Method and system for multi-mode coverage for an autonomous robot

• US 9,104,204 B2
• Filed: 05/14/2013
• Issued: 08/11/2015
• Est. Priority Date: 06/12/2001
• Status: Expired due to Term

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Jones, Joseph L., Mass, Philip R.
• Primary Examiner(s): Black, Thomas G
• Assistant Examiner(s): NELSON, SARA J
• Application Number:
  US13/893,762
• Publication Number:
  US 20130325178A1
• Time in Patent Office: 819 Days
• Field of Search: 318/434, 701/23, 701/301, 180/167, 180/168, 180/169, 153/19, 700/245, 700/250, 700/253, 700/255, 700/258
• US Class Current: 1/1
• CPC Class Codes: A47L 11/00 Machines for cleaning floors, carpets, furniture, walls, or wall coverings
• CPC Class Codes: B25J 11/0085 Cleaning
• CPC Class Codes: B25J 9/1694 characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
• CPC Class Codes: G05D 1/0219 ensuring the processing of the whole working surface
• 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: G05D 1/0255 using acoustic signals, e.g. ultra-sonic singals sonar systems designed for anti-collision purposes G01S15/93
• CPC Class Codes: G05D 1/0272 comprising means for registering the travel distance, e.g. revolutions of wheels measuring distance traversed on the ground by vehicles, e.g. using odometers G01C22/00
• CPC Class Codes: Y10S 901/01 Mobile robot

Abstract

A control system for a mobile robot (10) is provided to effectively cover a given area by operating in a plurality of modes, including an obstacle following mode (51) and a random bounce mode (49). In other embodiments, spot coverage, such as spiraling (45), or other modes are also used to increase effectiveness. In addition, a behavior based architecture is used to implement the control system, and various escape behaviors are used to ensure full coverage.

Claims

1. A mobile coverage robot, comprising:

a drive mechanism comprising drive wheels that both drive the robot forward across a surface in a drive direction and turns the robot to change the drive direction;

a floor cleaner disposed on a lateral side of the robot;

a proximity sensor aimed forward of the drive wheels in the drive direction, the proximity sensor responsive to an object proximate the lateral side of the robot;

a tactile sensor responsive to a bump event between the robot and an object, the tactile sensor comprising a bumper switch; and

a plurality of floor level sensors, each floor level sensor responsive to a condition of an area below the robot, the floor level sensors comprising;

a cliff sensor aimed forward of the drive wheels in the drive direction and responsive to a presence of a cliff in the drive direction of the robot; and

a wheel drop sensor responsive to a wheel drop event; and

a drive controller in communication with the proximity sensor, the tactile sensor, and the plurality of floor level sensors, the drive controller configured to;

operate the robot to follow a sensed object on the lateral side of the robot;

operate the robot to travel in an altered direction in response to a bump event between the robot and the object, and to shut off the robot in response to determining that the bumper switch has been constantly depressed for a predetermined amount of time;

operate the robot to avoid a cliff; and

reduce the velocity of the robot in response to a wheel drop event.

2. The mobile robot of claim 1, wherein the floor cleaner comprises a rotating brush, and wherein the drive controller is further configured to:

change a moving direction of the robot when a stall rate of the brush exceeds a predetermined threshold and a slope of the stall rate is positive, and

shut the robot off when the stall rate of the brush continues to exceed the predetermined threshold, and the slope of the stall rate continues to be positive, after the drive controller changes the moving direction multiple times.

3. The mobile robot of claim 1, wherein the drive controller operates the robot to avoid a cliff by rotating the robot away from the cliff.

4. The mobile robot of claim 1, wherein the proximity sensor is aimed at a finite volume of detection space at an expected object.

5. The mobile robot of claim 1, wherein the tactile sensor further comprises a second mechanical bumper switch.

6. The mobile robot of claim 5, wherein the first mechanical bumper switch and the second mechanical bumper switch are located on opposing lateral sides of the robot.

7. The mobile robot of claim 5, wherein each of the first and second bumper switches are located forward of the drive mechanism in the drive direction.

8. The mobile robot of claim 5, wherein the drive controller is configured to determine an angle relative to the robot at which the bump event occurred by calculating an elapsed time between activation of the first and second mechanical bumper switches.

9. The mobile robot of claim 8, wherein the drive controller is configured to determine that the bump event occurred directly in front of the robot in the drive direction when the first and second mechanical bumper switches are activated simultaneously.

10. The mobile robot of claim 1, wherein the tactile sensor further comprises a plurality of sensors responsive to movement of the bumper switch.

11. The mobile robot of claim 10, wherein the drive controller is configured to determine an angle relative to the robot at which the bump event occurred by calculating an elapsed time between activation of the sensors.

12. The mobile robot of claim 10, wherein the sensors divide a forward portion of the robot into a plurality of regions, and wherein the drive controller is configured to determine the region in which the bump event occurred.

13. The mobile robot of claim 1, wherein the drive controller is configured to monitor a number of bump events that have occurred within a period of time, and to alter operation of the robot when the number of bump events has surpassed a predetermined threshold within the period of time.

14. The mobile robot of claim 1, wherein the drive controller is configured to monitor an average distance between bump events, and to alter operation of the robot when the average distance has surpassed a predetermined threshold.

15. The mobile robot of claim 1, wherein the drive controller is configured to monitor a number of wheel drop events that have occurred within a period of time, and to shut the robot off when the number of wheel drop events has passed a selected threshold.

16. The mobile robot of claim 1, wherein the drive controller operates the robot to avoid a cliff by

monitoring the cliff sensor to detect when a cliff is present proximate the drive direction of the robot;

and

in response to detecting that a cliff is present proximate the drive direction of the robot, turning the robot away from the cliff.

17. The mobile robot of claim 16, wherein the drive controller is further configured to reduce the velocity of the robot in response to detecting the cliff.

18. The mobile robot of claim 16, wherein the drive controller is further configured to monitor a duration of cliff detection and shut the robot off when the duration has passed a selected threshold.

19. The mobile robot of claim 1, wherein the drive controller is further configured to operate the robot to align the lateral side with an object by

monitoring the tactile sensor to detect when a bump event has occurred between the robot and the object;

and

in response to detecting that a bump event has occurred, turning the robot such that the object is located on the lateral side of the robot.

20. The mobile robot of claim 1, wherein the drive controller operates the robot to travel in a direction away from an object in response to a bump event between the robot and the object by

monitoring the tactile sensor to detect when the bump event has occurred;

and

in response to detecting that the bump event has occurred, turning the robot away from a surface of the object.

21. The mobile robot of claim 20, wherein the drive controller is further configured to drive the robot forward while turning the robot.

22. The mobile robot of claim 20, wherein the drive controller is further configured to determine a selected angle and direction by which to turn the robot based on an angle relative to the robot at which the bump event occurred.

23. The mobile robot of claim 1, wherein the drive controller is further configured to shut the robot off in response to continued detection of a wheel drop event by the wheel drop sensor for a predetermined amount of time.

24. A mobile coverage robot, comprising:

a drive mechanism comprising drive wheels that both drives the robot forward across a surface in a drive direction and turns the robot to change the drive direction;

a floor cleaner disposed on a lateral side of the robot;

a proximity sensor aimed forward of the drive wheels in the drive direction, the proximity sensor responsive to an object proximate the lateral side of the robot;

a tactile sensor responsive to a bump event between the robot and an object, the tactile sensor comprising a bumper switch; and

a plurality of floor level sensors, each floor level sensor responsive to a condition of an area below the robot, the floor level sensors comprising;

a cliff sensor aimed forward of the drive wheels in the drive direction and responsive to a presence of a cliff in the drive direction of the robot; and

a wheel drop sensor responsive to a wheel drop event; and

a drive controller in communication with the proximity sensor, the tactile sensor, and the plurality of floor level sensors, the drive controller configured to;

operate the robot to follow a sensed object on the lateral side of the robot;

operate the robot to travel in an altered direction in response to a bump event between the robot and the object; and

in response to one or more predetermined signals from a sensor, operate the robot according to an escape sequence, and to shut off the robot in response to determining that the bumper switch has been constantly depressed for a predetermined amount of time during the escape sequence.

25. The mobile robot of claim 24, wherein the floor cleaner comprises a motorized rotating brush and a brush sensor responsive a current a brush motor, the brush sensor in communication with the drive controller, and wherein the one or more predetermined signals comprises a signal from the brush sensor indicating a current rise of the brush motor above a predetermined threshold.

26. The mobile robot of claim 24, wherein the escape sequence comprises turning the robot in place at an initial velocity, and progressively decreasing the velocity over time.

27. The mobile robot of claim 24, wherein the one or more predetermined signals comprise at least one of:

a detection signal from the cliff sensor;

a detection signal from the wheel drop sensor;

a plurality of detection signals from the tactile sensor within a predetermined distance of travel by the robot.