Autonomous robot auto-docking and energy management systems and methods

• US 9,884,423 B2
• Filed: 04/19/2017
• Issued: 02/06/2018
• 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:
  US15/491,599
• Publication Number:
  US 20170217019A1
• Time in Patent Office: 293 Days
• Field of Search: 320104, 320107, 320109, 320134, 701 25, 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. A method of docking a robotic cleaning device with a base station that includes a plurality of signal emitters including a right signal emitter and a left signal emitter, the method comprising:

directing the robotic cleaning device about a room at a first velocity;

detecting, by a sensor mounted on the robotic cleaning device, a right signal transmitted by the right signal emitter of the base station and a left signal transmitted by the left signal emitter of the base station;

controlling forward movement of the robotic cleaning device toward the base station at a second velocity less than the first velocity while orienting the robotic cleaning device in relation to the right signal and the left signal;

detecting contact with charging terminals on the base station;

stopping the forward movement of the robotic cleaning device in response to detecting contact with the charging terminals on the base station; and

charging a battery of the robotic cleaning device.

2. The method of claim 1, further comprising:

detecting a presence of the robotic cleaning device at the charging terminals on the base station using a first non-charging sensing current level, and

providing a second charging current level upon detecting the presence of the robotic cleaning device at the charging terminals.

3. The method of claim 1, further comprising:

detecting an energy level of the battery of the robotic cleaning device, and

seeking, by the robotic cleaning device, the right signal and the left signal when the energy level of the battery is less than a predetermined energy level.

4. The method of claim 3, further comprising stopping, by the robotic cleaning device, a task when the energy level of the battery is below the predetermined energy level while seeking the right signal and the left signal.

5. The method of claim 4, further comprising resuming, by the robotic cleaning device, the task upon completion of charging of the battery.

6. The method of claim 3, further comprising altering a movement characteristic of the robotic cleaning device in seeking the right signal and the left signal.

7. The method of claim 1, further comprising alternately moving the robotic cleaning device rightward to position the left signal to a left of the robotic cleaning device, and leftward to position the right signal to a right of the robotic cleaning device.

8. The method of claim 1, further comprising recognizing the left signal as being different from the right signal by detecting a difference in at least one of carrier frequencies, modulations, bit patterns, or wavelengths of the right signal and the left signal.

9. The method of claim 1, further comprising avoiding, by the robotic cleaning device, the right signal and the left signal while an energy level of the battery of the robotic cleaning device remains above a predetermined energy level.

10. The method of claim 1, wherein the sensor is an omnidirectional sensor.

11. The method of claim 1, wherein charging the battery of the robotic cleaning device comprises only partially charging the battery of the robotic cleaning device prior to departure from the base station.

12. The method of claim 1, wherein controlling the forward movement of the robotic cleaning device toward the base station at the reduced second velocity comprises initiating the forward movement at the second velocity in response to detecting the right signal or the left signal.

13. An autonomous cleaning robot, comprising:

an undercarriage;

a motive system configured to propel the undercarriage;

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

a navigational control system configured to autonomously;

control the motive system to direct the cleaning robot about a room at a first velocity;

control forward movement of the cleaning robot toward the base charging station at a second velocity less than the first velocity before completing a cleaning task in the room and in response to detecting a need to charge the energy storage unit;

stop the forward movement of the cleaning robot to dock the cleaning robot to the base charging station;

charge the energy storage unit with the cleaning robot docked at the base charging station; and

control the motive system to direct the cleaning robot to continue to clean the room at the first velocity.

14. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to track a cleaning route of the cleaning robot and monitor an amount of the room remaining to be cleaned.

15. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to direct the cleaning robot to a portion of the room still requiring cleaning following charging the energy storage unit.

16. The autonomous cleaning robot of claim 13, wherein the cleaning 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.

17. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to direct the cleaning robot to leave the base charging station and continue to clean the room upon determining that the energy storage unit has reached an amount of charge needed to complete the cleaning task in the room.

18. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to return the cleaning robot to the base charging station before completing the cleaning task in the room in response to a level of energy remaining in the energy storage unit falling to a predetermined threshold.

19. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to control the forward movement of the cleaning robot toward the base charging station at the second velocity while orienting the cleaning robot relative to one or more signals emitted by the base charging station.

20. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to initiate the forward movement of the cleaning robot toward the base charging station at the second velocity in response to detecting a signal emitted by the base charging station.

25. The autonomous cleaning robot of claim 13, wherein the navigational control system is configured to control the forward movement of the cleaning robot toward the base charging station at the second velocity while orienting the cleaning robot relative to one or more signals emitted by the base charging station.

21. An autonomous cleaning robot, comprising:

an undercarriage;

a motive system configured to propel the undercarriage;

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

a navigational control system configured to autonomously;

control the motive system to direct the cleaning robot about a room at a first velocity;

control forward movement of the cleaning robot toward the base charging station at a second velocity less than the first velocity in response to detecting a need to charge the energy storage unit;

stop the forward movement of the cleaning robot to dock the cleaning robot to the base charging station; and

charge the energy storage with the cleaning robot docked at the base charging station.

22. The autonomous cleaning robot of claim 21, wherein the navigational control system is configured to track a cleaning route of the cleaning robot and monitor an amount of the room remaining to be cleaned.

23. The autonomous cleaning robot of claim 21, wherein the navigational control system is configured to direct the cleaning robot to a portion of the room still requiring cleaning following charging the energy storage unit.

24. The autonomous cleaning robot of claim 21, wherein the cleaning 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.

26. The autonomous cleaning robot of claim 21, wherein the navigational control system is configured to initiate the forward movement of the cleaning robot toward the base charging station at the second velocity in response to detecting a signal emitted by the base charging station.