Proximity sensing on mobile robots

• US 10,429,851 B2
• Filed: 08/23/2016
• Issued: 10/01/2019
• Est. Priority Date: 09/21/2012
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Shamlian, Steven V., Duffley, Samuel, Romanov, Nikolai, Goel, Dhiraj, Hook, Frederic D., Munich, Mario E.
• Primary Examiner(s): Kiswanto, Nicholas
• Application Number:
  US15/244,603
• Publication Number:
  US 20170031366A1
• Time in Patent Office: 1,134 Days
• CPC Class Codes: G01B 11/026 by measuring distance between sensor and object G01B11/0608 takes precedence
• CPC Class Codes: G05D 1/0227 using mechanical sensing means, e.g. for sensing treated area
• CPC Class Codes: G05D 1/0238 using obstacle or wall sensors G05D1/0246 and G05D1/0289 take precedence; lidar systems designed for anti-collision purposes G01S17/93
• CPC Class Codes: G05D 1/0242 using non-visible light signals, e.g. IR or UV signals
• CPC Class Codes: G05D 1/027 comprising intertial navigation means, e.g. azimuth detector inertial navigation G01C21/16; inertial navigation combined with non-inertial navigation instruments G01C21/165

Abstract

A proximity sensor includes first and second sensors disposed on a sensor body adjacent to one another. The first sensor is one of an emitter and a receiver. The second sensor is the other one of an emitter and a receiver. A third sensor is disposed adjacent the second sensor opposite the first sensor. The third sensor is an emitter if the first sensor is an emitter or a receiver if the first sensor is a receiver. Each sensor is positioned at an angle with respect to the other two sensors. Each sensor has a respective field of view. A first field of view intersects a second field of view defining a first volume that detects a floor surface within a first threshold distance. The second field of view intersects a third field of view defining a second volume that detects a floor surface within a second threshold distance.

Claims

1. An autonomous robot comprising:

a drive system supporting a robot body and configured to maneuver the robot over a first floor surface; and

a sensor system disposed on the robot body, the sensor system including at least one proximity sensor comprising;

a first emitter for emitting a first optical signal from the autonomous robot toward the first floor surface;

a first detector for detecting the first optical signal; and

a housing for the first emitter and the first detector comprising;

a first baffle defining a field of view of the first emitter, the first baffle directing the first optical signal transmitted from the emitter to the first floor surface; and

a second baffle defining a field of view of the first detector, the second baffle directing the first optical signal, the first optical signal being reflected from the first floor surface to the first detector at a first angle, wherein one of the first baffle or the second baffle is a double baffle including an upper pinch point and a lower pinch point, the upper pinch point defining an upper aperture in the housing and the lower pinch point defining a lower aperture in the housing further from the first emitter or the first detector, respectively, than the upper aperture.

2. The autonomous robot of claim 1, the proximity sensor further comprising:

a second detector for detecting the first optical signal, wherein the housing comprises a fourth baffle defining a field of view of the second detector, the fourth baffle being positioned in the housing to pass the first optical signal reflected from the first floor surface to the second detector at a second angle different from the first angle.

3. The autonomous robot of claim 2, wherein an overlap of the field of view of the first detector and the field of view of the first emitter define a first volume of overlap at a first distance from the housing, the first volume of overlap being defined by the first and second baffles, and wherein an overlap of the field of view of the second detector and the field of view of the first emitter define a third volume at a third distance from the housing, the position of the third volume being defined by the first and fourth baffles, and wherein the third distance is further from the housing than the first distance.

4. The autonomous robot of claim 3, wherein the first distance is between 1 inch and 3 inches and wherein the third distance is greater than 3 inches.

5. The autonomous robot of claim 1, the proximity sensor further comprising:

a second emitter for emitting a second optical signal from the autonomous robot; and

the housing comprising a third baffle directing a field of view of the second emitter, the third baffle being positioned in the housing to pass the second optical signal transmitted from the second emitter to a second floor surface further from the housing than the first floor surface.

6. The autonomous robot of claim 5, wherein an overlap of the field of view of the first emitter and the field of view of the first detector define a first volume of overlap at a first distance from the housing, the first volume of overlap being defined by the first and second baffles, and wherein an overlap of the field of view of the second emitter and the field of view of the first detector define a second volume at a second distance from the housing, the position of the second volume being defined by the second and third baffles, and wherein the second distance is further from the housing than the first distance.

7. The autonomous robot of claim 6, wherein the first distance is between 1 inch and 3 inches and the second distance is greater than 3 inches.

8. The autonomous robot of claim 1, wherein the first baffle is a double baffle including an upper pinch point and a lower pinch point, the upper pinch point defining an upper aperture in the housing and the lower pinch point defining a lower aperture in the housing further from the first emitter than the upper aperture.

9. The autonomous robot of claim 8, wherein the upper aperture of the first baffle and the lower aperture of the first baffle are in sequence and the center of the upper aperture is horizontally offset from the center of the lower aperture.

10. The autonomous robot of claim 8, wherein the first emitter includes a light emitting diode, and wherein the lower aperture is sized at an opening width spanning a distance approximately equivalent to half the power angle of the light emitting diode.

11. The autonomous robot of claim 1, wherein the second baffle is a double baffle including an upper pinch point and a lower pinch point, the upper pinch point defining an upper aperture in the housing and the lower pinch point defining a lower aperture in the housing further from the first detector that the upper pinch point than the upper aperture.

12. The autonomous robot of claim 11, wherein the upper aperture of the second baffle and the lower aperture of the second baffle are in sequence and the center of the upper aperture is horizontally offset from the center of the lower aperture.

13. The autonomous robot of claim 1, wherein the first baffle prevents portions of the first optical signal reflected from a wall of the housing from reaching the first floor surface.

14. The autonomous robot of claim 1, wherein the second baffle prevents portions of the first optical signal reflected from a wall of the housing from reaching the first detector.

15. An autonomous mobile robot comprising:

a drive system supporting a robot body and configured to maneuver the robot over a floor surface;

a vacuum assembly configured to remove debris from the floor surface; and

a sensor system disposed on the robot body, the sensor system including at least one proximity sensor positioned on a bottom surface of the robot for determining a distance from the robot to a floor surface, the at least one proximity sensor comprising;

an emitter configured to emit a light beam from the robot towards the floor surface;

a first receiver positioned at a first location configured to receive a first portion of the emitted light beam reflected from a first portion of the floor surface corresponding to a first range of distances between the floor surface and the proximity sensor; and

a second receiver positioned at a second location different from the first location configured to receive a second portion of the emitted light beam reflected from a second portion of the floor surface corresponding to a second range of distances larger than the first range of distances between the floor surface and the proximity sensor; and

a controller configured to issue a stop command, a reverse command, or a turn away command to the drive system in response to light above a first threshold received at the second receiver, and light below a second threshold received at the first receiver.

16. The autonomous mobile robot of claim 15, wherein the first range of distances includes distances less than 5 cm and the second range of distances includes distances between 5 cm and 10 cm.

17. The autonomous mobile robot of claim 15, wherein the first range of distances includes distances less than 5 cm and the second range of distances includes distances between 5 cm and 25 cm.

18. The autonomous mobile robot of claim 15, wherein the first range of distances includes distances between 1 and 3 inches and the second range of distances includes distances larger than 3 inches.

19. An autonomous mobile robot comprising:

a drive system supporting a robot body and configured to maneuver the robot over a floor surface;

a vacuum assembly configured to remove debris from the floor surface; and

a sensor system disposed on the robot body, the sensor system including at least one proximity sensor positioned on a bottom surface of the robot for determining a distance from the robot to a floor surface, the at least one proximity sensor comprising;

an emitter configured to emit a light beam from the robot towards the floor surface;

a first receiver positioned at a first location configured to receive a first portion of the emitted light beam reflected from a first portion of the floor surface corresponding to a first range of distances between the floor surface and the proximity sensor; and

a second receiver positioned at a second location different from the first location configured to receive a second portion of the emitted light beam reflected from a second portion of the floor surface corresponding to a second range of distances larger than the first range of distances between the floor surface and the proximity sensor; and

a controller configured to issue a stop command in response to light below a first threshold received at the second receiver, and light above a second threshold received at the first receiver.

20. The autonomous mobile robot of claim 19, wherein the first range of distances includes distances less than 5 cm and the second range of distances includes distances between 5 cm and 10 cm.

21. The autonomous mobile robot of claim 19, wherein the first range of distances includes distances less than 5 cm and the second range of distances includes distances between 5 cm and 25 cm.

22. The autonomous mobile robot of claim 19, wherein the first range of distances includes distances between 1 and 3 inches and the second range of distances includes distances larger than 3 inches.