Autonomous robot auto-docking and energy management systems and methods

• US 9,550,294 B2
• Filed: 11/20/2015
• Issued: 01/24/2017
• Est. Priority Date: 01/21/2004
• Status: Expired due to Term

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Cohen, David A., Ozick, Daniel N., Vu, Clara, Lynch, James, Mass, Philip R.
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): PIGGUSH, AARON C
• Application Number:
  US14/946,999
• Publication Number:
  US 20160075021A1
• Time in Patent Office: 431 Days
• Field of Search: 320/104, 320/107, 320/109, 320/134, 700/258, 700/262, 901/46, 180/167
• US Class Current: 1/1
• 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. An autonomous cleaning robot, comprising:

an undercarriage;

a motive system configured to propel the undercarriage across a ground surface;

an energy storage unit supported by the undercarriage and configured to be charged while the robot is positioned at a base charging station; and

a navigational control system configured to autonomously;

control the motive system to direct the robot about a room, while mapping the room with respect to objects as points of reference;

return the robot to the base charging station before completing a cleaning task in the room, in response to detecting a need to recharge the energy storage unit;

dock the robot to the base charging station upon return;

recharge the energy storage unit with the robot docked; and

then to

control the motive system to direct the robot to continue to clean the room.

2. The autonomous cleaning robot of claim 1, wherein the control system is configured to track a cleaning route of the robot and monitor an amount of the room remaining to be cleaned.

3. The autonomous cleaning robot of claim 1, wherein the control system is configured to use a known position of the base charging station as a point of reference in mapping the room.

4. The autonomous cleaning robot of claim 1, wherein the control system is configured to determine, through use of route-tracking subroutines while controlling the motive system to direct the robot about the room, which portion of the room still requires cleaning.

5. The autonomous cleaning robot of claim 4, wherein the control system is configured to direct the robot to the portion of the room still requiring cleaning, following recharging the energy storage unit.

6. The autonomous cleaning robot of claim 1, wherein the robot is configured to control charging at the base charging station by only partially charging the energy storage unit before leaving the base charging station to continue cleaning the room.

7. The autonomous cleaning robot of claim 6, wherein the robot is configured to leave the base charging station and continue to clean the room upon determining that the energy storage unit has reached a minimum amount of stored energy necessary to complete the cleaning task in the room.

8. The autonomous cleaning robot of claim 1, wherein the control system is configured to return the robot to the base charging station before completing the cleaning task in the room, in response to a quantity of energy remaining in the energy storage unit falling to a predetermined threshold.

9. The autonomous cleaning robot of claim 8, wherein the navigational control system is configured to direct the robot to the base charging station by seeking a base station homing signal.

10. The autonomous cleaning robot of claim 8, wherein the robot is configured to determine the quantity of energy in the energy storage unit using at least one of coulometry and operating time.

11. The autonomous cleaning robot of claim 1, wherein the robot is configured to disable a cleaning function while returning to the base charging station.

12. The autonomous cleaning robot of claim 1, wherein the energy storage unit comprises a battery.

13. The autonomous cleaning robot of claim 1, wherein the energy storage unit comprises electrical contacts arranged to automatically make electrical contact with the base charging station upon docking of the robot.