Autonomous robot auto-docking and energy management systems and methods

• US 9,931,750 B2
• Filed: 11/18/2016
• Issued: 04/03/2018
• Est. Priority Date: 01/21/2004
• Status: Active Grant

• 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:
  US15/355,518
• Publication Number:
  US 20170072564A1
• Time in Patent Office: 501 Days
• Field of Search: 320104, 320107, 320109, 320134, 700258, 700262
• 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:

a housing;

a motive system to propel the housing across a ground surface;

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

a plurality of detectors mounted on the housing, the plurality of detectors comprising a first detector positioned on a front portion of the housing and a second detector positioned on the housing below the first detector, the first detector being an omnidirectional detector mounted at a highest point of the robot; and

a navigational control system to autonomously control the motive system to

direct the robot about a room to clean the room,

direct the robot to seek the base charging station upon detecting a need to recharge the energy storage unit, and

direct the robot to approach the base charging station to dock the robot based on a first signal emitted by a first emitter of the base charging station and received by the first detector, and based on a second signal emitted by a second emitter of the base charging station and received by the second detector.

2. The robot of claim 1, further comprising a vacuum system operable

in a first energy level mode while the robot is directed about the room to clean the room, and

in a second energy level mode while the robot is directed to seek the base charging station.

3. The robot of claim 2, wherein the vacuum system is operable in the first energy level mode for a predetermined time period before being operated in the second energy level mode.

4. The robot of claim 2, further comprising an energy level monitor to detect a low energy level, wherein the vacuum system is configured to adjust operation of the vacuum system from the first energy level mode to the second energy level mode in response to detecting the low energy level.

5. The robot of claim 1, wherein the second detector is positioned on a side of the robot.

6. The robot of claim 1, wherein the navigational control system is configured to direct the robot to seek the base charging station based on the first signal received by the first detector.

7. The robot of claim 1, wherein the navigational control system is configured to direct the robot to seek the base charging station by executing a following behavior in which the robot moves along an obstacle to seek the base charging station.

8. The robot of claim 1, wherein the navigational control system is configured to direct the robot to approach the base charging station by reorienting the robot relative to the base charging station based on the second signal.

9. The robot of claim 8, wherein the navigational control system is configured to direct the robot to approach the base charging station by reorienting the robot relative to the base charging station based on the second signal and based on a third signal emitted by a third emitter of the base charging station.

10. The robot of claim 1, wherein the robot is configured to receive programming information from the base charging station.

11. The robot of claim 1, wherein:

the second signal is one of a plurality of second signals emitted by the base charging station, and

the navigational control system is configured to control the motive system to direct the robot to approach the base charging station further based on the plurality of second signals emitted by the base charging station and received by the second detector.

12. A system comprising:

a base charging station comprising

a backstop, and

emitters comprising an upper emitter positioned on the backstop and a plurality of lower emitters positioned on the backstop below the upper emitter; and

an autonomous cleaning robot comprising a navigational control system to direct the robot to approach the base charging station to recharge an energy storage unit of the robot based on a first signal emitted by the upper emitter and received by the robot and based on a plurality of second signals emitted by the plurality of lower emitters and received by the robot.

13. The system of claim 12, wherein the base charging station is configured to transmit programming information to the autonomous cleaning robot.

14. The system of claim 12, wherein the base charging station is configured to transmit and receive data between the base charging station and the autonomous cleaning robot.

15. The system of claim 12, wherein the robot comprises a first detector to receive the first signal from the base charging station, and a second detector positioned below the first detector to receive the plurality of second signals transmitted from the base charging station.

16. The system of claim 12, wherein the upper emitter is an omnidirectional emitter mounted on a topmost portion of the base charging station.

17. A method of docking an autonomous cleaning robot, the method comprising:

seeking a base charging station;

detecting, using a first detector mounted at a highest point of the robot, a first signal emitted by the base charging station, the first signal indicative of a presence of the base charging station, the first detector being omnidirectional; and

in response to detecting the first signal, approaching the base charging station to dock the robot at the base charging station while detecting, using a second detector positioned below the first detector, a second signal emitted by the base charging station.

18. The method of claim 17, wherein seeking the base charging station comprises seeking the base charging station while a vacuum operation is in a reduced energy level mode.

19. The method of claim 17, wherein:

the second signal is one of a plurality of second signals emitted by the base charging station, and

approaching the base charging station comprises approaching the base charging station while detecting, using the second detector, the plurality of second signals emitted by the base charging station.

20. The method of claim 19, wherein approaching the base charging station comprises approaching the base charging station while reorienting the robot relative to the base charging station based on an overlap of the plurality of second signals.