Autonomous mobile robot systems

Abstract

Systems and methods for handling, manipulating, loading, and / or unloading objects in a retail environment include a mobile robot system. The mobile robot system may include a mobile robot and a first sensor system communicatively coupled to the mobile robot. The first sensor system has a trigger area and generates a signal in response to detecting an object in the trigger area. The mobile robot system further includes a sensor mount coupled to the mobile robot and the first sensor system. The sensor mount includes a gimbal that changes a sensor angle between the first sensor system and the mobile robot and affects a location of the trigger area in response to tilting of the mobile robot relative to a horizontal plane.

Description

AUTONOMOUS MOBILE ROBOT SYSTEMSCross-Reference to Related Patent Applications

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 543,860 filed on October 12, 2023, which is incorporated by reference herein in its entirety.Technical Field

[0002] This invention relates generally to autonomous mobile robot systems.Background

[0003] Traditionally, sensors are rigidly affixed to a statically positioned or mobile automation system component. This provides for system stability by serving as a reference point from which a sensor’s trigger distances are based, which may be may important when distances are specifically set to maintain appropriate gaps between automation systems and external objects that may encroach thereupon, for example, a human encroaching upon a path of movement of a first autonomous mobile robot (AMR), or a second AMR encroaching into the path of the object being moved by the first AMR.

[0004] Generally, when automated systems require a more than static level of mobility, conventional rigidly mounted sensors are prone to unintentional triggering. For example, when a front facing safety area scanner is rigidly affixed onto an AMR traversing a trailer dock plate incline into a trailer, as the AMR transitions from level ground into an approximate 1 -12 (or more) degree incline, the rigidly affixed sensor may either fault out, or may interpret as normal and safe a potentially unsafe condition as a result of the AMR being inclined at angle that reduces the trigger distance of the static sensor (which inclines together with the AMR).Brief Description of the Drawings

[0005] Disclosed herein are embodiments of autonomous mobile robot systems. This description includes drawings, wherein:

[0006] FIG. 1 is a block diagram of an example of a mobile robot system in accordance with some embodiments;- 1 -SUBSTITUTE SHEET (RULE 26)

[0007] FIG. 2 is a diagram depicting an example situation, where a mobile robot travels along a flat surface, and an obstacle such as a person is located outside a trigger area of a rigidly / statically mounted sensor system;

[0008] FIG. 3 is a diagram depicting an example situation, where a mobile robot travels along a flat surface, and an obstacle such as a person is located inside a trigger area of a rigidly / statically mounted sensor system;

[0009] FIG. 4 is a diagram depicting an example situation, where a mobile robot travels along an inclined surface, and an obstacle such as a person is located outside of the trigger area of a rigidly / statically mounted sensor system, but the condition is unsafe, since the trigger area of the rigidly / statically mounted sensor system is reduced as a result of the mobile robot being inclined;

[0010] FIG. 5 is a diagram depicting an example situation, where a mobile robot including a gimbal-mounted sensor system in accordance with some embodiments travels along an inclined surface, and an obstacle such as a person is located outside of the trigger area of the gimbalmounted sensor system, and the condition is safe, since the gimbal increases the angle of the gimbal-mounted sensor system to maintain a proper trigger area of the gimbal-mounted sensor system despite the mobile robot being inclined;

[0011] FIG. 6 is a block diagram of an example of a mobile robot system in accordance with some embodiments;

[0012] FIG. 7 is a flow chart diagram of one example method of operation of a mobile robot system in accordance with some embodiments;

[0013] FIG. 8 is a flow chart diagram of another example method of operation of a mobile robot system in accordance with some embodiments;

[0014] FIG. 9 is a front perspective view of an example sensor system and an active gimbal in accordance with some embodiments;

[0015] FIG. 10 is a rear perspective view of the example sensor system and active gimbal of FIG. 9; and

[0016] FIG. 11 is front perspective view of an example sensor system and a passive gimbal in accordance with some embodiments.- 2 -SUBSTITUTE SHEET (RULE 26)

[0017] Elements in the figures are illustrated for simplicity and clarity and have not been drawn to scale. For example, the dimensions and / or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.Detailed Description

[0018] Generally speaking, pursuant to various embodiments, systems, apparatuses, devices, and methods are provided herein useful to handle, manipulate, load, and / or unload objects such as freight, cases, and boxes in a retail environment. In some aspects, a mobile robot system may comprise a mobile robot, a first sensor system communicatively coupled to the mobile robot, the first sensor system having a trigger area and generating a signal in response to detecting an object in the trigger area, and a sensor mount coupled to the mobile robot and the first sensor system, the sensor mount comprising a gimbal that changes a sensor angle between the first sensor system and the mobile robot and affects a location of the trigger area in response to tilting of the mobile robot relative to a horizontal plane.

[0019] In workspaces in which mobile robots operate, collisions between humans and other objects, with mobile robots can lead to serious injuries and capital / human loss. To prevent these collisions, it is important to properly monitor the surroundings of the mobile robot.

[0020] Embodiments of systems and methods disclosed herein may provide safe and efficient systems for manipulation, loading, and / or unloading of objects such as freight, cases, and boxes. Embodiments of systems and methods disclosed herein may provide stability and improve safety in various workspaces. Embodiments of systems and methods disclosed herein may also reduce risks associated with unpredicted obstacles in operating a mobile robot.- 3 -SUBSTITUTE SHEET (RULE 26)

[0021] Various embodiments and examples of systems, devices, apparatus, and methods are described herein. Example FIGS. 1-8 are provided to illustrate various embodiments. It is noted that when describing certain embodiments, certain features may be shown in one or more of FIGS. 1-8.

[0022] FIG. 1 is a block diagram of an example of a mobile robot system 100 in accordance with some embodiments. The mobile robot system 100 comprises a mobile robot 110, a sensor mount 120, and a sensor system 130.

[0023] The mobile robot 110 may be capable of traversing and traveling over various surfaces including inclines and declines such as ramps. For example, the mobile robot 110 may traverse a dock plate and into a trailer or container. The mobile robot 110 may also traverse a workspace including multiple levels with inclines / declines connecting the different levels. In some embodiments, the mobile robot 110 may move and rotate in all directions. The mobile robot 110 may comprise various types of a moving mechanism 112. The moving mechanism 112 may comprise driven steering wheels, mecanum-type wheels, tracks, rails, or similar mechanisms for providing locomotion to the mobile robot 110.

[0024] In some embodiments, the mobile robot 110 may include an object interfacing mechanism 114 that can manipulate / handle objects and / or freight. The object interfacing mechanism 114 may include, but not be limited to, a robotic arm, a pallet fork, other types of payload interface mechanism, and / or any combination thereof. In some embodiments, the robotic arm may be a multi-axis robotic arm. In some embodiments, the robotic arm may be a custom design robotic arm with two or more axes. In some embodiments, the robotic arm may have four or six axes. In some embodiments, the robotic arm includes multiple arm segments that are pivotally, rotatably, and / or statically attached. In some embodiments, the mobile robot 110 may not include an object interfacing mechanism 114.

[0025] In some embodiments, the sensor mount 120 may be coupled to the mobile robot 110 and the sensor system 130, such that the sensor system 130 is physically coupled to the mobile robot 110 via the sensor mount 120. In some embodiments, the sensor mount 120 includes a gimbal 122 (further described below) configured to change a sensor angle between the sensor system 130- 4 -SUBSTITUTE SHEET (RULE 26)and the mobile robot 110 in response to tilting of the mobile robot 110 relative to a horizontal plane.

[0026] The mobile robot 110 may include a controller 140 configured to determine and / or control the operation and movement of the mobile robot. In some embodiments, the controller 140 may be housed within the mobile robot 110. In some aspects, the controller 140 may also be partially or wholly remote with respect to the mobile robot 110.

[0027] The controller 140 may comprise a memory 142 and a control circuit 144. The control circuit 144 may operably and communicatively couple to the mobile robot 110, and sensor system 130. When the sensor mount 120 includes any electronic components such as a motor- driven gimbal (further described below), the control circuit 144 may also operably and communicatively coupled to the sensor mount 120.

[0028] The memory 142 may store data and codes to operate the mobile robot system 100. The memory 142 may include but is not limited to non-volatile memory such as read-only memory (ROM) and / or volatile memory such as an erasable programmable read-only memory (EPROM). The control circuit 144 may access the memory 142 and execute the codes stored in the memory 142, for example, by using the corresponding programming, as will be well understood by those skilled in the art. In some embodiments, the memory 142 may be integral to the control circuit 144 or may be physically discrete in whole or in part from the control circuit 144 as desired. This memory 142 may also be local with respect to the control circuit 144 (where, for example, both share a common circuit board, chassis, power supply, and / or housing) or may be partially or wholly remote with respect to the control circuit 144 (where, for example, the memory is physically located in another housing).

[0029] The sensor system 130 may be communicatively coupled to the controller 140 of the mobile robot 110. The communication between the various components of mobile robot system 100 (including the communication between the sensor system 130 and the mobile robot 110) may be take place over hard-wired, wireless, cellular, Wi-Fi or Bluetooth networked components or the like.

[0030] In some embodiments, the sensor system 130 is configured to capture data from the surroundings of the mobile robot 110. For example, the sensor system 130 may be front facing and- 5 -SUBSTITUTE SHEET (RULE 26)may scan the area in the moving direction of the mobile robot 110. In some embodiments, the sensor system 130 may include a laser sensor, a radar sensor, a depth sensor, a 3D sensor, an infrared sensor, an image sensor, or any combination thereof.

[0031] The sensor system 130 may have a trigger area within its sensing area. In some embodiments, the mobile robot system 100 may be configured to stop the movement of the mobile robot 110 when the sensor system 130 detects an object. For example, the mobile robot 110 may stop its movement in response to the detection of an external object or a human in the trigger area. In some embodiments, the controller 140 and / or the processor 132 may use the data captured form the sensor system 130 to determine whether the detected object is expected or unexpected in the path / operation of the mobile robot, and only stop movement in response to unexpected objects. In some embodiments, the sensor system 130 may generate a detection signal in response to detecting an object in the trigger area and send the detection signal to the mobile robot 110. In this embodiment, the mobile robot 110 may stop the movement in response to receiving the detection signal.

[0032] In some embodiments, the control circuit 144 may receive the detection signal from the sensor system 130 and determine the operation strategy of the mobile robot 110 whether to stop or keep moving the mobile robot 110 based on the received detection signal. The control circuit 144 may cause the mobile robot 110 to stop the movement when the determined operation strategy is to stop the mobile robot 1 10.

[0033] In some embodiments, the mobile robot system 100 may further include a processor 132. The processor 132 may be coupled to the sensor system 130 or be a part of the sensor system 130. In some embodiments, the processor 132 may determine the operation strategy based on the object in the trigger area detected by the sensor system 130. When the determined operation strategy is to stop the mobile robot 110, the processor 132 may send a stop signal to the control circuit 144. The control circuit 144 may, then, cause the mobile robot 110 to stop the movement in response to receiving the stop signal. In some embodiments, the processor 132 may be a processor device separate from and in communication with the control circuit 144 of the controller 140. In some embodiments, one or more functions of the processor 132 may be performed by the control circuit 144.- 6 -SUBSTITUTE SHEET (RULE 26)

[0034] FIGS. 2-3 are illustrations to describe a concept of a trigger area. The area indicated with reference numeral 204 represents an area scanned by a trigger area of a sensor system 202. FIG. 2 illustrates a situation where an obstacle (e.g., a person 206 in FIG. 2) is outside the trigger area, and FIG. 3 illustrates a situation where the obstacle, such as a person 206, is in the trigger area of the sensor system 202. In FIGS. 2 and 3, the sensor system 202 is mounted at an angle 234 relative to the plane 216 of travel of the mobile robot 210 and the distance (D) between the mobile robot 110 the boundary of the trigger area of the sensor system 202 is affected by the angle 234 of the sensor system 202. In FIGS. 2-3, a plane 216a is a virtual plane that is parallel to the plane 216 of travel of the mobile robot 210 illustrated to indicate the angle 234 relative to the plane 216.

[0035] However, when a robot system has a more than static level of mobility, rigidly / statically mounted sensor systems may cause unintentional triggering and / or present unsafe conditions. These unintentional triggering and unsafe conditions may occur when a robot system with a rigidly / statically mounted sensor system traverses differently inclined surfaces (e.g., from an inclined plane to a horizonal plane or vice versa), for instance, when a mobile robot with a rigidly affixed facing sensor system traverses a trailer dock plate inclined into a trailer having a horizontal bottom surface.

[0036] FIG. 4 illustrates an example of an unsafe condition. As shown in FIG. 4, the size / scope of the trigger area 404 of a rigidly / statically mounted sensor system 402 may change (i.e., be reduced) when the mobile robot 410 traverses a declined surface 408 (especially, when surfaces of different inclines are included in the area scanned by the trigger area of the sensor system). In this case, the distance 412 from the mobile robot 410 to the boundary of the trigger area 404 scanned by the trigger area may not be long enough to provide a safe stopping distance to avoid a collision between the mobile robot 410 and an approaching person 406.

[0037] Embodiments of systems and methods disclosed herein seek to reduce or minimize these unsafe conditions and unintentional triggering. Referring back to FIG. 1, in some embodiments, the sensor mount 120 includes a gimbal 122 configured to change a sensor angle between the sensor system 130 and the mobile robot 110 in response to tilting of the mobile robot 110 relative to a horizontal plane. Changing the sensor angle may affect a location the trigger area relative to the mobile robot 110.- 7 -SUBSTITUTE SHEET (RULE 26)

[0038] FIG. 5 illustrates an example of the mobile robot system 100, in accordance with some embodiments. In FIG. 5, some components of the mobile robot system 100 may not be shown or simplified. The gimbal 122 may change the sensor angle 534 to compensate for the change of the size / scope of the trigger area 504 of the sensor system 130. In some embodiments, as illustrated in FIG. 5, the gimbal 122 may increase the sensor angle 534 to maintain the location / coverage the trigger area of the sensor system 130 over a safety area of the mobile robot system 100 to avoid presenting unsafe conditions. The safety area may refer to an area relative to the mobile robot 110 defined to maintain the necessary gaps between the mobile robot and the external object (and human) to avoid collisions, accidents, injuries, and capital / human loss. For example, the safety area may exceed the braking distance of a mobile robot 110 traveling at full speed. In this case, the distance 512 from the mobile robot 110 to the boundary of the trigger area 504 scanned by the trigger area may be long enough to avoid a collision between the mobile robot 110 and an approaching person 506.

[0039] In some embodiments, the gimbal 122 may change the sensor angle 534 by pivoting the sensor system 130 in a direction opposite the tilting of the mobile robot 110 relative to the horizontal plane.

[0040] In some embodiments, the gimbal 122 of the sensor mount 120 may include a passive mechanical gimbal. The mechanical gimbal may include a counterweight configured to maintain the angle of the sensor system 130 relative to the horizontal plane 516. For example, the mechanical gimbal may keep constant the rotation / tilting degree of the sensor system 130 relative to the horizontal plane by balancing the sensor system 130 and the counterweight based on the center of gravity of the sensor system 130 and the counterweight.

[0041] In some embodiments, the gimbal 122 of the sensor mount 120 may include an active gimbal. The active gimbal may include a gimbal controller 124 (shown in FIG. 1) configured to control the angle of the sensor system 130 relative to the horizontal plane 516. The gimbal controller 124 may determine the angle of the sensor system 130 in various ways. In some embodiments, the gimbal 122 may include an internal gyroscopic and the gimbal controller 124 may determine the angle of the sensor system 130 relative to the horizontal plane 516 based on the data captured from the internal gyroscope. In some embodiments, the gimbal controller 124 may- 8 -SUBSTITUTE SHEET (RULE 26)determine the angle of the sensor system 130 based on an input from the mobile robot 110. For example, the mobile robot 110 may determine its tilting degree from its internal tilting sensor (e.g., internal gyroscope of the mobile robot 110) and may send a data regarding its tilting to the sensor system 130 and the sensor system 130 may determine the angle of the sensor system 130 relative to the horizontal plane 516 based on the data received from the mobile robot 110. The active gimbal may be a motor-driven gimbal with an actuator configured to rotate the sensor system 130 to change the sensor angle 534. The active gimbal may actively rotate the sensor system 130 about its rotation axis(axes). In some embodiments, the active gimbal may have multiple rotation axes, and the active gimbal may pivot the sensor system 130 about one or more of the multiple rotation axes one at a time or simultaneously. For example, the motor-driven gimbal may have three rotation axes that are perpendicular to each other, and the motor-drive gimbal may pivot the sensor system 130 about two or more axes at the same time. In some embodiments, the motor-driven gimbal may rotate the sensor system 130 in any direction.

[0042] In some embodiments, the mobile robot system 100 may include multiple sensor systems (e.g., dual sensor systems, dual-check sensor system, dual-chain sensor systems) to detect fault conditions / operations of the sensor system 130 and / or fault conditions / operations of the gimbal 122. FIG. 6 illustrates a mobile robot system 100 in accordance with some embodiments. In FIG. 6, the sensor system 130 and the processor 132 are indicated as a first sensor system 130 and a first processor 132 for descriptive convenience.

[0043] In some embodiments, the mobile robot system 100 may further include a second sensor system 640. The first sensor system 130 and the second sensor system 640 may be independently operated with decoupled processors. For example, the first sensor system 130 may be operated with the first processor 132 and the second sensor system 640 may be operated with a second processor 642, which is operatively decoupled from the first processor 132. The second sensor system 640 and the second processor 642 may detect a failure of the gimbal 122 and / or the first sensor system 130.

[0044] In some embodiments, the second sensor system 640 may be calibrated to the first sensor system 130 in various manners. For example, the sensor mount 120 may include an additional gimbal operating similarly to the gimbal 122, and the second sensor system 640 may be- 9 -SUBSTITUTE SHEET (RULE 26)attached to mobile robot 110 via the additional gimbal of the sensor mount 120. The additional gimbal may be configured the same as or different from the gimbal 122.

[0045] In some embodiments, the second sensor system 640 may have a trigger area which corresponds to the trigger area of the first sensor system 130 and may be configured to scan the same area scanned by the first sensor system 130. In some embodiments, the second sensor system 640 may be configured to scan the different area from the first sensor system 130.

[0046] In some embodiments, the first processor 132 may determine an operation strategy for whether to stop the mobile robot 110 based on the information collected by the first sensor system 130, and independently from the first processor 132, the second processor 642 may determine an operation strategy for whether to stop the mobile robot 110 based on the information collected by the second sensor system 640. The information collected by the first sensor system 130 may include information on the detected object in the trigger area of the first sensor system 130. In some embodiments, the information collected by the second sensor system 640 may include the information related to the mobile robot 110, the first sensor system 130, the gimbal 122, the surroundings of the mobile robot 110, or a combination thereof detected by the second sensor system 640. When the second sensor system 640 has a trigger area, the information collected by the second sensor system 640 may include information about the detected object in the trigger area of the second sensor system 640.

[0047] The operation strategy determined by the first processor 132 and the operation strategy determined by the second processor 642 may be sent to the control circuit 144 and the control circuit 144 may compare the operation strategies. When the operation strategy determined by the first processor 132 and the operation strategy determined by the second processor 642 are different from one another, the control circuit 144 may decide that there exists a fault condition and may cause the mobile robot 110 to stop its movement and operation.

[0048] It is noted that FIG. 6 illustrates one example of various dual sensor systems, and in addition to the embodiment of FIG. 6, differently or similarly configured dual sensor systems such as known or future dual sensor systems may be used to detect fault safety conditions. In some embodiments, a mobile robot 110 system may include three or more sensor systems operated on similar principles.- 10 -SUBSTITUTE SHEET (RULE 26)

[0049] FIGS. 7 and 8 are flowcharts depicting example methods 700, 800 to operate the mobile robot system 100. The controller 140, the processor 132, and / or the gimbal controller 124 may control each device, apparatus, and component of the mobile robot system 100 by sending electrical signals to each of them. The controller 140, the processor 132, and / or the gimbal controller 124 (e.g., with the control circuit thereof) is configured (for example, by using corresponding programming as will be well understood by those skilled in the art) to carry out one or more of the steps, actions, and / or functions described herein by causing the devices, apparatuses, and components of the mobile robot system 100 to move, actuate, and operate properly. Although methods 700, 800 are mainly illustrated with the mobile robot system 100, methods 700, 800 may also be performed with differently configured mobile robot systems.

[0050] Referring to FIG. 7, the flow begins at step 702. In step 702, the mobile robot 110 moves. In some embodiments, the mobile robot 110 may move within a workspace having inclines and / or declines. For example, the mobile robot 110 traverses an inclined trailer dock plate to enter a trailer.

[0051] In step 704, the first sensor system 130 scans the trigger area to detect for objects in the trigger area. Step 704 may be performed while the mobile robot 110 is in motion in step 702. In some embodiments, the sensor system 130 may keep scanning the trigger area while the mobile robot 110 is stopped.

[0052] In step 706, the gimbal 122 may change the sensor angle 534 between the mobile robot 110 and the sensor system 130 in response to a tilting of the mobile robot 110 relative to a horizontal plane. By changing the sensor angle 534, the gimbal 122 may compensate, at least in part, change of the location of the trigger area of the sensor system 130 caused by the tilting of the mobile robot 110. In some embodiments, the gimbal controller 124 may determine the tilting of the mobile robot 110 from the data captured by its internal gyroscope. In some embodiments, the gimbal controller 124 may determine the tilting of the mobile robot 110 based on the input / signal / data from the mobile robot 110. In this case, the mobile robot 110 may determine the degree of the tilting from its internal gyroscope or other types of tiling sensors. In some embodiments, the mobile robot 110 may determine the degree of the tilting by processing the data captured from its perception system / image sensors for determining the path / operation of the- 11 -SUBSTITUTE SHEET (RULE 26)mobile robot 1 10. In some embodiments, changing the sensor angle between the sensor system 130 and the mobile robot 110 may include pivoting, with the gimbal 122, the sensor system 130 in a direction opposite the tilting of the mobile robot 110 relative to the horizontal plane. In some embodiments, when the gimbal 122 include the motor-driven gimbal with multiple rotation axes, the motor-driven gimbal may pivot the sensor system 130 about one or more of the multiple rotation axes one at a time or simultaneously. For example, when the motor-driven gimbal has three rotation axes that are perpendicular to each other, the motor-drive gimbal may pivot the sensor system 130 about two or more axes at the same time. In some embodiments, the motor- driven gimbal may rotate the sensor system 130 in any direction. Step 706 may be performed while the mobile robot 110 moves in step 702. Further, step 706 may be performed while the sensor system 130 is scanning the trigger area in step 704. When the sensor system 130 does not detect an unexpected object in the trigger area, the flow may circulate back to step 702 and the mobile robot may keep moving.

[0053] In step 708, when the sensor system 130 detects an unexpected object in the trigger area, the sensor system 130 generates a detection signal in response to detecting an object in the trigger area. In some embodiments, the sensor system 130 may generate a detection signal in response to detection of an external object that has not been considered by the mobile robot system 100.

[0054] In step 710, the mobile robot may stop its movement and operation in response to the detection signal. In some embodiments, the sensor system 130 may send the generated detection signal to the control circuit 144 and the control circuit 144 may determine the operation strategy whether to stop the movement of the mobile robot 110 based on the received detection signal. When the determined operation strategy is to stop the mobile robot, the control circuit 144 may cause the mobile robot 110 to stop.

[0055] FIG. 8 is a flowchart depicting an example method 800 to operate the mobile robot system 100 including a first sensor system and a second sensor system. Although method 800 is mainly illustrated with the mobile robot system 100 of FIG. 6, the method 800 may also be performed with differently configured mobile robot systems. The flow begins at step 802.- 12 -SUBSTITUTE SHEET (RULE 26)

[0056] In step 802, the mobile robot 110 moves. The mobile robot 1 10 may traverse inclined and declined surfaces. In step 804, the first sensor system 130 scans the trigger area to detect objects in the trigger area. In step 806, the gimbal 122 changes the sensor angle between the mobile robot 110 and the first sensor system 130 in response to a tilting of the mobile robot 110. The mobile robot 110 may be tilted relative to a horizontal plane when the mobile robot 110 traverses an inclined surface. In step 808, the second sensor system 640 collects information. The information collected by the second sensor system 640 may be information necessary to detect fault conditions such as information related to the mobile robot 110, the first sensor system 130, the gimbal 122, surroundings of the mobile robot 110, or a combination thereof detected by the second sensor system 640. By one optional approach, in step 810, the second sensor system 640 may be calibrated to the first sensor system 130. Depending on the function and configuration of the second sensor system 640, the second sensor system 640 may or may not be calibrated to the first sensor system 130. In step 812, the first processor 132 determines an operation strategy for the mobile robot 110 based on the information of the trigger area collected with the first sensor system 130. In step 814, the second processor 642 independently determines an operation strategy for the mobile robot 110 based on the information collected with the second sensor system 640. In step 816, the control circuit 144 may receive the operation strategies from the first and second processors 132, 642 and compare the operation strategies. When the operation strategies from the first and second processors 132, 642 are different from one another, the control circuit 144 may decide that there is a failure of a component of the mobile robot system 100. In step 820, the control circuit 144 may cause the mobile robot 110 to stop its movement in the event that the operation strategy determined by the first processor 132 is different from the operation strategy determined by the second processor 642. The control circuit 144 may also stop the movement of the mobile robot when at least one of the operation strategies determined by the first and second processors 132, 642 is to stop the movement of the mobile robot 110.

[0057] FIG. 9 is an illustration of the sensor system 130 and an active gimbal 922 in a top front perspective view in accordance with some embodiments. FIG. 10 is a top back perspective view of FIG. 9.

[0058] In some embodiments, the sensor mount 120 may include the active gimbal 922 and the sensor system 130 may be coupled to the active gimbal 922. The active gimbal 922 may- 13 -SUBSTITUTE SHEET (RULE 26)include a mounting portion 926. The mounting portion 926 may be rigidly coupled to another object such as the mobile robot 110. In some embodiments, the active gimbal 922 may include one or more actuators 925, 927 configured to rotate the sensor system 130 to change the sensor angle 534 between the sensor system 130 and the mobile robot 110. Via the active gimbal 922, the sensor system 130 may be rotatably mounted to the mobile robot 110. In the embodiment shown in FIG. 9, the active gimbal 922 includes a first actuator 925 configured to rotate the sensor system 130 about the axis 901 and a second actuator 927 configured to rotate the sensor system 130 about the axis 902. In some embodiments, the axis 901 and the axis 902 may be substantially perpendicular to one another.

[0059] In some embodiments, the first and second actuators 925, 927 may be motorized actuators. In some embodiments, the first and second actuators 925, 927 may operate independently. In some embodiments, the first and second actuators 925, 927 may operate one at a time or simultaneously. The first and second actuators 925, 927 may adjust / change the sensor angle 534 between the sensor system 130 and the mobile robot 110 in response to tilting of the mobile robot 110 relative to the horizontal plane 516.

[0060] In some embodiments, the sensor system 130 may include one or more sensor window 933 through which optical, acoustic, and / or electromagnetic waves can be emitted and / or received to detect an object in the trigger area of the sensor system 130. The sensor system 130 may include other types of sensor devices / mechanism. In some embodiments, the sensor system 130 may include a user interface panel 935 including operation buttons and / or a display. In some embodiments, alerts may be displayed and / or voided via the user interface panel 935. In some embodiments, the sensor system 130 further includes an audio device configured to produce warning sounds.

[0061] FIG. 11 is an illustration of the sensor system 130 and a passive mechanical gimbal 1022 in accordance with some embodiments. In some embodiments, the sensor mount 120 may include the passive mechanical gimbal 1022 and the sensor system 130 may be coupled to the passive mechanical gimbal 1022. The passive mechanical gimbal 1022 may include a mounting portion 1026 and the mounting portion 1026 may be rigidly coupled to another object such as the mobile robot 110. The passive mechanical gimbal 1022 may allow the sensor system 130 to- 14 -SUBSTITUTE SHEET (RULE 26)rotation and, via the passive mechanical gimbal 1022, the sensor system 130 may be rotatably mounted to the mobile robot 110.

[0062] The passive mechanical gimbal 1022 may include one or more rotation points and one or more counterweights to maintain the angle of the sensor system 130 relative to the horizontal plane 516. Referring to FIG. 11, in some embodiments, the passive mechanical gimbal1022 may include two rotation points 1025, 1027 allowing the sensor system 130 to rotate and a counterweight 1023 affixed to the underneath of the sensor system 130. The first rotation point 1025 may allow the sensor system 130 to rotate about the axis 1001 and the second rotation point 1027 may allow the sensor system 130 to rotate about the axis 1002. The counterweight 1023 may exert a force pulling the sensor system in a direction in which gravity acts on the counterweight1023 (e.g., a direction 1003 perpendicular to the horizontal plane 516). The force applied by the counterweight 1023 and the rotation points 1025, 1027 may allow the sensor system 130 to maintain the angle of the sensor system 130 relative to the horizontal plane 516 so that the passive mechanical gimbal 1022 may change the sensor angle 534 between the sensor system 130 and the mobile robot 110 in response to tiling of the mobile robot 110 relative to the horizontal plane 516.

[0063] In some embodiments, a mobile robot system may include a mobile robot, a first sensor system communicatively coupled to the mobile robot, the first sensor system having a trigger area and generating a signal in response to detecting an object in the trigger area, and a sensor mount coupled to the mobile robot and the first sensor system, the sensor mount comprising a gimbal that changes a sensor angle between the first sensor system and the mobile robot and affects a location of the trigger area in response to tilting of the mobile robot relative to a horizontal plane.

[0064] In some embodiments, a method to operate a mobile robot system may include, moving a mobile robot, scanning, with a first sensor system having a trigger area, the trigger area, changing, with a gimbal of a sensor mount, a sensor angle between the first sensor system and the mobile robot in response to a tilting of the mobile robot relative to a horizontal plane, and generate, by the first sensor system, a signal in response to detecting an object in the trigger area.

[0065] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above-described embodiments- 15 -SUBSTITUTE SHEET (RULE 26)without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.- 16 -SUBSTITUTE SHEET (RULE 26)

Claims

CLAIMSWhat is claimed is:

1. A mobile robot system comprising: a mobile robot; a first sensor system communicatively coupled to the mobile robot, the first sensor system having a trigger area, wherein the first sensor system generates a signal in response to detecting an object in the trigger area; and a sensor mount coupled to the mobile robot and the first sensor system, the sensor mount comprising a gimbal, wherein the gimbal changes a sensor angle between the first sensor system and the mobile robot and affects a location of the trigger area in response to tilting of the mobile robot relative to a horizontal plane.

2. The mobile robot system of claim 1, wherein the mobile robot stops movement in response to the signal generated by the first sensor system.

3. The mobile robot system of claim 1, wherein the gimbal changes the sensor angle by pivoting the first sensor system in a direction opposite the tilting of the mobile robot relative to the horizontal plane.

4. The mobile robot system of claim 1, wherein the gimbal comprises a mechanical gimbal with a counterweight.

5. The mobile robot system of claim 1, wherein the gimbal comprises a motor-driven gimbal.

6. The mobile robot system of claim 1, wherein the gimbal has multiple rotation axes and pivots the first sensor system about one or more of the multiple rotation axes.- 17 -SUBSTITUTE SHEET (RULE 26)7. The mobile robot system of claim 1 , wherein the mobile robot includes an object interfacing mechanism.

8. The mobile robot system of claim 1, wherein the first sensor system comprises a laser sensor, a radar sensor, a depth sensor, a 3D sensor, an infrared sensor, and / or an image sensor.

9. The mobile robot system of claim 1 further comprising a first processor that determines an operation strategy for whether to stop the mobile robot based on the object detected by the first sensor system.

10. The mobile robot system of claim 1 further comprising: a second sensor system communicatively coupled to the mobile robot; a first processor that determines an operation strategy for whether to stop the mobile robot based on the object detected by the first sensor system; and a second processor that determines an operation strategy for whether to stop the mobile robot based on information collected by the second sensor system, wherein the mobile robot stops movement in an event that the operation strategy determined by the first processor is different from the operation strategy determined by the second processor.

11. The mobile robot system of claim 10, wherein the first sensor system and the first processor independently operate from the second sensor system and the second processor.

12. The mobile robot system of claim 10, wherein the second sensor system is calibrated to the first sensor system.

13. A method to operate a mobile robot system, the method comprising: moving a mobile robot; scanning, with a first sensor system having a trigger area, the trigger area;- 18 -SUBSTITUTE SHEET (RULE 26)changing, with a gimbal of a sensor mount, a sensor angle between the first sensor system and the mobile robot in response to a tilting of the mobile robot relative to a horizontal plane; and generating, by the first sensor system, a signal in response to detecting an object in the trigger area.

14. The method of claim 13, wherein changing, with the gimbal of the sensor mount, the sensor angle between the first sensor system and the mobile robot comprises pivoting the first sensor system in a direction opposite the tilting of the mobile robot relative to the horizontal plane.

15. The method of claim 13 wherein changing, with the gimbal of the sensor mount, the sensor angle between the first sensor system and the mobile robot comprises pivoting the first sensor system about one or more of multiple rotation axes of the gimbal.

16. The method of claim 13 further comprising stopping movement of the mobile robot in response to the signal generated by the first sensor system.

17. The method of claim 13, wherein scanning, with the first sensor system having the trigger area, the trigger area comprises scanning, with a laser sensor, a radar sensor, a depth sensor, a 3D sensor, an infrared sensor, and / or an image sensor, the trigger area.

18. The method of claim 13 further comprising determining, with a first processor, an operation strategy for whether to stop the mobile robot based on the object detected by the first sensor system.

19. The method of claim 13 further comprising: determining, with a first processor, an operation strategy for whether to stop the mobile robot based on the object in the trigger area detected by the first sensor system; collecting, with a second sensor system, information;- 19 -SUBSTITUTE SHEET (RULE 26)determining, with a second processor and based on the information collected by the second sensor system, an operation strategy for whether to stop the mobile robot; and stopping movement of the mobile robot in an event that the operation strategy determined by the first processor is different from the operation strategy determined by the second processor.

20. The method of claim 19 further comprising calibrating the second sensor system to the first sensor system.- 20 -SUBSTITUTE SHEET (RULE 26)

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