Autonomous robot auto-docking and energy management systems and methods

• US 8,461,803 B2
• Filed: 12/29/2006
• Issued: 06/11/2013
• Est. Priority Date: 01/21/2004
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Cohen, David A., Ozick, Daniel, Vu, Clara, Lynch, James, Mass, Philip R.
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): PIGGUSH, AARON C
• Application Number:
  US11/648,241
• Publication Number:
  US 20070114975A1
• Time in Patent Office: 2,356 Days
• Field of Search: 320/109, 320/132, 700/262, 901/46
• US Class Current: 320/109
• CPC Class Codes: A47L 2201/02 Docking stations; Docking operations
• CPC Class Codes: A47L 2201/022 Recharging of batteries
• CPC Class Codes: A47L 2201/04 Automatic control of the travelling movement; Automatic obstacle detection
• CPC Class Codes: A47L 9/0063 External storing devices; Stands, casings or the like for the storage of suction cleaners
• CPC Class Codes: A47L 9/009 Carrying-vehicles; Arrangements of trollies or wheels; Means for avoiding mechanical obstacles
• CPC Class Codes: A47L 9/2805 Parameters or conditions being sensed
• CPC Class Codes: A47L 9/2852 Elements for displacement of the vacuum cleaner or the accessories therefor, e.g. wheels, casters or nozzles
• CPC Class Codes: A47L 9/2857 User input or output elements for control, e.g. buttons, switches or displays
• CPC Class Codes: A47L 9/2873 Docking units or charging stations for autonomous or robotic vacuum cleaners A47L2201/02
• CPC Class Codes: A47L 9/2889 Safety or protection devices or systems, e.g. for prevention of motor over-heating or for protection of the user
• CPC Class Codes: A47L 9/2894 Details related to signal transmission in suction cleaners
• CPC Class Codes: B25J 11/0085 Cleaning
• CPC Class Codes: B25J 19/005 using batteries, e.g. as a back-up power source
• CPC Class Codes: B25J 5/00 Manipulators mounted on wheels or on carriages B25J1/00 takes precedence; programme-controlled manipulators B25J9/00 ; vehicle aspects B60, B62, e.g. remote-controlled steering for motor vehicles B62D1/24; control of position of vehicles G05D1/00
• CPC Class Codes: B25J 9/1664 characterised by motion, path, trajectory planning
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: G01S 1/16 Azimuthal guidance systems, e.g. system for defining aircraft approach path, localiser system
• CPC Class Codes: G01S 1/7034 Mounting or deployment thereof
• CPC Class Codes: G01S 1/7038 Signal details
• CPC Class Codes: G01S 2201/01 adapted for specific applications or environments
• CPC Class Codes: G05D 1/0219 : ensuring the processing of the whole working surface
• CPC Class Codes: G05D 1/0225 : involving docking at a fixed facility, e.g. base station or loading bay parking aids B62D15/027
• CPC Class Codes: G05D 1/0227 : using mechanical sensing means, e.g. for sensing treated area
• CPC Class Codes: G05D 1/0242 : using non-visible light signals, e.g. IR or UV signals
• CPC Class Codes: H02J 7/00 : Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00309 : Overheat or overtemperature protection
• CPC Class Codes: H02J 7/0036 : using connection detecting circuits H02J7/0034 takes precedence
• CPC Class Codes: H02J 7/0044 : specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H02J 7/0045 : concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/00714 : in response to battery charging or discharging current
• CPC Class Codes: H02J 7/007182 : in response to battery voltage
• CPC Class Codes: H02J 7/04 : Regulation of charging current or voltage
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 901/01 : Mobile robot

Abstract

A method for energy management in a robotic device includes providing a base station for mating with the robotic device, determining a quantity of energy stored in an energy storage unit of the robotic device, and performing a predetermined task based at least in part on the quantity of energy stored. Also disclosed are systems for emitting avoidance signals to prevent inadvertent contact between the robot and the base station, and systems for emitting homing signals to allow the robotic device to accurately dock with the base station.

Claims

1. A method of charging a battery of a device at a base station, the method comprising the steps of:

providing a non-charging, sensing energy at charging contacts of the base station;

confirming docking of the device across the charging contacts of the base station by recognizing a specific load identifying a voltage divider including a first circuit in the base station combined with a complementary second charging circuit in the device powered by the battery;

in response to recognizing the specific load, increasing energy available from the charging contacts of the base station from the non-charging, sensing energy to a charging energy available to charge the battery;

detecting the presence of the charging energy at the charging contacts of the device; and

in response to detecting the presence of the charging energy at the charging contacts of the device, changing the state of a switch within the device to allow charging energy to energize the device, wherein confirming docking of the device across the charging contacts of the base station comprises checking for the specific load at regular intervals, the regular intervals comprising intervals of 10 times per second to once per minute.

2. The method according to claim 1, further comprising the steps of:

determining a level of charge in the device; and

permitting charging of the battery in the device when the level of charge is below a predetermined threshold.

3. The method of claim 1, wherein the device comprises an autonomous mobile device.

4. The method of claim 1, further comprising maintaining the higher energy level above a predetermined threshold regardless of a battery level of the mobile device to ensure sufficient energy to operate control circuits of the mobile device.

5. The method of claim 1, wherein the non-charging energy is about 5 volts limited to 1 mA maximum short circuit current flow.

6. A system for charging a mobile device at a base station, the system comprising:

a base station comprising a plurality of first charging contacts, and;

a first circuit for confirming docking of the device across the first charging contacts by recognizing a specific load;

a base station switching circuit configured to allow current flow into the device after the specific load is recognized; and

a mobile device comprising;

a battery;

a second circuit configured to provide part of the specific load;

a plurality of second charging contacts adapted to mate with first charging contacts;

a microprocessor configured to detect the presence of a charging voltage across the second charging contacts, and

a device switching circuit configured to allow current flow into the battery in response to detection of the charging voltage across the second charging contacts; and

wherein the first circuit and the second circuit combined form a voltage divider that creates the specific load and wherein the first circuit confirms docking of the device across the first charging contacts by recognizing the specific load at regular intervals, the regular intervals comprising intervals of 10 times per second to once per minute.

7. The system of claim 6, wherein the circuitry of the base station determines a level of charge in the battery and controls a power level provided to the first charging contacts.

8. The system of claim 7 wherein the circuitry is configured to change from a non-charging, sensing energy to a charging current provided to the first charging contacts upon measuring a predetermined voltage across the first charging contacts when mated with the second charging contacts.

9. The system of claim 6, wherein the base station is configured to maintain the higher energy level above a predetermined threshold regardless of a battery level of the mobile device to ensure sufficient energy to operate control circuits of the mobile device.

10. The system of claim 6, wherein the microprocessor of the mobile device is configured to measure a device battery level and determine a charging control cycle to be used in allowing current to flow into the battery.

11. A method of charging a device including an internal battery and a device processor at a base station, the method comprising the steps of:

providing a non-charging, sensing energy at charging contacts of the base station;

confirming docking of charging contacts present on the device across the charging contacts of the base station by recognizing a specific load identifying a voltage divider including a first circuit connected to the charging contacts in the base station combined with a complementary second charging circuit connected to the charging contacts on the device;

in response to recognizing the specific load, increasing energy available from the charging contacts of the base station from the non-charging, sensing energy to a charging energy available to power the device processor;

detecting the presence of the charging energy at the charging contacts of the device; and

in response to detecting the presence of the charging energy at the charging contacts of the device, changing, by the device processor, the state of a switch within the device to allow charging energy to energize the device internal battery, wherein confirming docking of charging contacts present on the device across the charging contacts of the base station comprises checking for the specific load at regular intervals, the regular intervals comprising intervals of 10 times per second to once per minute.

12. The method according to claim 11, wherein the base station provides the non-charging, sensing energy at the charging contacts of the base station;

the base station confirms docking of the charging contacts present on the device across the charging contacts of the base station by recognizing the specific load identifying the voltage divider including the first circuit connected to the charging contacts in the base station combined with the complementary second charging circuit connected to the charging contacts on the device; and

the base station, in response to recognizing the specific load, increases energy available from the charging contacts of the base station from the non-charging, sensing energy to the charging energy available to power the device processor.

13. The method according to claim 12, wherein the device processor detects the presence of the charging energy at the charging contacts of the device;

and the device processor, in response to detecting the presence of the charging energy at the charging contacts of the device, changes the state of a switch within the device to allow charging energy to energize the device internal battery.