comprises the mechanical backbone ofportable computer 100, the frame has two holes for receiving guide pins from the electromechanical docking mechanism (described below) and two openings to receive and lock with mating hooks from the same mechanism.
FIG. 4 is a block diagram of the circuitry ofportable computer 100.Computer 100'sCPU 201 comprises aMotorola 68030 microprocessor with a clock speed of either 25 or 33 MHz. As this microprocessor is known and commercially available, it requires no further description here.
CPU 201 is coupled to both random access memory ("RAM") 203 andROM 205 by means ofbus 210. Main system controller ("MSC") 207 is also coupled tobus 210 and controls memory reading/writing as well as power control, I/O state machines and other support functions.Gray scale controller 215 is coupled tobus 210, video RAM ("VRAM") 217 andLCD panel 112. Input/output ("I/O")support chip 223 is coupled tobus 210,serial port 139 andhard disk storage 240. I/O support chip 223 facilitates data transfer to and from external sources and the internal hard disk drive storage. Finally, 152-pin connector 160 is coupled tobus 210.
EverWatch microcontroller 260 performs many functions relating to power management and the computer's operation, including reducing power consumption during periods of reduced computer use by placing the computer in a "sleep" mode, recharging the computer's internal battery, etc.EverWatch microcontroller 260 is coupled toMSC 207,power supply 261, on/offbutton 144,clamshell switch 101,keyboard 123 andtrackball 125.
Modem 270 is coupled to bothEverWatch microcontroller 260 and, throughMux 271, to 152-pin connector 160. Static RAM ("SRAM") 265 is also coupled tomodem 270 andEverWatch microcontroller 260.
Various aspects of the construction and operation ofportable computer 100 have been described in related patent applications. These include "Power Management System for Battery Powered Computers", Ser. No. 770,193, filed Oct. 1, 1991, now U.S. Pat. No. 5,254,928; "An Increased Efficiency Power Supply For Portable Computers", Ser. No. 802,810, filed Dec. 6, 1991, "Method and Apparatus For Variable Frame Rate Control", Ser. No. 819,169, filed Jan. 8, 1992, "Glichless High Speed Clock Mux", Ser. No. 893,635, filed Jun. 5, 1992, "Method and Apparatus For Reducing Transitions On Computer Signal Lines", Ser. No. 904,735, filed Jun. 26, 1992, and "Method and Apparatus for Battery Pack Testing", Ser. No. 893,863, filed Jun. 5, 1992. These disclosures are incorporated herein for all purposes. Other features ofportable computer 100 which relate to the mechanical and electrical interface with docking station 500 will be described below.
DOCKING STATIONA front perspective of docking station 500 is shown in FIG. 5. As shown in FIG. 5, docking station 500 is comprised ofbase 502 and top 504. Portablecomputer insertion slot 506 is defined by top 504 and the front lip offrying pan 508. Also visible in FIG. 5 arespeaker grill 512, floppydisk insertion slot 510 andelectrical ejection button 514.
As shown in FIG. 6, top 504 has two structural cross beam supports 516 mounted thereon. When the present invention is in its operating configuration, these two cross beams help support the weight of a cathode ray tube ( "CRT") monitor which is placed on the top of the docking station. The cross beams can be attached to the internal top surface of top 504 in any one of several known manners including adhesives and plastic rivets.Electrical ejection button 514 is mounted in top 504 by means ofstud 518 and is used to trigger the electrical eject cycle if certain conditions are met. These conditions are fully described later.Top 504 attaches to base 502 by means ofclips 503.
FIG. 7 illustrates how the various components of docking station 500 are assembled together. These major components and assemblies center aboutbase 502,frying pan 508 andskeleton 520, and top 504. The construction of each of these major assemblies will now be described in detail.
FIG. 8 is an exploded isometric drawing ofbase 502 and the components assembled thereon.Power supply assembly 522, which has an integral cooling fan, is mounted as a unit intobase 502 and provides a continuous 75 watts of power which is supplied to the circuitry of both docking station 500 andportable computer 100, when that computer is docked with the station and powered on. During docked operations, whenever AC power is supplied,power supply 522 provides two non-switched voltages: +19 V at 1 amp and +5 V at 80 milliamps. The +19 V voltage chargesportable computer 100's, internal battery automatically under the control of EverWatch microcontroller 260 (see FIG. 4) whether or not the system is turned on. Motor assembly 630 (see FIG. 14) is also coupled to the +19 V voltage, which allows docking and undocking to occur at any time AC is present, even when docking station 500 is turned off. The +5 V voltage powers the motor control circuitry, which also allows docking and undocking to occur even if docking station 500 is turned off. The motor control circuitry comprises at least programmed array logic ("PAL") 690 (see FIG. 21), photodetector 584 (see FIG. 20),microswitches 586 and 588 (see FIG. 16) and eject button 514 (see FIG. 5) in this first embodiment. In successive embodiments it would be possible to use the +5 V voltage to power a LED which would indicate whether or not the docking station is locked. Alternatively, the same voltage source could power a small piezoelectric speaker which would indicate to the user when an attempt was made to remove or insert the portable computer from or into a locked docking station.Fan shroud 524 mounts atop and aroundpower supply 522 and helps direct the cooling air supplied by the power supply's integral cooling fan. The rear ofbase 502 also has two openings designed to accept I/O bus subsystem cards compatible with NUBUS® I/O bus architecture and protocol promulgated by Texas Instruments, Dallas, Tex. (NUBUS is a registered trademark owned by Texas Instruments). Such I/O expansion cards which comply with and operate under the NUBUS standard are hereinafter referred to asNUBUS cards 552 which permit the installation of one 25 W or two standard 15 W NUBUS card(s).
Columns 526 mount inbase 502. They are spaced along the side edges ofbase 502 and clip into position. Once mounted, and with top 504 in its proper position, these columns are located respectively underneath the four ends of cross beams 516 (see FIG. 6), which rest directly on top of the columns when station 500 is completely assembled. When a CRT monitor (up to 50 lb. in weight in this first embodiment) is then placed ontop 504, its weight is supported by the cross beams and the load is transmitted through them into the columns and thence into the desk or table that supports station 500. The use of this internal structural framework increases the size and weight of the monitor that the station can support and also eliminates loading eitherportable computer 100 when it is inserted into the docking station or the docking station's internal skeleton 520 (see FIG. 9) or both.Feet 530 are adhesively mounted withpads 528 on the outer bottom surface ofbase 502 in recesses (not shown) in the base underneath each of the four columns. They help prevent damaging the surface that the docking station is placed upon and provide the necessary friction to keep the docking station stationary whenportable computer 100 is inserted into the station.
Lock 532 is mounted through the side ofbase 502 inlock hole 534 which extends through the sidewall ofbase 502.Door bar lock 542 is mounted and pivots on the interior of the same sidewall through which lock 532 extends usingdoor bar retainer 546 to attachdoor bar lock 542 tobase pivot 544.Door bar lock 542 is coupled to rearrotating stud 536 oflock 532 by means oflock linkage plate 538, which has a first opening cut to fitstud 536 and a second opening cut to fit the end ofdoor lock bar 542.Bracket 540 locks locklinkage plate 538 to bothstud 536 anddoor bar lock 542. Whenlock 532 is turned to lock docking station 500,door bar lock 542 pivots aboutbase pivot 544 and coversmanual eject slot 550, which extends through the same sidewall ofbase 502 as does lockhole 534.Ejection slot block 548 is attached to the end ofdoor bar lock 542 and blocks slot 550 as the key is turned. Asdoor bar lock 542 moves, it also interacts with manual ejection linkage 662 (see FIG. 20) to releaselock switch 686 onlogic board 580. Releasinglock switch 686 provides a signal toPAL 690 which controls the operation ofmotor 631, the releasesignal preventing motor 631 from running.
Lock 532, when locked, prevents the removal ofportable computer 100 by causing the blockage ofmanual ejection slot 540 inbase 502 and by preventing docking motor 631 (see FIG. 14) from turning on. Thus, if the system is locked, a user cannot ejectcomputer 100 manually or electrically. Any forceful attempt to do so might damagecomputer 100. If docking station 500 is locked when noportable computer 100 is docked to the station, no computer can be inserted becausemotor 631 will not turn on to begin docking. Even if someone attempts to force aportable computer 100 into the docking station, hooks 638 ofmotor assembly 630 will be in their raised position and would strike the frame ofcomputer 100, preventing further insertion, before the connectors in the docking station and computer were close enough to be mated.
Slot 531 in the rear ofbase 502 andlock plate 533 allow the user of the docking station to insert a locking fixture which can secure the docking station to the desk upon which it is resting.
FIG. 9 shows a front perspective ofskeleton 520. Most of the internal mechanical components, as well as the circuit boards comprising the electrical systems of docking station 500 mount in or onskeleton 520. Skeleton floppydisk insertion slot 554 is cut intofloppy disk panel 578 which attaches to the right sidewall of skeleton 520 (see FIG. 10).Speaker 570 mounts inenclosure 572 in the front ofskeleton 520. Logicboard mounting area 562 provides support for mountinglogic board 580, modem DAA card 583 (see FIG. 20) and motor assembly 630 (see FIG. 14).Docking slot 564 allows the 152-pin connector 160 incomputer 100 to mate with 152-pin connector 582 onlogic board 580.Guide pin slots 566 allow guide pins 634 onmotor frame 632 to extend from logicboard mounting area 562 throughdocking wall 574.Hook slots 568 permit the same extension throughwall 574 forhooks 638 onmotor carriage 636. Door block opening 560 permits the installation of gate 610 (see FIG. 12). RightCPU pushout slot 556 and leftCPU pushout slot 558 permit the installation of a damped spring ejection mechanism for portable computer 100 (see FIG. 13).Docking indicator slot 576 indocking wall 574 allows adocking indicator flag 592 onleft CPU pushout 590 to extend throughdocking wall 574 to a photodetector unit 584 (see FIG. 20) mounted onlogic board 580.
FIG. 10 is an exploded isometric drawing of the upper portion ofskeleton 520. As stated earlier,speaker 570 mounts inspeaker enclosure 572 andfloppy disk panel 578 mounts on the right side ofskeleton 520.
FIG. 11 is an exploded isometric drawing of the underside ofskeleton 520.Floppy disk drive 624 is held in position by a plurality of floppy disk drive clips 652. NUBUScard guide support 626 is held in position by card guide clips 654.NUBUS connector bracket 628 clips onto the rear ofskeleton 520 and helps support optional NUBUS cards.Bracket 628 can also have connector covers 650 attached thereto. Floppydisk drive cable 656 couplesfloppy disk drive 624 tologic board 580.Insulation sheets 651 are applied as indicated in the figure.
Frying pan 508 is shown assembled in FIG. 12 and in an exploded isometric view, looking at the bottom offrying pan 508, in FIG. 13.Gate 610 prevents the insertion ofportable computer 100 if the computer's rear connector door 131 (see FIGS. 2 and 3) is in its closed, lowered position. Whendoor 131 is closed andcomputer 100 inserted into docking station 500,tab 135 ofdoor 131 contacts the center area 611 ofgate 610. Asgate 610 is mounted infrying pan 508 using a gate spring (not shown) whichbiases gate 610 in an upwards position so that it rises above the planar surface defined byfrying pan 508, contact betweentab 135 and gate center 611jams gate 610 in its upwards biased position, blocking further motion ofcomputer 100 into docking station 500. As CPU pushout springs 598 and 600 were stretched by insertingcomputer 100 until it hitgate 610, releasingcomputer 100 after it hitsgate 610 results in the computer being spring ejected from the docking station. Alternatively, ifdoor 131 is open, the edges ofpanel cutout 137 ride up the rampedside portions 613 ofgate 610, pushing the gate down and allowingcomputer 100 to be fully inserted into the docking station.
Left CPU pushout 590 mounts in left frying panCPU pushout slot 606 infrying pan 508.Spring 598 attaches to leftfrying pan stud 620 and provides part of the necessary spring force to ejectcomputer 100.Left CPU pushout 590 rides inslot 558 in skeleton 520 (see FIG. 10) when the frying pan is properly mounted atop the skeleton. Part ofleft CPU pushout 590 has been shaped as a flat vertically oriented panel, herein calleddocking indicator flag 592. Whencomputer 100 is inserted into docking station 500, both the left and right CPU pushouts and their related springs are stretched. Whencomputer 100 has been inserted to a point where hooks 638 of motor assembly 630 (see FIG. 14) can properly capture the frame ofcomputer 100, dockingindicator flag 592 extends through frying pan insertion indicator slot 618 and skeleton insertion indicator slot 576 (see FIG. 10) intophotodetector unit 584 on logic board 580 (see FIG. 20). Breaking the light path ofphotodetector unit 584 indicates to PAL 690 (see FIG. 21) controllingmotor assembly 630 thatdocking motor 631 should be started to begin the electromechanical docking ofcomputer 100, unless lock switch 686 (see FIG. 20) indicates that the docking station is locked. Onceportable computer 100 has been docked, a subsequent transmission of light inphotodetector 584, which would occur whenflag 592 is removed from the photodetector, turns onmotor 631 and returns it to its ready position. This automatic resetting of the motor is critical for proper operation after a manual ejection occurs, whether or not there has been an interruption of AC power.
Right CPU pushout 594 mounts in right frying panCPU pushout slot 604. One side of rightCPU pushout slot 604 is lined withlinear gear teeth 602. The lower portion ofright CPU pushout 594 comprises a dampingunit 596. Although not shown, dampingunit 596 has pinion gear teeth which mesh withlinear gear teeth 602. During ejection, the contraction of right and left CPU pushout springs 598 and 600 is slowed by the interaction of the pinion gear teeth of dampingunit 596 andlinear gear teeth 602.Right ejection spring 600 provides a second part of the needed spring force to help ejectcomputer 100 and attaches toright CPU pushout 594 andright spring stud 622. RightCPU pushout slot 604 aligns withskeleton 520's rightCPU pushout slot 556 when the frying pan is properly mounted on the skeleton.
Assembleddocking motor assembly 630 is shown in both FIG. 14 and 15. FIGS. 16 and 17 are exploded isometric drawings of the motor assembly, showing the relationship of the parts to one another.Motor frame 632 provides the plastic structure which supports the other components of the assembly.Frame 632 has twoguide pins 634 which insert into holes in the internal frame ofcomputer 100. The proper insertion of the pins into the frame of the portable computer insures that the connector shells ofconnectors 160 and 582 (see FIGS. 3 and 20, respectively) are properly aligned for mating.Motor carriage 636 has two docking hooks 638 which insert through the frame ofcomputer 100 and lock onto it. These hooks apply the force generated by the motor assembly to the computer.Bore 639 incarriage 636 allows the carriage to move through a 5 mm docking/ejection stroke.
In order to mate the portable computer to the docking station, a total of 30 lb. of force is needed, that force to be generated over a distance of 4.7 mm. Of that total force, 26 lbs. is needed to mateconnectors 160 and 582 and 4 lbs. is needed to overcome the spring resistance ofCPU pushouts 590 and 594 (see FIG. 13).
Motor 631 is an inexpensive D.C. motor which turns at a high RPM rate but which generates little torque In order to generate the needed torque,motor 631 drives a gearing system comprised ofworm 648 andwormgear 646. The worm/wormgear combination provide a gear ratio reduction of 100:1. An additional 12.5:1 gear ratio reduction is achieved by the nature of the offset cam which forms part of the wormgear. Together, the worm/wormgear/cam combination provides a 1250:1 total gear ratio reduction and generates 30 lbs. offorce Wormgear axle 647, which is used to mountwormgear 646 to frame 632, passes throughbore 639 incarriage 636.Worm 648 meshes withwormgear 646, the wormgear rotating once for every 100 revolutions ofworm 648. As shown in FIG. 17, the undersurface ofwormgear 646 has a rampedeccentric slot 684 cut therein, the eccentric offset being 2.5 mm from the true center of the wormgear and the ramp having a single high point, oriented along the gear's axle.Spring 640 is attached at one end to hook 904 oncarriage 632 and at the other end to hook 906 oncarriage 636.Cam follower 683, mounted onmotor carriage 636 by means ofaxle 902, rides in rampedslot 684 and is held in this position bymotor spring 640, which normallybiases carriage 636 to its lowered position, the position it has when engaged with the frame of the portable computer. Aswormgear 646 rotates withcam follower 683 held in rampedeccentric slot 684 byspring 640, the ramp profile ofslot 684 gradually forcescarriage 636 to pivot onpivots 682 into a raised position, where hooks 638 release from the frame ofcomputer 100, allowing the computer to be ejected, provided the power stroke ofmotor assembly 630 has already decoupled the connectors.Carriage 636 is only placed in this raised position once every full rotation ofwormgear 646. A small resting "ledge" 908 inslot 684 supportscam follower 683 whenwormgear 646 has reached the point where the hooks should release. The hooks remain in this raised position until docking indicator flag 592 (see FIG. 13) triggers photodetector unit 584 (see FIG. 20). indicating that a portable computer has been inserted, and lockingswitch 686 indicates that a computer can be inserted. Oncemotor 631 begins to turn,cam follower 683 moves off this lip inslot 684, whereuponspring 640 returnscarriage 636 to its lowered position, allowinghooks 638 to latch onto the frame of the portable computer. When hooks 638 are latched onto the frame ofcomputer 100, the reciprocating motion ofcarriage 636 pullscomputer 100 to its fully docked position. For every 180° of rotation ofwormgear 646, a power stroke of 5 mm is generated.
During both docking and ejection, it is critical that the motor assembly stop in a particular point. For example, if the motor continued to spin after the computer had been fully docked, the connectors might be disconnected. Similarly, if the motor continued to spin after the computer was fully ejected, hooks 638 might capture the frame of the computer again before the user could remove it. As the motor runs at slightly different speeds as it ages and under different load and temperature condition, an electronic braking system has been provided to insure that the motor stops as quickly as possible after current flow to the motor has been stopped. This brake system absorbs the momentum of the motor by electronically converting the motor into a generator with a direct current path to ground. Braking system 800 is shown in FIG. 18.
The signal to turn offmotor 631, MOTON, turns offtransistor 807.Motor 631 still has a certain voltage across it. Withtransistor 807 off anddiode 809 reverse biased,transistor 801 turns on, providing a current path to ground which very rapidly drains off the remaining voltage onmotor 631, braking it to a complete stop in a very short time interval.
Ejectingcomputer 100 from docking station 500 first requires a power stroke frommotor assembly 630 to disconnect the connectors. After the power stroke, hooks 638 must be released from the frame ofcomputer 100. Once the hooks are released,CPU pushouts 590 and 594 eject the computer assprings 598 and 600 return to their relaxed, contracted state. As stated, the motion ofcam follower 683 in rampedeccentric slot 684 forces hooks 638 ofcarriage 639 into this raised position once every full rotation ofwormgear 646. This deflecting motion occurs after a sufficient amount of linear reciprocating motion has occurred to disconnect the 152-pin connectors.Hooks 638 remain in this raised position as long ascam follower 683 rests on the lip inslot 684.
To activate and control the insertion and ejection process, docking station 500 is provided with several sensors and switches. Attached to leftCPU pushout 590 is a small docking indicator flag 592 (see FIG. 13). Ascomputer 100 is inserted into docking station 500, it contacts the CPU pushouts and begins to extend them. At the point where hooks 638 can properly engage with the frame of the portable computer,flag 592 projects through fryingpan docking slot 608 andskeleton docking slot 576 into aphotodetector unit 584 on logic board 580 (see FIG. 20), breaking the light, which causesphotodetector unit 584 to generate a first "insertion beginning" signal. This signal triggers the start ofmotor 631, iflock switch 686 indicates that the docking station is unlocked.
The lower surface ofwormgear 646 has a small projection 655 (see FIG. 17) extending therefrom. Mounted onlogic board 580 are twosmall switches 586 and 588 (see FIG. 16). Aswormgear 646 rotates, switches 586 and 588 are turned on momentarily in sequence, one switch being triggered by each 180° ofwormgear 646's rotation. It should be noted thatwormgear 646 only rotates in one direction. Given this unidirectional motion, it takes a combination of signals fromlock switch 686 andswitches 586 and 588 to indicate whetherportable computer 100 has been successfully docked or not A signal fromswitch 586 andphotodetector 584 indicates that the computer has been successfully docked. A signal fromswitch 588 and a low signal from photodetector 584 (light being transmitted in the photodetector) indicates that the portable computer has been ejected successfully.
The signals fromswitches 586 and 588 are debounced by an RC filter network and then applied to a Schmitt trigger inverter before being used byPAL 690. Photodetector 584s signal is applied to a Schmitt trigger inverter for hysteresis before being used by the PAL. Together, the signals fromswitches 586 and 588,photodetector 584,eject button 514 and lockswitch 686 feed a gray code state machine which allowssynchronous PAL 690 to function properly in response to asynchronous human and mechanical docking/undocking indicators.
FIG. 19 is a state table diagram which illustrates the different states that motor assembly 630 can be in. Although it is not possible to designate any one state as the "starting position" of the present invention, a logical place to begin this description of the state machine is at state 901, Gearin. State 901 can be reached in any one of three ways. First, initial AC powering of docking station 500 or any other "power-on-reset" signal places the machine in state 901. Additionally, a power fail warning signal or a "motorin" signal can place the machine in state 901, depending on the previous state. In state 901, hooks 638 are in their fully retracted position. If the portable computer has not been inserted or if the system is not locked and an ejection request has been received, then the system moves to state 907, Eject. The system remains in state 907 untilmicroswitch 588 provides a "motorout" signal, indicating that hooks 638 are in their fully extended position. Upon receiving the "motorout" signal, the system moves to state 909, Waitout. State 909 provides a waiting period of variable length which lasts until a clear indication is received from the photodetector unit that the portable computer has been fully ejected. Upon receipt of that signal from the photodetector unit, the system moves to state 911, Gearout, where hooks 638 are in their fully extended, raised position. Upon receipt from the photodetector of the signal indicating that aportable computer 100 has been inserted and receipt of a signal indicating that the docking station has not been locked, the system moves to state 913, Dock. In state 913, the motor assembly turns on and remains on until a signal frommicroswitch 586 indicates thatmotor 631 has rotated the correct amount. The system then returns to state 901. State 903, Pwron, is reached from state 901 if a power failure warning is not received andVSC 712 has power. In state 903, a power fail warning signal returns the system to state 901. If the system is not locked andVSC 712 provides an ejection enable signal or the photodetector signals that the portable computer is not in the docking system, then the system moves to state 905. Wait 5 V. The system waits in state 905 until eitherVSC 712 indicates that power is off or the photodetector continues to indicate that there is no portable computer in the docking station. If either signal is received, the system goes to state 907. It should be noted that the motor is on only when looping in states 907 and 913 and that the motor continues to run until the appropriate microswitch generates a signal that the motor's rotation has carried it to that switch.
FIG. 20 is an exploded isometric drawing showing howfrying pan 508,skeleton 520 and their related components are mated together.Motor assembly 630 is aligned tologic board 580 by means of several plastic studs 681 (see FIG. 17) which extend through the logic board intoskeleton 520. When the logic board is attached to the skeleton, hooks 638 extend throughhook slots 568, guide pins 634 extend throughguide pin slots 566, and 152-pin connector 582 extends intodocking slot 564. Electromagnetic interference ("EMI")shield 666 surroundsconnector 582 and mounts indocking slot 564.Logic board 580 is attached to logicboard mounting area 562 by means of a plurality of metal screws. Logicboard insulator sheet 668 is placed betweenlogic board 580 and logicboard mounting area 562.Modem card 583 is electronically coupled tologic board 580 using a 10-pin connector and is also mounted on logicboard mounting area 562 in the same manner as the logic board.
Manual ejection linkage 662 mounts alongdocking wall 574 ofskeleton 520. As shown,linkage 662 mounts onmanual ejection stud 672 and slides laterally in manualejection linkage track 674.Manual ejection spring 661 biases the linkage to its inactive state, withejection plate 663 abuttingmanual ejection slot 550 inbase 502. During use of the docking station, if a complete power failure occurs, or if for any other reason electrical ejection cannot be accomplished, a key, thin blade screwdriver, key, or similar tool may be inserted intoslot 550 to contact and push againstejection plate 663. Pushing onejection plate 663 pusheslinkage 662 laterally acrossskeleton 520. Eventually, a rampededge 665 oflinkage 662contacts motor assembly 630 and deflectshooks 638 upwards. Immediately afterhooks 638 are pushed upwards, they release from the frame ofportable computer 100. The user of the system can then manually release the computer from the 152-pin connector and remove the computer from the docking system. When power is returned to the system, PAL 690 (see FIG. 21) detects the low signal fromphotodetector 584, which indicates that the computer has been removed. As the state of the docking station in this situation is not a valid operating state,PAL 690 turns onmotor 631. As the motor rotates,linkage 662 is released and pops out again.Lock switch 686, which was released by pushingejection plate 663, is then depressed.PAL 690 continues to drivemotor 631 untilswitch 588 is actuated and hooks 638 are in their raised position again.
Ifmotor assembly 630 jams, a resettable thermal fuse blows to prevent overheating and possible damage to the docking station. Once the jam condition is corrected, the fuse automatically resets. If the motor is not in a valid docked state (the photodetector does not indicate thatportable computer 100 is in the docking station) or in a valid undocked state, with the hooks fully extended and raised,PAL 690 will return the system to a correct position based on the previously discussed state table diagram (see FIG. 19). This safeguard is also necessary to insure that hooks 638 are moved to their proper position when the docking station is first powered up.
Electronic ejection switch 660 attaches to the side offrying pan 508. This switch is triggered by pressing onelectronic ejection button 514 mounted in top 504 (see FIG. 5). When pressed, the switch triggers an electronic eject ofcomputer 100 if the requisite conditions exist. On/offbutton 664, which extends through the rear ofbase 502 when the docking station is completely assembled, provides a reset signal to the system when pressed.
FIG. 21 is a block diagram of the electronic components of docking station 500. As stated earlier, the purpose of the docking station is to add display, I/O, video random access memory ("VRAM"), NUBUS expansion possibilities, and, optionally, computational power toportable computer 100.
The backbone of docking station electronics 700 issystem bus 702, which provides a 32-bit address and data path. Configuration ROM 706 is coupled tobus 702 and provides docking station configuration information toCPU 201 inportable computer 100 when the computer and the station are docked. If desired, a floating point unit ("FPU") 704, also known as an arithmetic co-processor can be coupled tobus 702.FPU 704 performs arithmetic calculations faster thanCPU 201, allowing math-intensive applications to run much more quickly.
Video controller 712 is coupled tobus 702 and controls video data and display for the docking station.VRAM 714 is also coupled tobus 702, as well as tovideo controller 712.VRAM 714 provides storage for video information prior to its display.VRAM 714 is coupled through Mux 715 to video digital/analog converter/color look-up table ("VDAC/CLUT") 716 which generates the red, green, and blue analog signals needed to drive a video monitor. Display video signals are then transmitted to a monitor through video port 734.
Floppy disk drive 708 is coupled through a floppy disk controller integrated intovideo controller 712 tobus 702.
One of the ways to expand the capabilities of docking station 500 is to add one or more NUBUS cards. The capabilities of a NUBUS card can include acceleration, expanded video capabilities, tape drive memory access, and networking. Provisions are made in this first embodiment of the present invention to couple up to two NUBUS cards tosystem bus 702. TwoNUBUS Muxes 724 and 726 provide the necessary gateways between the bus and the NUBUS cards.NUBUS controller 720 with 40 Mhz clock 722 controls the flow of information to and from the NUBUS cards.
Additional I/O capabilities and memory expansion is available in the docking station. I/O controller 710 is coupled toserial ports 738 and 740, as well asSCSI port 742.Controller 710 permits the installation of optional SCSI devices 742a that could include a hard disk drive in the hard disk drive bay, which would then be coupled tosystem bus 702 through thecontroller 710. External devices such as a hard disk drive, a CD drive or a scanner would also be coupled to the docking station throughcontroller 710.Power supply 750 supplies power to both docking station 500 andportable computer 100, as well as providing power to a switched AC convenience output source for the monitor. It should be noted thatpower supply 750 supplies +19 V to drivemotor assembly 630 and to charge the batteries inportable computer 100, this voltage being available whenever AC power is supplied to the docking station. Additionally, a special, low current 5 V is also available whenever AC power is supplied to the docking station to provide power forphotodetector 584 and the other motor control circuitry. The availability of this low current +5 V source, separate from the main +5 V source, and control logic inPAL 690 allow the possibility in a second embodiment of the present invention of powering a speaker or LED which would indicate thatlock 532 is in its locked position. Motor logic, also known asPAL 690, controls the operation ofmotor assembly 630. Finally, docking station has sound in and outports 736, anADB port 732, on/offbutton 754 andmodem port 730.
DOCKING AND UNDOCKINGIn the present invention, the computer and the docking station are coupled together using a mechanically triggered electromechanical docking/undocking mechanism. If this docking were to occur while either one of the docking station or the computer is in an active "on" condition, transient signals and voltages could destroy components and data could be corrupted and lost. The present invention incorporates numerous safety features which either prevent the docking/undocking of active units or, if such active docking/undocking can not be prevented, minimize the chances of damaging components and/or losing data.
The normal sequence for inserting the portable computer into the docking station begins with the portable computer off and the docking station off. When the portable computer is inserted, itsEverWatch microcontroller 260 detects the attempted docking by means of a sense pin in the 152-pin connector. Once it detects docking,controller 260 waits for the on/off button on the docking station or the `on` key on the keyboard to be pressed. Once an `on` signal is received, the computer is first powered up butMSC 207 is held in a reset mode, which in turn maintains the expansion bus in a quiescent state and keepsCPU 201 powered off. TheEverWatch microcontroller 260 drives a power fail warning signal high, which turns onpower supply 522 in the docking station.Microcontroller 260 waits until a +5 V Ext-- Sense line goes high, which indicates that power has stabilized in docking station 500.Microcontroller 260 then takesMSC 207 out of its reset mode, allowingCPU 201 to be powered up. During this normal docking, the signal provided by clamshell switch 101 (see FIG. 4) is ignored bymicrocontroller 260. It should be noted that whenevermotor 631 is running,PAL 690 generates a power failure warning signal which shuts offpower supply 522. This guarantees that the docking station will be powered down during any docking attempt. Normal computer operations follow this initial power-up stage.
A request to ejectportable computer 100 from docking station 500 can be received at any time. In the most complex case, the computer and docking station are both operating and performing some task such as word processing. If the user presses the eject button while the system is in this state, the button causes a level 2 interrupt to be sent toCPU 201. The interrupt service routine which occurs in response to the interrupt calls the "docking manager" inROM 205 which uses control and status calls from the configuration ROM 706 in the docking station to determine the validity of the eject request by readingMSC 207 andVSC 712. The docking manager also checksVSC 712 to determine if the docking station is locked. If it is locked, a dialog box is displayed on the video monitor indicating that ejection cannot take place because the system is locked. If the system is not locked, the docking manager, along with configuration ROM 706, clears the interrupt request, issues a software request to the operating system to shutdown, and sets the eject enable bit inVSC 712,VSC 712 being coupled toPAL 690. Once the eject enable bit is on, the state machine inPAL 690 waits until power to the docking station goes off before ejecting the computer. Next, the operating system requests that application programs quit because of the ejection request. The user is provided with a dialog box if data or changes might be lost so that they can be saved, following which the application program quits. The operating system then signalsEverWatch microcontroller 260 to perform a shut down.Microcontroller 260 resetsMSC 207 which turns offCPU 201 and then turns off docking station 500 andcomputer 100 in sequence.PAL 690 detects that power has been shut off and signalsmotor assembly 630 to turn on and eject the computer.
If a manual ejection is performed when docking station 500 is still on,PAL 690 turns off the docking station's power before the connectors between the docking station and the portable computer can be disengaged. The mechanism used in the mechanical ejection raiseshooks 638 to allow the user to manually separate the units. As this method of ejection can occur at any time and in an "uncontrollable" manner, orderly closing of applications and saving data cannot take place. However, by insuring that power is properly shut off, the present invention prevents damage to either the docking station or the portable computer. Once the hooks have been raised and the portable computer manually removed,PAL 690 turns onmotor assembly 630 until the motor assembly returns to its ready state.
When the docking station is not locked, the worst scenario would be if anactive computer 100 were to be docked to the docking station, regardless of whether or not the station was on. If this was allowed to occur, both the data incomputer 100, as well as its circuitry could be damaged by voltage transients.
A first failsafe mechanism islatch switch 101 activated bylatch 117 incomputer 100. Anytimecomputer 100 is closed,latch switch 101 provides a signal toEverWatch microcontroller 260, which signal allowsEverWatch microcontroller 260 andMSC 207 to begin and complete the process of placing the computer in a sleep mode. Docking operations are permitted in sleep mode because power to the CPU and other delicate circuits is cut off. In general, it is very difficult if not impossible to insertportable computer 100 into docking station 500 withoutcomputer 100 being completely closed and therefore in a sleep state.
If the user attempts to insertcomputer 100 into docking station 500 whilecomputer 100 is in a sleep state, no damage occurs to the computer, but the system is inoperable. Once inserted and an `on` signal received,computer 100 will power up bothCPU 210 and docking station 500 as previously described. Although the hardware used in this first embodiment permits full operation of the system with the portable computer coming out of a sleep state, the first embodiment's operating software cannot compensate for the change in display screens. Therefore, oncecomputer 100 detects that it has been coupled to a docking station and that it has just come from a sleep state, it immediately returns to sleep, saving data, turning off the docking station and immediately ejecting the computer from the docking station. Once ejected, whencomputer 100's "on" is pressed.LCD 110 will display a message requesting that the user order a full shutdown before attempting to dock the computer again.
In the extremely unlikely event that closingcomputer 100 did not result inswitch 101 providing the proper signal toEverWatch microcontroller 260 to placecomputer 100 in sleep mode, the present invention has an extraordinary response to attempted insertions while the portable computer is still in a run mode. 152-pin 160 incomputer 100 has several long pins, including a "sense" pin, a +19 V power pin, and a ground pin, which make contact with sockets in docking station 500's 152-pin connector 582 before the remaining short pins, which include the other power pins, are connected. The long sense pin informsMSC 207 that docking is occuring. Ifcomputer 100 is still on,MSC 207 immediately cuts power toCPU 201. Although this results in data stored in RAM 203 being lost, this is preferable to allowing transient voltages and currents to be applied to the circuitry ofcomputer 100, which circuitry might be damaged. This loss of data would occur in any event, as the system could not continue to function when connected to a powered down docking station. AfterMSC 207 has cut power toCPU 201,EverWatch microcontroller 260 completes a graceful shutdown ofcomputer 100. This shutdown process insures thatcomputer 100 is in a known state prior to any attempt to restart or use the system. It should also be noted that one of the short pins in the 152-pin connector also acts as a sense pin, providing to computer 100 a reliable indication that the connectors have been completely mated. Only afterEverWatch microcontroller 260 receives this signal will the power planes be turned on. This eliminates the arcing and pitting of the connectors that can occur when an unpowered line is mated with a powered one.
Although the present invention has now been explained with reference to a particular embodiment, it should be apparent to one skilled in the art that numerous changes and modifications may be made thereto without departing from the scope or spirit of the invention. Dynamic changes of the monitors, even if the portable computer is in a sleep mode, will be permitted in later embodiments of the present invention. For example, it is inherent in the described embodiment that the docking station can be expanded in numerous ways. These include providing the docking station with a hard disk storage unit or a CD-ROM drive. It is not inconceivable that the docking station could be equipped with a separate CPU for special situations. The portable computer in other embodiments will be powered by different types of batteries, necessitating changes in the EverWatch microcontroller. Other changes, modifications and applications of the invention will become apparent to one skilled in the art in view of this disclosure. Thus, the invention should be limited only in accordance with the appended claims.