Robot management systems for determining docking station pose including mobile robots and methods using same

• US 10,335,004 B2
• Filed: 12/23/2016
• Issued: 07/02/2019
• Est. Priority Date: 10/05/2012
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Fong, Philip, Meltzer, Jason, Gutmann, Jens-Steffen, Karapetyan, Vazgen, Munich, Mario E.
• Primary Examiner(s): Kiswanto, Nicholas
• Application Number:
  US15/389,926
• Publication Number:
  US 20170105592A1
• Time in Patent Office: 921 Days
• CPC Class Codes: A47L 2201/02 Docking stations; Docking operations
• CPC Class Codes: A47L 2201/04 Automatic control of the travelling movement; Automatic obstacle detection
• CPC Class Codes: A47L 9/2873 Docking units or charging stations for autonomous or robotic vacuum cleaners A47L2201/02
• CPC Class Codes: A47L 9/2894 Details related to signal transmission in suction cleaners
• CPC Class Codes: A47L 9/30 Arrangement of illuminating devices
• CPC Class Codes: B25J 11/0085 Cleaning
• CPC Class Codes: B25J 13/006 by means of a wireless system for controlling one or several manipulators
• 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: B25J 9/1666 Avoiding collision or forbidden zones
• CPC Class Codes: B25J 9/1697 Vision controlled systems
• 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 1/0234 using optical markers or beacons optical beacons per se G01S1/70
• CPC Class Codes: G05D 1/0274 using mapping information stored in a memory device navigation using map-matching G01C21/30
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: Y10S 901/01 Mobile robot

Abstract

A mobile robot system is provided that includes a docking station having at least two pose-defining fiducial markers. The pose-defining fiducial markers have a predetermined spatial relationship with respect to one another and/or to a reference point on the docking station such that a docking path to the base station can be determined from one or more observations of the at least two pose-defining fiducial markers. A mobile robot in the system includes a pose sensor assembly. A controller is located on the chassis and is configured to analyze an output signal from the pose sensor assembly. The controller is configured to determine a docking station pose, to locate the docking station pose on a map of a surface traversed by the mobile robot and to path plan a docking trajectory.

Claims

1. A mobile robot system comprising:

a docking station comprising;

at least two pose-defining fiducial markers, the at least two pose-defining fiducial markers having a predetermined spatial relationship with respect to one another and/or to a reference point on the docking station;

an evacuation receptacle on the docking station;

a mobile robot including;

a chassis,

a motorized drive for moving the mobile robot to a docked position,

a pose sensor assembly configured to output a signal in response to the at least two pose-defining fiducial markers in a pose sensor field of view; and

a controller configured to analyze the signal from the pose sensor assembly to determine a docking station pose that is based on a stored spatial relationship of the pose-defining fiducial markers and the signal from the pose sensor assembly, to path plan a docking trajectory comprising a pre-planned path from the robot to the dock, based on a current robot position on the map of the surface and the docking station pose and to provide instructions to the motorized drive to move the mobile robot along the docking trajectory and into a docking lane aligned with the evacuation receptacle of the docking station.

2. The mobile robot system of claim 1, wherein the docking station further comprises an evacuation adapter configured to receive debris from the robot, and the robot comprises an air path, wherein the controller is configured to path plan the docking trajectory such that the air path of the robot is aligned with the evacuation adapter of the docking station.

3. The mobile robot system of claim 2, wherein when the air path of the robot is aligned with the evacuation adapter, the robot is positioned above the evacuation adapter.

4. The system of claim 1, further comprising a database of image data comprising images of the docking station at a plurality of viewpoints, wherein the controller is configured to compare the image data from the pose sensor assembly with the database of image data, and to estimate a pose of the docking station responsive to a comparison of the image data from the pose sensor assembly with the database of image data.

5. The system of claim 4, wherein the controller outputs a three-dimensional position and orientation of the robot with respect to the docking station based on the estimate of the pose of the docking station, and before making a maneuvering decision based on the estimate of the pose of the docking station, the robot determines whether the three-dimensional position and orientation is consistent with an expected three-dimensional space of positions and orientations.

6. The system of claim 5, wherein the database of image data is generated from a three-dimensional computer model of the docking station and the fiducial markers thereon.

7. The system of claim 1, wherein the controller is further configured to return to the docking station using a signal identifying the location of the docking station such that the robot turns at a location to align with detected signals and approach the docking station along the docking lane and path planning to the docking having a pose known to the robot controller.

8. The system of claim 1, wherein the controller is configured to path plan around obstacles that are disposed between the robot and the docking lane of the docking station by determining a path that avoids collisions with the obstacles and controlling the robot to move along the path that avoids collisions with obstacles.

9. The system of claim 1, wherein the controller is located on the chassis of the mobile robot.

10. The system of claim 1, wherein the controller determines the pose of the docking station by acquiring data including observations of the fiducial markers of the docking station from at least two positions of the robot and triangulating a location and angular orientation of the docking station in response to the data.

11. The system of claim 10, wherein the fiducial markers are LEDs that are configured indicate a beam direction to the pose sensor assembly.

12. The system of claim 11, wherein the LEDs have different light-emitting characteristics such that the pose sensor assembly is configured to identify an orientation of the LEDs responsive to the predetermined spatial relationship of the LEDs.

13. The system of claim 12, wherein the pose sensor assembly comprises a directional sensor.

14. The system of claim 13, wherein the directional sensor comprises twin photodiodes.

15. The system of claim 13, wherein the fiducial markers are collimated and/or baffled LED lights that generally emit light in a direction such that the pose sensor assembly is configured to plot a line of sight when the robot crosses the emitted light.

16. The system of claim 13, wherein the fiducial markers comprise a portion that transmits IR light and a portion that blocks IR light.

17. The system of claim 1, wherein the fiducial markers comprise a spatially recognizable visual pattern.