Docking station for autonomous floor cleaners

Abstract

A docking station for charging an autonomous floor cleaner includes a transmitter that can transmit a signal for detection by a robot. The docking station may include an opaque shield for the transmitter and / or spring-loaded charging contacts. The autonomous floor cleaner may include a passive receiver that detects signals transmitted from the docking station, and a time-of-flight sensor for position / proximity sensing. The robot may selectively turn off the time-of-flight sensor when docking with or avoiding the docking station. Methods for docking, re-docking, low-power charging, docking station avoidance, obstacle response during docking, and proximity docking are disclosed.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 967,074, filed on January 29, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present application relates to a docking station for an autonomous floor cleaner. Background Art

[0004] Autonomous or robotic floor cleaners can move to clean floor surfaces without the assistance of a user or operator. For example, a floor cleaner can be configured to vacuum or sweep dirt (including dust, hair, and other debris) into a collection box carried on the floor cleaner. Some floor cleaners are also configured to apply and extract liquids for wet cleaning of bare floors, carpets, mats, and other floor surfaces. Floor cleaners can move randomly around a floor surface while cleaning it, or use a mapping / navigation system for guided navigation around a surface.

[0005] Typically, these autonomous floor cleaners include a rechargeable battery, and charging contacts for the battery may be provided on an outer surface of the floor cleaner. A charging stand or docking station may be provided with corresponding charging contacts that may mate with charging contacts on the floor cleaner. Some docking stations may also remove dirt stored in a collection bin.

[0006] Autonomous floor cleaners need to return to the docking station to recharge their batteries and / or empty the collection box. In some cases, the user must manually return the autonomous floor cleaner to the docking station, which invalidates some of the conveniences of automatic cleaning. The automatic docking process is also known for some floor cleaners and docking stations. For example, some autonomous floor cleaners use infrared beams on the docking station and infrared receivers on the robot to detect the docking station and navigate until docking. However, this system still exhibits many operational limitations, including difficulty in navigating to the docking station and properly aligning with the docking station, and difficulty in effectively cleaning around the docking station.

[0007] In order to overcome the above problems, a reliable system and method for automatic docking must be developed. Summary of the invention

[0008] The present disclosure relates to an autonomous floor cleaner and a docking station for the autonomous floor cleaner. Various methods for automatically docking the autonomous floor cleaner with the docking station are described herein. In addition, various methods for charging the autonomous floor cleaner at the docking station are described herein. Still further, various methods for navigating the autonomous floor cleaner around the docking station or obstacles are described herein.

[0009] In one aspect, a docking station for an autonomous floor cleaner includes: a shell; electrical contacts or charging contacts disposed on the shell, the electrical contacts or charging contacts being adapted to cooperate with charging contacts of a robot to charge a battery of the robot; and at least one transmitter that can transmit at least one signal or coded beam for detection by the robot.

[0010] In one embodiment, the docking station includes a plurality of emitters that can emit at least one signal or coded beam for detection by the robot. An opaque shield may be provided for one or more emitters to direct the light signal emitted from the emitter along a desired path, reduce light leakage, and / or define the emission area of ​​the emitter. The shield may have at least one shield segment surrounding the emitter. The shield segment may include a wall surrounding the emitter and an aperture in the wall through which light from the emitter is emitted. The wall may have an inner surface that faces the emitter and reflects light emitted from the emitter.

[0011] In one embodiment, the docking station includes spring-loaded charging contacts. The charging contacts are spring-biased to a neutral position, which may correspond to a state where the robot is not docked with the docking station. A force applied to the spring-loaded charging contacts, i.e., docking of the robot with the docking station, causes the charging contacts to move to a contact position, which may establish positive electrical contact between the charging contacts of the robot and the charging contacts of the docking station. Optionally, the docking station includes an optical switch that is blocked by at least one of the spring-loaded charging contacts when depressed to indicate the presence of the robot.

[0012] In one embodiment, the docking station includes: a shell; charging contacts; a central transmitter configured to transmit at least one light signal within a first emission area; a right transmitter disposed on a side of the central transmitter and configured to transmit at least one light signal within a second emission area; and a left transmitter disposed on a side of the central transmitter and configured to transmit at least one light signal within a third emission area. The shield within the shell includes: a central shield segment, which surrounds the central emitter and defines a first light chamber, the first shield segment includes an opaque first wall surrounding the central emitter and a first hole in the first wall, light can be emitted through the first hole, and the first hole defines the direction and angle of the first emission area; a right shield segment, which surrounds the right emitter and defines a second light chamber, the second shield segment includes an opaque second wall surrounding the right emitter and a second hole in the second wall, light can be emitted through the second hole, and the second hole defines the direction and angle of the second emission area; and a left shield segment, which surrounds the left emitter and defines a third light chamber, the third shield segment includes an opaque third wall surrounding the left emitter and a third hole in the third wall, light can be emitted through the third hole, and the third hole defines the direction and angle of the third emission area.

[0013] In another aspect, the present disclosure relates to an autonomous floor cleaning system including an autonomous floor cleaner and a docking station. The autonomous floor cleaner includes: an autonomously movable housing; a drive system for autonomously moving the housing over a surface to be cleaned; and a controller for controlling the operation of the autonomous floor cleaner.

[0014] In one embodiment, the autonomous floor cleaner may include a rechargeable battery, and electrical or charging contacts for the battery may be provided on an exterior surface of the robot.

[0015] In one embodiment, the autonomous floor cleaner may include one or more receivers that detect signals emitted from the docking station. Optionally, the autonomous floor cleaner may also include one or more time-of-flight sensors for position / proximity sensing. In one embodiment, the receiver is a passive infrared receiver that operates at the same frequency as the time-of-flight sensor. In some embodiments, the robot selectively turns off the time-of-flight sensor when docking with or avoiding the docking station. At this point, the robot can rely on the passive infrared receiver and the signal from the docking station to navigate.

[0016] The autonomous floor cleaner may include a recovery system. The recovery system may include: a recovery passage through the housing, the recovery passage having an air inlet and an air outlet; a debris container, tank or recovery tank; and a suction source in fluid communication with the air inlet and the debris container, tank or recovery tank to generate a working airflow through the recovery passage.

[0017] The autonomous floor cleaner may include a fluid delivery system. The fluid delivery system may include: a supply tank for storing a supply of cleaning fluid; at least one fluid dispenser in fluid communication with the supply tank; and a fluid delivery pump configured to control the flow of cleaning fluid to the at least one fluid dispenser.

[0018] In yet another aspect, a method for automatic docking of an autonomous floor cleaner with a docking station is provided. In one embodiment, when a return to docking event occurs, the robot can turn off the time-of-flight sensor and rely on a passive receiver and a docking signal from the docking station to dock with the docking station. The method may include driving toward the docking station, rotating the robot to align the charging contacts with the docking station, and docking with the docking station.

[0019] In yet another aspect, a method for re-docking a robot at a docking station after loss of charge is provided. In one embodiment, if the robot loses charging contact with the docking station after docking, the robot can drive away from the docking station, realign with the docking station relying on a passive receiver and a short docking signal from the docking station, and re-dock with the docking station.

[0020] In even another aspect, a method for low-power charging of a robot via a docking station is provided. In one embodiment, when the robot is docked, the docking station is configured to operate in a wake mode and a sleep mode, and wherein the docking station is further configured to enter the sleep mode and stop charging the battery after fully charging the battery, and resume charging the battery after switching from the sleep mode to the wake mode. In such an embodiment, the docking station may also be configured to resume to the sleep mode once the battery is fully charged (i.e., topped up).

[0021] In yet another aspect, a method for docking station avoidance performed by a robot is provided. In one embodiment, if the robot detects a long-range docking signal during cleaning, the robot can turn off the time-of-flight sensor and rely on a passive receiver and a stop-entry signal from the docking station to navigate around and / or away from the docking station.

[0022] In yet another aspect, a method for obstacle response during docking performed by a robot is provided. In one embodiment, if the robot encounters an obstacle during docking or re-docking, the robot may temporarily ignore all docking signals from the docking station and perform obstacle avoidance behavior. Once the obstacle has been avoided, the robot may continue to follow the docking signals from the docking station.

[0023] In yet another aspect, a method for close range docking performed by a robot is provided. In one embodiment, when the robot is already within range of a short-range docking signal and returns to a docking event, the robot can turn off the time-of-flight sensor and rely on a passive receiver and a short docking signal from the docking station to dock with the docking station.

[0024] These and other features and advantages of the present disclosure will become apparent from the following description of specific embodiments, when viewed in light of the accompanying drawings and appended claims.

[0025] Before describing the embodiments of the present invention in detail, it should be understood that the present invention is not limited to the details of operation or the details of the construction and arrangement of the components set forth in the following description or shown in the accompanying drawings. The present invention can be implemented in various other embodiments and can be practiced or executed in alternative ways that are not explicitly disclosed herein. Moreover, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive. The use of "include" and "comprise" and its variations means including the items listed thereafter and their equivalents and additional items and their equivalents. In addition, enumeration can be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be interpreted as limiting the present invention to any particular order or number of components. Nor should the use of enumeration be interpreted as excluding from the scope of the present invention any additional steps or components that may be combined with or combined into the steps or components of the enumeration. Any reference to "at least one of X, Y and Z" of a claim element is intended to include any of X, Y or Z alone, and any combination of X, Y and Z, such as X, Y, Z; X, Y; X, Z; and Y, Z. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In the attached picture:

[0027] Figure 1 is a schematic diagram of an autonomous floor cleaning system according to one embodiment of the present invention, the system comprising at least one autonomous floor cleaner or robot, and a docking station;

[0028] Figure 2 is used for Figure 1 A perspective view of one embodiment of an autonomous floor cleaner or robot of the system;

[0029] Figure 3 yes Figure 2 Bottom view of the robot;

[0030] Figure 4 yes Figure 2 Schematic diagram of the robot;

[0031] Figure 5is an enlarged view of a portion of the robot with a sensor cover removed, illustrating one embodiment of a distance sensor for the robot;

[0032] Figure 6 is a top schematic diagram of a robot showing a plurality of receivers in an exemplary layout and coverage patterns provided by the receivers;

[0033] Figure 7 yes Figure 2 A rear view of a robot showing one embodiment of charging contacts for the robot;

[0034] Figure 8 is used for Figure 1 A front perspective view of one embodiment of a docking station of the system;

[0035] Fig. 9 yes Figure 8 Top view of the docking station;

[0036] Fig.10 yes Figure 8 A side view of a docking station;

[0037] Fig.11 yes Figure 8 A front view of the docking station;

[0038] Fig.12 yes Figure 8 A rear perspective view of the docking station;

[0039] Fig.13 yes Figure 8 An exploded view of the docking station;

[0040] Fig.14 yes Figure 8 A partially exploded view of a docking station showing a plurality of transmitters in an exemplary layout;

[0041] Fig.15 It passes through Figure 8 A perspective cross-sectional view of the docking station taken along line XV-XV;

[0042] Fig.16 It passes through Figure 8 A top cross-sectional view of the docking station taken along line XV-XV;

[0043] Fig.17 is used for Figure 8 Optical simulation of the performance of one embodiment of a launcher and shield of a docking station;

[0044] Fig.18 is a top schematic diagram of a docking station illustrating one embodiment of a long range signal transmission mode provided by the docking station;

[0045] Fig.19 is a top schematic diagram of a docking station illustrating one embodiment of a short-range signal transmission mode provided by the docking station;

[0046] Fig. 20 is a top schematic diagram of a docking station illustrating another embodiment of a long range signal transmission mode provided by the docking station;

[0047] Fig.21 is a flow chart illustrating a portion of a method for docking a robot with a docking station;

[0048] Fig. 22 It shows Fig.21 A flowchart of another part of the method;

[0049] Fig.23 It shows Fig.21 a flowchart of yet another part of the method;

[0050] Fig.24 is a flow chart illustrating one embodiment of a method for re-docking a robot at a docking station after loss of charge;

[0051] Fig.25 is a flow chart illustrating one embodiment of a method for low power charging of a robot via a docking station;

[0052] Fig.26 is a flow chart illustrating one embodiment of a method for avoiding a docking station performed by a robot;

[0053] Fig. 27 is a flow chart illustrating one embodiment of a method for obstacle response during docking performed by a robot;

[0054] Fig.28 is a flow chart illustrating one embodiment of a method for close-range docking performed by a robot;

[0055] Figures 29 to 34 Yes Execution Figure 21 to Figure 23 Schematic diagram of the docking method of the robot. DETAILED DESCRIPTION

[0056] The present disclosure generally relates to docking stations for autonomous floor cleaners. More specifically, the present disclosure relates to a docking station for charging a battery of an autonomous floor cleaner and a method of positioning the docking station to avoid or dock with the docking station.

[0057] Figure 1is a schematic diagram of an autonomous floor cleaning system 10 according to one embodiment of the present invention. The autonomous floor cleaning system 10 includes an autonomous floor cleaner 12 and a docking station 14 for the autonomous floor cleaner 12. The autonomous floor cleaner 12 can clean a variety of floor surfaces, including bare floors (e.g., hardwood, tile, and stone) and soft surfaces (e.g., carpets and mats). Optionally, an artificial barrier system 20 can be provided with the system 10 for containing the autonomous floor cleaner 12 within user-determined boundaries.

[0058] In one embodiment, the autonomous floor cleaner 12 can be a dry vacuum cleaning robot that includes at least a vacuum collection system for generating a partial vacuum to suck debris (which may include dirt, dust, soil, hair, and other debris) from the floor surface and collect the removed debris in a space provided on the robot for post-processing.

[0059] In another embodiment, the autonomous floor cleaner 12 can be a deep cleaning robot that includes a fluid delivery system for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned, and a fluid recovery system for removing cleaning fluid and debris from the surface to be cleaned and storing the recovered cleaning fluid and debris. The fluid delivery system can be configured to deliver liquid, steam, mist, or vapor to the surface to be cleaned.

[0060] In yet another embodiment, the autonomous floor cleaner 12 can be a wet mopping or sweeping robot that includes a fluid delivery system for storing and delivering cleaning fluid to the surface to be cleaned, and a mopping or sweeping system for removing cleaning fluid and debris from the surface to be cleaned without using suction. The fluid delivery system can be configured to deliver liquid, steam, mist, or vapor to the surface to be cleaned.

[0061] In yet another embodiment, the autonomous floor cleaner 12 may be a dry cleaning robot including a cleaning system for removing dry debris from the surface to be cleaned without using suction and collecting the removed debris in a space provided on the robot for post-processing.

[0062] The docking station 14 can recharge the power source of the autonomous floor cleaner 12. In one example, the docking station 14 can be connected to a household power source, such as an A / C power outlet 16, and can include a converter 18 for converting AC voltage to DC voltage to recharge the power source installed on the autonomous floor cleaner 12, which can be a battery. The docking station 14 can also include various sensors and transmitters (not shown) for monitoring the status of the autonomous floor cleaner 12, enabling automatic docking functions, communicating with the autonomous floor cleaner 12, and features for network and / or Bluetooth connectivity.

[0063] In another embodiment, the docking station 14 may perform service, maintenance, or diagnostic checks on the autonomous floor cleaner 12 in addition to or as an alternative to recharging the autonomous floor cleaner 12. For example, the docking station 14 may be configured to automatically empty the collection bin in the case of a dry vacuum or deep cleaning robot, and / or automatically fill or refill the supply tank in the case of a deep cleaning robot.

[0064] Figures 2 to 4 Shown for Figure 1 An embodiment of an autonomous floor cleaner 12 of the system 10 is also referred to herein as a robot 12. It should be noted that Figures 2 to 4 The robot 12 shown is just one example of an autonomous floor cleaner that may be used with the system 10 and with the docking station 14 , and other autonomous floor cleaners may be used with the system 10 and the docking station 14 .

[0065] The robot 12 mounts components of various functional systems of an autonomous floor cleaner in an autonomously movable unit or housing 22, including components of a vacuum collection system 24 for generating a working airflow to remove dirt (including dust, hair and other debris) from the surface to be cleaned and storing the dirt in a collection space on the vacuum cleaner, a drive system 26 for autonomously moving the robot 12 above the surface to be cleaned, and a navigation / mapping system 28 for guiding the movement of the robot 12 on the surface to be cleaned, generating and storing a map of the surface to be cleaned, and recording status or other environmental variable information.

[0066] The controller 30 is operably coupled to the various functional systems 24, 26, 28 of the robot 12 for controlling the operation of the robot 12. The controller 30 may be a microcontroller unit (MCU) including at least one central processing unit (CPU).

[0067] As shown, the housing 22 of the robot 12 may be D-shaped, having a first end 32 and a second end 34. The first end 32 defines the front of the robot 12 and may be a straight edge portion of the D-shaped housing 22, which may optionally include a bumper 36. The second end 34 may define the rear of the robot 12 and may be a rounded portion of the D-shaped housing 22. Other shapes and configurations of the robot 12 are possible, including: the rounded portion of the D-shaped housing 22 may define the front of the robot 12 and the straight edge portion of the D-shaped housing 22 may define the rear of the robot 12.

[0068] The forward movement of the robot 12 is represented by arrow 38, and the bumper 36 surrounds the first end 32 of the robot 12 to cover the front of the robot 12. During a collision with an obstacle, the bumper 36 can move or translate to record the detection of the object. The bumper 36 can also surround and cover a portion of each lateral side 40 of the robot 12, and can optionally be adapted to move bidirectionally to sense obstacles in front of and to the sides of the robot 12. The lateral sides 40 of the robot 12 extend between the first end 32 and the second end 34 of the robot 12.

[0069] The vacuum collection system 24 may include a working air path through a unit having an air inlet and an air outlet, a suction nozzle 42, a suction source 44 in fluid communication with the suction nozzle 42 to generate a working airflow, and a collection box 46 for collecting dirt from the working airflow for post-processing. The suction nozzle 42 may define the air inlet of the working air path, wherein the inlet opening of the suction nozzle 23 is arranged on the lower side 48 of the housing 22 and faces the surface to be cleaned. The suction source 44 may include a vacuum motor 50 carried by the housing 22, which is upstream of the fluid of the air outlet (not shown) and may define a portion of the working air path. The collection box 46 may also define a portion of the working air path and include a dirt box inlet (not shown) in fluid communication with the suction nozzle 42. Optionally, a separator (not shown) may be formed in a portion of the collection box 46 for separating fluid and entrained dirt from the working airflow. Some non-limiting examples of separators include cyclone separators, filter screens, foam filters, HEPA filters, filter bags, or combinations thereof. Optionally, a pre-motor filter and / or a post-motor filter (not shown) may also be disposed in the working air path. The working air path may also include various conduits, ducts, or tubes for fluid communication between the various components of the vacuum collection system 24. The vacuum motor 50 may be positioned fluidically downstream or fluidically upstream of the collection tank 46 in the working air path.

[0070] The robot 12 may include a brush chamber 56 at the front of the housing 22 in which a brush roll 58 is mounted. The brush roll 58 is mounted to rotate about a substantially horizontal axis relative to the surface on which the robot 12 moves. A drive assembly including a brush motor 60 may be provided within the robot 12 to drive the brush roll 58. In other embodiments, other configurations of agitators or brush rolls may be provided, including one or more fixed or non-moving brushes, or one or more brushes that rotate about a substantially vertical axis.

[0071] In this embodiment, the brush roll 58 is mounted on the front of the robot 12, wherein the brush roll 58 is generally parallel to the first end 32. The brush roll 58 may be at least partially surrounded by a transparent window 62 on the front of the housing 22.

[0072] The drive system 26 may include a drive wheel 64 for driving the robot 12 across the surface to be cleaned. The drive wheel 64 may be operated by a common wheel motor 66 or a separate wheel motor 66 coupled to the drive wheel 64 through a transmission, which may include a gear train assembly or another suitable transmission. The drive system 26 may receive input from the controller 30 to drive the robot 12 across the floor based on input from the navigation / mapping system 28 for an autonomous operating mode or based on input from a smart phone, tablet or other remote device for an optional manual operating mode. The drive wheel 64 may be driven in a forward or reverse direction to move the unit forward or backward. In addition, the drive wheels 64 may be operated simultaneously at the same rotational speed for linear motion, or independently at different rotational speeds to make the robot 12 turn in a desired direction. Although the drive system 26 is shown here as including a rotating wheel 64, it should be understood that the drive system 26 may include an alternative traction device for moving the robot 12 across the surface to be cleaned.

[0073] In addition to the drive wheels 64 or other traction devices, the robot 12 may include one or more additional wheels 54 supporting the housing 22, such as casters on a central rear portion of the underside 48 of the housing 22, and a pair of wheels adjacent to the rear edge of the opening defining the suction nozzle 42.

[0074] The controller 30 may receive input from the navigation / mapping system 28 or from a remote device such as a smart phone (not shown) for guiding the robot 12 over the surface to be cleaned. The navigation / mapping system 28 may include a memory 68 that may store any data useful for navigation, mapping, or conducting an operation cycle, including, but not limited to, maps for navigation, input from various sensors for guiding the movement of the robot 12, and the like. For example, a wheel encoder 70 may be placed on the drive shaft of the drive wheel 64 and configured to measure the distance traveled by the robot 12. This distance measurement may be provided as an input to the controller 30. In another example, the navigation / mapping system 28 may receive input from the docking station 14 for guiding the robot 12 to move to dock at the docking station 14 and / or avoid the docking station 14 during cleaning operations. Such input may include a docking signal and / or an avoidance signal, also referred to herein as a stop entry signal, embodiments of which will be described in further detail below.

[0075] In the autonomous operating mode, the robot 12 can be configured to travel in any pattern for cleaning or disinfecting, including staggered travel or alternating rows (i.e., the robot 12 travels from right to left and from left to right on alternating rows), spiral trajectories, etc., while cleaning the floor surface, using input from various sensors to change direction as needed or adjust its route to avoid obstacles. In an optional manual operating mode, the movement of the robot 12 can be controlled using a mobile device such as a smart phone or tablet.

[0076] The robot 12 may include any number of motors for performing motion and cleaning. In one example, three dedicated motors 50, 60, 66 may be provided to generate a partial vacuum at the nozzle 4, rotate the brush roller 58, and drive the wheel 64. In another example, these motion and cleaning operations are performed by less than three or more than three motors.

[0077] The robot 12 may include any number of motor drivers for controlling the motors 50, 60, 66. In the illustrated embodiment, a vacuum motor driver 72, a brush motor driver 74, and a wheel motor driver 76 may be provided for controlling the vacuum motor 50, the brush motor 60, and the wheel motor 66, respectively. The motor drivers 72-76 may serve as an interface between the controller 30 and its corresponding motors. The motor drivers 72-76 may also be integrated circuit chips (ICs).

[0078] The motor drives 72-76 may be electrically coupled to a battery management system 78 including a rechargeable battery 80, which may include a battery pack. In one example, the battery pack may include a plurality of batteries that may include lithium-ion batteries. Batteries with other battery chemistries are also possible, such as nickel metal hydride and nickel cadmium. Electrical contacts or charging contacts 82 for the battery 80 may be disposed on an outer surface of the robot 12, and in one embodiment, the charging contacts 82 are disposed on the second end or rear portion 34 of the robot 12. In another embodiment, the charging contacts 82 are disposed on the underside 48 of the robot 12.

[0079] The controller 30 is also operably coupled to a user interface (UI) 84 on the robot 12 for receiving input from a user. The UI 84 may be used to select an operating cycle of the robot 12 or otherwise control the operation of the robot 12. The UI 84 may have a display 86, such as an LED display, for providing visual notifications to the user. A display driver 88 may be provided for controlling the display 86 and serving as an interface between the controller 30 and the display 86. The display driver 88 may be an IC. The robot 12 may be provided with a speaker (not shown) for providing auditory notifications to the user.

[0080] The UI 84 may also have one or more switches 90 that are actuated by a user to provide input to the controller 30 to control the operation of various components of the robot 12. A switch driver 92 may be provided for controlling the switches 90 and serving as an interface between the controller 30 and the switches 90.

[0081] The robot 12 may be provided with one or more cameras or stereo cameras (not shown) for obtaining visual notifications from the user. In this way, the user may convey instructions to the robot 12 through gestures. For example, the user may wave their hands in front of the camera to instruct the robot 12 to stop or move away.

[0082] The controller 30 may be operably coupled to various sensors mounted on the robot 12 for receiving input regarding the environment and input from the docking station 14, and may use the sensor input to control the operation of the robot 12, as described in further detail below. Some sensors may detect features of the robot 12's surrounding environment, including, but not limited to, walls, floors, furniture, pets, stairs, ledges, etc. Some sensors may detect the docking station 14. The sensor input may also be stored in the memory 68 or used to form a map by the navigation / mapping system 28. Figure 4 Some exemplary sensors are shown in and described below. Although it should be understood that not all of the sensors shown may be provided, additional sensors may be provided, and all possible sensors may be provided in any combination.

[0083] The robot 12 may include one or more distance sensors 94 for position / proximity sensing. Each distance sensor 94 has a field of view or sensing area, which may optionally overlap with each other, to detect obstacles toward the front and sides of the robot 12. Input from the distance sensors 94 is used by the controller 30 to slow down and / or adjust the path of the robot 12 when the sensors 94 detect an object.

[0084] In the illustrated embodiment, four distance sensors 94 are provided, two near each lateral side of the housing 22. Other numbers and locations of the distance sensors 94 are possible. The sensors 94 are mounted to the housing 22, above the window 62, and behind a transparent or translucent portion of the housing 22. For example, the housing 22 may include a transparent or translucent sensor cover 96 for covering and protecting the sensors 94 while also allowing light signals to pass through. The sensor cover 96 may include a single continuous sensor cover or include separate lens inserts for each distance sensor 94.

[0085] The robot 12 may include one or more of a collision sensor 102 , a wall following sensor 104 , a steep wall sensor 106 , an inertial measurement unit (IMU) 108 , a lift sensor 110 , a box sensor 112 , or a floor condition sensor 114 , including any combination or multiples thereof.

[0086] The collision sensor 102 determines a frontal or side impact to the robot 12 and may be integrated with the housing 22, such as with the bumper 36 ( Figure 2 The output signal from the collision sensor 102 provides input to the controller 30 for selecting an obstacle avoidance algorithm.

[0087] The wall following sensor 104 (also referred to as a side wall sensor) may be located near the side of the housing 22 and may include a side-facing position sensor that provides distance feedback and controls the robot 12 so that the robot 12 can follow near a wall without contacting the wall. The wall following sensor 104 may be an optical, mechanical, or ultrasonic sensor, including a reflectance or time-of-flight sensor. In another embodiment, a wall following sensor is not provided, and the distance sensor 94 is used as a wall following sensor.

[0088] The wall sensor 106 may be a ground-facing position sensor that provides distance feedback so that the robot 12 can avoid excessive falls along stairwells, ledges, etc. The wall sensor 106 may be an optical, mechanical, or ultrasonic sensor, including a reflectance or time-of-flight sensor.

[0089] The IMU 108 uses a combination of at least one accelerometer, gyroscope, and optional magnetometer or compass to measure and report the robot's acceleration, angular rate, or magnetic field around the robot 12. The IMU 108 can be an integrated inertial sensor located on the controller 30, and can be a nine-axis gyroscope or accelerometer to sense linear, rotational, or magnetic field acceleration. The IMU 108 can use acceleration input data to calculate changes in velocity and posture and transmit them to the controller 30 for navigating the robot 12 around the surface to be cleaned.

[0090] The lift sensor 110 detects when the robot 12 is lifted off the surface to be cleaned, for example, if the user lifts the robot 12. This information is provided as input to the controller 30, which can stop the operation of the motors 50, 60, 66 in response to the detected lift event. The lift sensor 110 can also detect when the robot 12 is in contact with the surface to be cleaned, such as when the user places the robot 12 back on the ground. Based on this input, the controller 30 can resume operation.

[0091] The robot 12 may optionally include a bin sensor 112 for detecting a characteristic or state of the collection bin 46. In one example, a pressure sensor may be provided for detecting the weight of the collection bin 46. In another example, a magnetic sensor may be provided for detecting the presence of the collection bin 46. In a non-limiting example, this information is provided as an input to the controller 30, which may prevent operation of the robot 12 until the collection bin 46 is emptied or properly installed. The controller 30 may also direct the display 86 to provide a notification to the user that the collection bin 46 is full or missing.

[0092] The floor state sensor 114 detects the state of the surface to be cleaned. For example, the robot 12 may be provided with an infrared (IR) dirt sensor, a stain sensor, an odor sensor, or a wet and dirty sensor. The floor state sensor 114 provides input to the controller 30, which can guide the operation of the robot 12 based on the state of the surface to be cleaned, such as by selecting or modifying a cleaning cycle. Optionally, the floor state sensor 114 can also provide input for display on a smart phone.

[0093] refer to Figure 5 , a portion of the robot 12 is shown with the sensor cover 96 removed. The one or more distance sensors 94 may be infrared sensors or time of flight (TOF) sensors. In the embodiment shown herein, each TOF sensor 94 has a transmitter 98 and a receiver 100. The TOF sensor 94 measures the time it takes for a light signal to travel from the transmitter 98 to the receiver 100 for determining the precise distance to an object near the robot 12. The transmitter 98 emits a pulsed light signal and may include an LED that emits the light signal. In one embodiment, the LED may be an infrared LED that emits an infrared beam.

[0094] refer to Figure 2 , Figure 4 and Figure 7 , the robot 12 may have at least one receiver 116 to detect a signal transmitted from the docking station 14. In some cases, the at least one receiver 116 is an infrared receiver or infrared transceiver that detects an infrared signal, such as a coded infrared beam, transmitted from the docking station 14. Optionally, the robot 12 includes a plurality of receivers 116 that can detect at least one signal, i.e., a coded beam, transmitted from the docking station 14. In one embodiment, the receiver 116 is a passive infrared receiver that is separate from the TOF sensor 94.

[0095] The receivers 116 are disposed at different locations on the housing 22 of the robot 12 and are spaced apart from one another so that signals from the docking station 14 can be detected when the robot 12 is disposed at different orientations relative to the docking station 14, as further described below. For example, the receivers 116 may be disposed on the front 32, rear 34, and / or lateral sides 40 of the housing 22 to receive signals transmitted from the docking station 14.

[0096] The receivers 116 may be mounted behind a transparent or translucent portion of the housing 22, for example, at least some of the receivers 116 may be mounted behind a sensor cover 96, which may include a single continuous sensor cover or include separate lens inserts for each distance sensor 94. At least some other receivers 116, such as those on the rear portion 34 of the housing 22, may be mounted behind other transparent or translucent covers (see Figure 7 ).

[0097] Figure 6 One embodiment of a receiver layout for a robot 12 and a coverage pattern provided by the receivers 116 is shown. A plurality of receivers 116 are provided, including a first or center right receiver 116CR, a second or side right receiver 116SR, a third or rear right receiver 116RR, a fourth or center left receiver 116CL, a fifth or side left receiver 116SL, and a sixth or rear left receiver 116RL. Each receiver 116 has a field of view or sensing zone. These zones collectively define a coverage pattern for the robot 12. The first or center right receiver 116CR is located at or near the front 32 of the housing 22 and is generally forward facing to provide a zone CR covering the right half of the front side of the robot 12. The second or side right receiver 116SR is located on the right lateral side 40 of the housing and is generally side facing to provide a zone SR covering the right lateral side of the robot 12. The third or rear right receiver 116RR is located on the rear 34 of the housing 22 and is generally rear facing to provide a zone RR covering the right rear side of the robot 12. The fourth or center left receiver 116CL is located at or near the front 32 of the housing and is generally forward facing to provide a zone CL covering the left half of the front side of the robot 12. The fifth or side left receiver 116SL is located on the left lateral side 40 of the housing 22 and is generally side facing to provide a zone SL covering the left lateral side of the robot 12. The sixth or rear left receiver 116RL is located on the rear 34 of the housing 22 and is generally rear facing to provide a zone RL covering the rear left side of the robot 12. Other locations and numbers of receivers 116 may be used. It should be noted that Figure 5 Schematically shows the receiver layout in , wherein, schematically depicts the receiver position. In fact, the receiver 116 can be located in various positions in the housing 22, behind the transparent or translucent part of the housing 22.

[0098] At least some of the receivers 116 may be oriented to provide overlapping fields of view. As the robot 12 travels over the floor surface, the field of view or area in which signals from the docking station 14 are sensed may change, or may be detected by more than one receiver 116. This allows the robot 12 to accurately and precisely determine the front / rear and lateral positions of the docking station 14 proximate to the robot 12. In the illustrated embodiment, the center right region CR overlaps the side right region SR at region CSR, the side right region SR overlaps the rear right region RR at region SRR, the rear right region RR overlaps the rear left region RL at region RRL, the rear left region RL overlaps the side left region SL at rear side RSL, and the side left region SL overlaps the center left region CL at region SCL.

[0099] Optionally, the center right zone CR and the center left zone CL do not overlap each other. This creates a zone gap G at the center front side of the robot 12. This zone gap G can be used for navigation, and can be used to guide the robot 12 to move in a straight line along the boundary between the center zones when docking, as described in further detail below. In the illustrated embodiment, the zone gap G is narrow relative to the center zones CR, CL, which can allow the robot 12 to remain on a compact path by adjusting the robot heading holding signal from the docking station 14 within the zone gap G. In one example, the zone gap G can have an approximately constant width of 15 mm, while the center zones CR, CL can have a minimum width of 7 mm and it increases in a direction away from the robot 12. In terms of "approximately constant" width, the zone gap G can deviate from ±1 mm, or ±2 mm.

[0100] Optionally, a rear dead zone DZ may be created between the rear right region RR and the rear left region RL. This dead zone DZ may be located at the center of the rear portion 34 of the robot 12. This dead zone DZ may also be used for navigation when docking with or avoiding the docking station 14, as described in further detail below. In the illustrated embodiment, the dead zone DZ is triangular and narrows to the point where the rear regions RR, RL intersect.

[0101] At least one receiver 116 outputs a corresponding signal to the controller 30, which can be used to control the operation of the robot 12. For example, upon receiving a predetermined signal from the docking station 14, the controller 30 may adjust the drive wheel control parameters to avoid the docking station 14. In another example, upon receiving another predetermined signal from the docking station 14, the controller 30 may adjust the drive wheel control parameters to guide the robot 12 toward the docking station 14.

[0102] refer to Figure 7, shows a rear portion of the robot 12, including charging contacts 82 disposed on the second end or rear side 34 of the robot 12. In one embodiment, when the robot 12 is docked with the docking station 14, the positive charging contact 82P and the negative charging contact 82N are utilized to detect a complete circuit. In other embodiments, a single charging contact 82 or more than two charging contacts 82 may be utilized. The additional charging contacts will provide redundancy in the event that one of the other charging contacts becomes dirty, blocked, or damaged. In other embodiments of the robot 12, additional contacts may be used to transmit data and information between the robot 12 and the docking station 14.

[0103] The charging contacts 82 are sized and positioned to reliably and repeatedly contact corresponding charging contacts on the docking station 14. For example, the charging contacts 82 may be elongated to ensure contact with the docking station charging contacts. The charging contacts 82 may be curved along the same or similar curvature as the rounded rear side 34. Figure 7 As shown, the charging contacts 82 may be curved contacts disposed horizontally on the rear side 34 of the housing 22, with the positive charging contact 82P vertically spaced apart from the negative charging contact 82N. Other shapes and relative arrangements of the charging contacts 82 are possible.

[0104] Figures 8 to 16 An embodiment of the docking station 14 is shown. The docking station 14 includes: a housing 120; electrical contacts or charging contacts 122 disposed on the housing 120, which are adapted to cooperate with the charging contacts 82 on the outer surface of the robot 12 to charge the battery 80 of the robot (see Figure 4 and Figure 7 ); and at least one emitter 124 that can emit at least one coded beam for detection by the robot 12. In the illustrated embodiment, the docking station 14 includes a plurality of emitters 124 that can emit at least one signal or coded beam for detection by the robot 12 and can be configured so that the signals are directed outwardly from the housing 120 in a plurality of different directions, as further described below.

[0105] The housing 120 may have a front side 126, a rear side 128, a first lateral side 130 and a second lateral side 132, a top side 134, and a bottom side 136. The front side 126 of the housing 120 may include a rear stop 138 for the robot 12. The bottom side 136 of the housing 120 may include a base on which the docking station 14 rests. The rear side 128 of the housing 120 may be flat and optionally positioned to abut against a wall or other vertical surface. Other shapes and configurations of the housing 120 of the docking station 14 are possible. Optionally, a logo 140 consisting of letters, numbers, characters, geometric shapes, or any combination thereof may be provided on the housing 120.

[0106] The rear stop 138 is generally perpendicular to the bottom side 136 or the ground on which the base rests, but may have a slight rearward or forward angle. The rear stop 138 may include a concave surface of the housing 120 to complement the rounded second end or rear side 34 of the robot 12 that contacts the rear stop 138 when docked with the docking station 14. Other shapes of the rear stop 138 are possible, including shapes that are complementary or non-complementary to the portion of the robot 12 that contacts the rear stop 138 when docked with the docking station 14.

[0107] The bottom side 136 or base of the housing 120 on which the docking station 14 rests may extend forward from the rear block 138 for stability. In some embodiments, the extended portion of the bottom side 136 may be angled or otherwise shaped to help position the robot 12 in the center of the docking station 14.

[0108] The charging contacts 122 of the docking station 14 are located on the rear block 138 to allow them to contact corresponding contacts 82 on the second end or rear side 34 of the robot 12 when the robot 12 encounters the rear block 138 during docking. Alternatively, the charging contacts 122 may be provided on an extension of the bottom side 136, the rear block 138, or other portion of the housing 120 and configured to contact corresponding contacts 82 on the underside 48 of the robot 12.

[0109] The docking station 14 may have a printed circuit board assembly (PCBA) 142 that includes circuitry for supplying appropriate voltage and current to the robot 12 via the charging contacts 122 when the robot 12 is docked. The PCBA 142 receives input power supplied to the docking station 14 through a power connector or socket 144 on the housing 120, and provides appropriate output voltage and current to the robot 12 via the charging contacts 122. The PCBA 142 is enclosed within the housing 120 and may optionally be at least partially supported by a PCBA bracket 146 mounted within the housing 120.

[0110] A socket 144 may be disposed on the rear side 128 of the housing 120 for connecting the device to the rear side 128 of the housing 120 via a cable 150 (in the Fig.10 The cable may include a converter 18 for converting AC voltage into DC voltage (see FIG. Figure 1 The receptacle 144 may alternatively be located elsewhere on the housing 120 , such as on one of the lateral sides 130 , 132 of the housing 120 .

[0111] An indicator light 148 may be disposed on the rear side 128 of the housing 120 for providing visual notification to the user. In one embodiment, the light 148 illuminates when the robot 12 is docked and charging. The light 148 may also communicate the charging mode of the docking station 14. As described in further detail below, the docking station 14 may operate in a high power charging mode or a low power charging mode. The light 148 may communicate whether the docking station 14 is in a high power charging mode or a low power charging mode, or may indicate when changing between modes. For example, when changing to a low power charging mode, the light 148 may flash, blink, or turn off as a signal that the mode has been successfully changed.

[0112] The housing 120 may optionally be provided with cable routing features for routing the power cable 150 along a pre-specified path. For example, a cable routing channel 152 may be provided in the rear side 128 of the housing 120 for holding a length of the power cable 150 therein and routing the power cable 150 from the outlet 144 toward one side of the housing 120. The cable routing channel 152 may have multiple branches, allowing a user to select a location where the power cable 150 is routed. In the illustrated embodiment, the cable routing channel 152 includes a first branch 154 for routing the power cable 150 toward the first lateral side 130 of the housing 120 and a second branch 156 for routing the power cable 150 toward the second lateral side 132 of the housing 120. According to the A / C power outlet 16 ( Figure 1 ) or other household power source is located relative to the desired location of the docking station 14, the user can route the power cable 150 through the first branch 154, the second branch 156, or neither branch. Fig.10 Two possible routes for the power cables 150 are shown in dashed lines in FIG. 1 , but it will be appreciated that other cabling arrangements are possible.

[0113] The bottom side 136 or base may optionally have friction pads 158 to prevent movement of the docking station 14. The friction pads 158 are made of a material with a high coefficient of friction, such as rubber. As shown, two friction pads 158 may extend in the docking direction D of the robot 12. A third friction pad 158 may be arranged transverse to the docking direction D.

[0114] In the illustrated embodiment, when the robot 12 is docked with the docking station 14, the positive charging contact 122P and the negative charging contact 122N are used to detect a complete circuit. In other embodiments, a single charging contact 122 or more than two charging contacts 122 may be utilized. The additional charging contacts will provide redundancy in the event that one of the other charging contacts becomes dirty, blocked, or damaged. In other embodiments of the docking station 14, the additional contacts may be used to transfer data and information between the robot 12 and the docking station 14.

[0115] The charging contacts 122 are sized and positioned to reliably and repeatedly contact corresponding charging contacts 82 on the robot 12. For example, the charging contacts 122 may be elongated to ensure contact with the robot charging contacts 82. The charging contacts 122 may be curved along the same or similar curvature as the concave rear stop 138. Figure 8 and Fig.13 As shown, the charging contacts 122 can be curved contacts horizontally disposed on the rear block 138 of the housing 120, wherein the positive charging contact 122P is vertically spaced apart from the negative charging contact 122N. Other shapes and relative arrangements of the charging contacts 122 are possible. The charging contacts 122 are conductive and can be formed of nickel-plated brass, copper alloys, or nickel-plated carbon steel. Other conductive materials (metals, etc.) are possible.

[0116] refer to Fig.13 , the illustrated embodiment includes two openings 160 in the rear block 138 through which the charging contacts 122 extend. The openings 160 can ensure proper alignment and restraint between the charging contacts 122, which can be provided as an elongated track supported by a track bracket 162 when the charging contacts 122 are repeatedly engaged by the robot 12.

[0117] The charging contacts 122 can be fixed or compliant. In the illustrated embodiment, the charging contacts 122 are compliant and are biased by springs 164 to a neutral position, which may correspond to a state in which the robot 12 is not docked with the docking station 14. The bracket 162 may support the contacts 122 aligned with the springs 164. Other elements for resiliently mounting the charging contacts 122 are possible. Due to the compliance or resilient mounting, the charging contacts 122 are pushed outward away from the rear block 138 so that the outer surface 166 of the charging contacts 122 extends through the opening 160 provided in the rear block 138. The force applied to the outer surface 166, i.e., the docking of the robot 12 with the docking station 14, causes the charging contacts 122 to retract into the opening 160 and move to a contact position, which may establish positive electrical contact between the charging contacts 82 of the robot and the docking station charging contacts 122.

[0118] In the neutral position, the outer surface 166 of the charging contact 122 can be flush with the rear stop 138, can extend slightly in front of the rear stop 138, or can be slightly recessed in the rear stop 138, depending on the installation in the housing 22 and the biasing force of the spring 164. In the contact position, the outer surface 166 of the charging contact 122 is set back relative to the housing 22 compared to the neutral position, but can still be flush with the rear stop 138, can extend slightly in front of the rear stop 138, or can be slightly recessed in the rear stop 138, depending on the neutral position and the compression of the charging contact 122.

[0119] An activation switch 168 is provided for controlling the supply of power to the charging contacts 122 and is operable to move between an on position and an off position. The activation switch cooperates with the PCBA 142 to control the flow of power to the contacts 122. When the activation switch is on, power is applied to the charging contacts 122. The activation switch 168 is configured to be actuated, i.e., moved to the on position, when the robot 12 is docked with the docking station 14.

[0120] In one embodiment, the activation switch 168 may include an optical switch mounted to the PCBA 142 that is blocked by one of the spring-loaded charging contacts 122 when depressed to indicate the presence of the robot 12. A portion of one of the charging contacts 122 may travel through the hole 170 in the bracket 146 to block the optical switch.

[0121] As briefly mentioned above, the docking station 14 includes a plurality of emitters 124 that can emit at least one coded beam for detection by the robot 12. In one example, the emitters 124 are infrared emitters that radiate infrared light and / or near infrared light. The infrared emitters can emit coded infrared beams in a predetermined direction within a predetermined time period. As further described below, the emitters 124 are configured so that the coded beams are directed outward from the housing 120 in a plurality of different directions.

[0122] In the illustrated embodiment, the docking station 14 may include a plurality of infrared emitters 124 located on a PCBA 142 of the docking station 14. The emitters 124 are electrically connected to and controlled by components of the PCBA 142. In particular, the emitters 124 are controlled to emit light. The infrared emitters 124 may be infrared light emitting diodes (LEDs). Other embodiments of the infrared emitters 124 are possible. In some embodiments, the infrared emitters 124 operate using infrared or near infrared wavelengths, such as 920-960 nm, or 940 nm.

[0123] Fig.14One embodiment of a transmitter layout for a docking station 14 is shown. A plurality of transmitters 124 are provided, including a first or center transmitter 124C, a second or right transmitter 124R, and a third or left transmitter 124L. These transmitters 124C, 124R, 124L transmit signals that can be detected by the robot 12 and used to dock with and / or avoid the docking station 14, as described in further detail below. Additional transmitters may be provided to transmit avoidance or prevent entry signals that the robot 12 can use to avoid the docking station 14. Such transmitters may include a fourth or inboard right transmitter 124RI, a fifth or outboard right transmitter 124RO, a sixth or inboard left transmitter 124LI, and a seventh or outboard left transmitter 124LO. The outboard transmitters are disposed at or near the outside of the PCBA 142 to provide a wide range of prevent entry signals.

[0124] In at least some embodiments, the intermediate transmitters 124C, 124R, 124L are configured to transmit docking signals and may be referred to herein as docking signal transmitters, and the lateral transmitters 124RI, 124RO, 124LI, 124LO are configured to transmit no entry signals and may be referred to herein as no entry signal transmitters.

[0125] The emitter 124 is mounted behind the transparent or translucent portion of the housing 120. For example, the housing 120 may include a housing front 120F and a housing rear 120R coupled to the housing front 120F. The entire housing front 120F may be transparent or translucent to allow light signals to pass through. Alternatively, the housing front 120F may include an opaque portion and one or more transparent or translucent portions aligned with the emitter 124.

[0126] Fig.15 is along Figure 8 1-1 is a cross-sectional view through the docking station 14 taken along line XV-XV of FIG. An opaque shield 172 may be provided for one or more emitters 124 to direct light signals emitted from the emitter along a desired path, reduce light leakage, and / or define an emission area of ​​the emitter 124. In the illustrated embodiment, the shield 172 surrounds the center emitter 124C, the right emitter 124R, and the left emitter 124L.

[0127] A shield 172 is generally disposed in front of the PCBA 142, wherein the shield 172 includes a separate opaque housing for each emitter 124C, 124R, 124L. The shield 172 may extend at least partially or completely between the PCBA 142 and the housing front 120F or the rear block 138. The shield 172 may optionally be supported by, formed with, or otherwise attached to the PCBA bracket 146 using any suitable manufacturing and / or attachment method.

[0128] In one embodiment, the shield 172 may have a first opaque housing or shield segment 174C surrounding the center emitter 124C and defining a first light chamber 176C, a second opaque housing or shield segment 174R surrounding the right emitter 124R and defining a second light chamber 176R, and a third opaque housing or shield segment 174L surrounding the left emitter 124L and defining a third light chamber 176L.

[0129] Each shield segment 174C, 174R, 174L surrounds one emitter 124 to prevent undesirable overlap between signals emitted from each emitter 124. In at least some embodiments, the emitters 124 radiate infrared light and / or near infrared light, and the shield segments 174C, 174R, 174L may reflect and / or absorb the infrared light and / or near infrared light emitted from the emitters 124.

[0130] Each shield segment 174C, 174R, 174L includes a wall 178C, 178R, 178L, respectively, surrounding one emitter, and an aperture 180C, 180R, 180L, respectively, in the wall through which light from the emitter is emitted. Each wall 178C, 178R, 178L has a respective inner surface 182C, 182R, 182L facing the emitter 124C, 124R, 124L. At least the inner surface 182C, 182R, 182L (and optionally the entire wall 178C, 178R, 178L) is opaque to light emitted from the emitter 124 and can reflect light emitted from the emitter 124.

[0131] Some of the light emitted from the emitters 124C, 124R, 124L will pass directly through the apertures 180C, 180R, 180L. Due to light scattering and the position of the emitters relative to the walls 178C, 178R, 178L, at least some of the light emitted from the emitters 124C, 124R, 124L will be reflected. In the illustrated embodiment, the walls 178C, 178R, 178L may have concave interior surfaces 182C, 182R, 182L that direct reflections back toward the emitters 124C, 124R, 124L. With the concave interior surfaces 182C, 182R, 182L, all of the bounced light within each light chamber 176C, 176R, 176L is reflected back inwardly and captured in each respective shield segment 174C, 174R, 174L. Light emitted by the emitter 124 can pass substantially only through the apertures 180C, 180R, 180L having controlled overlap and sharp edges. Other shield profiles are possible that effectively eliminate unwanted reflections.

[0132] The walls 178C, 178R, 178L may be rounded or curved to provide a concave inner surface 182C, 182R, 182L, and may optionally have a convex outer surface 190C, 190R, 190L. Portions of the walls 178C, 178R, 178L may converge to be shared by more than one shroud segment 174C, 174R, 174L. Fig.16 As best shown in FIG. 1 , the inboard portion of wall 178R forming right shroud segment 174R may meet the right-hand portion of wall 178C forming center shroud segment 174C. The inboard portion of wall 178L forming left shroud segment 174L may meet the left-hand portion of wall 178C forming center shroud segment 174C.

[0133] The shield 172 may fit tightly around the emitters 124 to prevent light from escaping or scattering from between the shield 172 and the PCBA 142. Optionally, a seal 188 may be provided between the PCBA 142 and the shield 172 to eliminate any air gaps between the PCBA 142 and the shield 172. Eliminating any air gaps prevents light from the emitters 124 from leaking through manufacturing defects in the shield 172 and prevents mixing of signals from different emitters 124.

[0134] The seal 188 may be at least opaque to, and may optionally absorb, the wavelengths of light emitted by the emitter 124. In this way, only light that passes through the openings in the shield segment will be able to enter the translucent or transparent housing front portion 120F.

[0135] The seal 188 may include an aperture aligned with each emitter 124 so as not to block light emitted from the emitters. Fig.16As best shown in FIG. 1 , the seal 188 may have a segment between the apertures that abuts an end portion of each wall 178C, 178R, 178L to seal each light chamber 176C, 176R, 176L except for the apertures 180C, 180R, 180L. It should be noted that while one seal is shown, more than one seal may be provided, such as by providing a separate seal around each shroud segment.

[0136] Alternatively, if Fig.17 As shown, the shroud 172 may include extensions 194R, 194L on the second shroud segment 174R and the third shroud segment 174L. The extensions 194R, 194L may extend from the walls 178R, 178L adjacent to the apertures 180R, 180L. In one example, the extensions 194R, 194L may include walls extending radially from the circular or curved walls 178R, 178L. In other embodiments of the shroud 172, for example, Fig.16 In the embodiment shown, no extension is present.

[0137] Fig.17 is an optical simulation of the performance of the emitters 124C, 124R, 124L and the shield 172. Each emitter 124C, 124R, 124L has an emission zone, which may optionally overlap with each other, wherein at least one signal is emitted outwardly from the docking station 14. The first or center emitter 124C provides a center emission zone TC, the second or right emitter 124R provides a left emission zone TL, and the third or left emitter 124L provides a right emission zone TR.

[0138] The apertures 180C, 180R, 180L may define the direction of each emission zone. The center aperture 180C may be axially aligned with the center emitter 124C. This provides a signal emitted straight from the docking station 14 in the center emission zone TC. The right aperture 180R and the left aperture 180L may be radially offset from their respective emitters 124R, 124L to provide angled signals in the right emission zone TR and the left emission zone TL. It should be noted that due to this radial offset, the outer emission zones TR, TL intersect each other and the center zone TC. In addition, the right emitter 124R emits a signal toward the left hand side of the docking station 14, and the left emitter 124L emits a signal toward the right hand side of the docking station 14.

[0139] The apertures 180C, 180R, 180L define the angle of each emission zone. The central aperture 180C may define a narrower zone TC, and the right aperture 180R and the left aperture 180L may define wider zones TR, TL. The central zone TC may be 16-22 times narrower than the outer zones TR, TL. In one example, the zone TC may be about 3.4 degrees or less, alternatively about 2.6 degrees or less. In one example, the zones TR and TL may be about 57 degrees. However, with the cross configuration of these zones, the system may allow for wider angles. Emitting wider signals from the right transmitter 124R and the left transmitter 124L provides the robot 12 with a greater chance of encountering a docking signal emitted from the docking station 14. Emitting narrower signals from the center of the docking station 14 may be useful for more accurate navigation, because the robot 12 may follow the narrow center signal to accurately find the center of the docking station 14. The widths of the outer apertures 180R, 180L (and thus the angles of their respective emission zones) may be substantially the same as shown herein, or may be different. As discussed in more detail below, the range of the signal emitted within these zones TC, TR, TL may vary while the angle remains the same.

[0140] Each aperture 180C, 180R, 180L is defined by a first edge and a second edge of its respective wall 178. The edges are spaced apart to define the width of the aperture 180C, 180R, 180L and the angle of the emission zone. In the embodiment shown herein, the center aperture 180C is defined by a first edge 184C and a second edge 186C, the right aperture 180R is defined by a first edge 184R and a second edge 186R, and the left aperture 180L is defined by a first edge 184L and a second edge 186L. The first or outer edges 184R, 184L of the outer apertures 180R, 180L may be substantially aligned with the emitters 124R, 124L to provide a crisp outer edge 192L, 192R of their respective emission zones TL, TR. In one embodiment, the first or outer edges 184R, 184L of the outer apertures 180R, 180L may be orthogonal to the center of the emitters 124R, 124L.

[0141] refer to Figure 18 to Figure 19, the docking station 14 may transmit a plurality of signals that enable the robot 12 to find the docking station 14, navigate to and dock with the docking station 14, and / or avoid the docking station 14. In one embodiment, the docking station 14 may transmit at least one long-range or long docking signal LL, CL, RL, at least one short-range or short docking signal LS, CS, RS, and at least one prevent entry signal KO. Generally, when one or more receivers 116 of the robot 12 detect a long or short docking signal from the docking station 14, and if the robot 12 is actively or passively looking for the docking station 14 (for recharging or other docking purposes), it may change its route toward the docking station 14. When one or more receivers 116 of the robot 12 detect a prevent entry signal KO from the docking station 14, the robot 12 may change its route as needed to avoid the docking station 14. Further details of some embodiments of the docking method and the docking station avoidance method are provided below.

[0142] The long range or long docking signal LL, CL, RL may be used to discover the docking station 14. Since this signal has a longer range than the short signal, and optionally covers a wider area around the docking station 14, the robot 12 may detect the long docking signal before any other signal from the docking station 14, thereby “discovering” the docking station 14. The robot 12 may follow the long docking signal to a short signal or a stop entry signal, which may have a shorter and / or narrower range than the long docking signal.

[0143] The short range or short docking signals LS, CS, RS may be used to park the robot 12 at the docking station 14. Since this signal has a shorter range than the long docking signals LL, CL, RL, and optionally covers a narrower area around the docking station 14, the robot 12 may use the short signals for precise maneuvering to align with the docking station 14 and park or dock at the docking station 14.

[0144] The long docking signal and the short docking signal may be transmitted at a predetermined distance away from the docking station 14, which may be predetermined based on the geometric relationship between the charging contacts 82 and the TOF sensor 94 on the robot 12, the charging contacts 122 on the docking station 14, and the overall size of the robot 12 and the docking station 14. Thus, the robot 12 may detect the long docking signal at an appropriate distance away from the docking station 14 to perform the necessary maneuvers to dock without hitting the docking station 14 and to minimize or eliminate backtracking in order to successfully dock. In one embodiment, a range of one to ten feet (approximately 0.3m to 3.0m) is suitable for the long docking signal, and a range of one to three feet (approximately 0.3m to 0.9m) and alternatively a range of 12-18 inches (approximately 0.3m to 0.46m) is suitable for the short docking signal.

[0145] The no entry signal KO may be used by the robot 12 to avoid the docking station 14. When the robot 12 detects a no entry signal from the docking station 14, the robot 12 may change its route as needed to avoid the docking station 14. Alternatively, if the robot 12 is actively or passively seeking a docking station 14 (for recharging or other docking purposes), it may change its route to increase the likelihood of finding long-range and short-range docking signals.

[0146] The stop entry signal KO may have a shorter range than the long docking signal and the short docking signal so that the robot 12 can clean close to the docking station 14 but still provide sufficient clearance around the docking station 14. The stop entry signal KO may optionally have a wider range than the short docking signal to cover a larger area around the docking station 14. Depending on the application, the stop entry signal range may extend at least beyond the front and sides of the docking station 14, up to and beyond a few feet from the docking station 14. In one embodiment, a range of 12-18 inches (approximately 0.3m to 0.46m) provides enough room for the robot 12 to maneuver to avoid the docking station 14 while allowing the robot 12 to clean close to the docking station 14.

[0147] The signal may be provided by at least one infrared beam from at least one infrared emitter 124 of the docking station 14. In one embodiment, the signal is provided by multiple infrared beams from multiple infrared emitters 124 of the docking station 14. Typically, each infrared beam is encoded. The encoding method and binary code used for each infrared beam is selected so that the robot 12 can detect the presence of each beam and distinguish between beams, even if the robot 12 detects multiple beams from the docking station 14 simultaneously. Other signal types and encoding methods are possible.

[0148] refer to Fig.18 , the long range signals LL, CL, RL may be provided by multiple beams from multiple transmitters 124 and may cover the sides and front of the docking station 14. Alternatively, the long range signals LL, CL, RL may cover the front of the docking station 14, such as Fig. 20 shown.

[0149] In the illustrated embodiment, the left long range signal LL may be transmitted from the right transmitter 124R within the left transmission zone TL, the center long range signal CL may be transmitted from the center transmitter 124CR within the left transmission zone TL outward from the center of the docking station, and the right long range signal RL may be transmitted from the left transmitter 124L within the right transmission zone TR. Fig.18 In the illustrated coverage pattern, the left long range signal LL may be additionally transmitted from the left transmitters 124LI, 124LO. The right long range signal RL may be additionally transmitted from the right transmitters 124RI, 124RO.

[0150] refer to Fig.19 In the illustrated embodiment, a left short range signal LS may be transmitted from a right transmitter 124R within a left transmission zone TL, a center short range signal CS may be transmitted from a center transmitter 124CR within a left transmission zone TL outward from the center of the docking station, and a right short range signal RS may be transmitted from a left transmitter 124L within a right transmission zone TR.

[0151] At least some of the transmitters 124 alternate between long range signals and short range signals. For example, the signals may be alternated by switching the voltage level applied to the infrared LEDs. The intermediate or middle transmitters 124C, 124R, 124L may alternate between long range mode and short range mode to cyclically provide long range signals LL, CL, RL and short range signals LS, CS, RS. The cycle time of each transmitter 124C, 124R, 124L may be the same or different, i.e., the center transmitter 124C may have the same or different duty cycle than the outer transmitters 124R, 124L.

[0152] refer to Fig.19 , the no entry signal KO may be provided by multiple beams from multiple emitters 124, and may cover the sides and front of the docking station 14. In the illustrated embodiment, the no entry signal KO may be emitted toward the sides and front of the docking station 14 from the side emitters 124LO, 124LI, 124RO, 124RI.

[0153] Whenever a measurable level of infrared radiation from the stop entry signal KO is detected by one of the receivers 116 of the robot 12, the robot's docking station avoidance behavior may be triggered. In one embodiment, the robot 12 may perform one or more predetermined maneuvers, such as a combination of forward driving and turning, until the stop entry signal KO is no longer detected by any receiver 116, i.e., until the infrared radiation from the stop entry signal KO drops below a detectable level. The robot 12 may then resume cleaning.

[0154] Due to potential interference from sunlight and other infrared sources, the TOF sensor 94 of the robot 12 and the transmitter 124 of the docking station 14 both operate at the same frequency. Therefore, the TOF sensor 94 makes the robot 12 invisible to the long docking signal, the short docking signal, and the stop entry signal. Although counterintuitive to effective navigation, in some embodiments, the robot 12 can selectively turn off the TOF sensor 94 when docking with the docking station 14 or avoiding the docking station. At this time, the robot 12 relies on the passive infrared receiver 116 and the signal from the docking station 14 to navigate.

[0155] Figure 21 to Figure 23is a flow chart illustrating one embodiment of a method 300 for docking a robot 12 at a docking station 14. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, additional or intervening steps may be included, or the described steps may be divided into multiple steps without departing from the present invention.

[0156] At step 302, the robot is cleaning. During cleaning, the vacuum motor 50 and / or the brush motor 60 may be activated.

[0157] At step 304, the robot 12 checks if a return to dock event has occurred. A return to dock event is any event that causes the robot 12 to seek out the docking station 14. Examples of return to dock events include, but are not limited to, the battery being below a predetermined level, or the user having commanded the robot 12 to dock (e.g., pressing a dock button or home button on the robot 12 or on a mobile device). In the case where the docking station 14 will automatically empty the collection bin 46 and / or automatically fill a supply tank, the return to dock event may be a threshold level within the bin or tank.

[0158] In one embodiment, while the robot 12 performs a cleaning operation, the controller 30 continuously or intermittently monitors whether the remaining power level of the battery 80 is below a threshold. For example, the controller 30 may monitor the voltage of the battery 80 and determine whether the voltage of the battery 80 is less than a predetermined voltage. If so, the controller 30 records a return to docking event, and the robot 12 may automatically return to the docking station 14 to recharge the battery 80. For example, if the voltage of the battery 80 is less than a predetermined voltage, the robot 12 will automatically return to the docking station 14. The user may also input a command to the robot 12 to return to the docking station 14, for example, by inputting a command via the user interface 84 of the robot 12 or inputting a command via a smart phone, tablet, or other remote device.

[0159] If a return to docking event has not occurred, the robot 12 continues cleaning. If a return to docking event has occurred, the robot 12 may stop cleaning at step 306 and begin searching for docking signals LL, CL, RL, step 308. Stopping cleaning may include turning off the vacuum motor 50 and / or the brush motor 60.

[0160] At step 308, the robot 12 stops cleaning at step 306 and begins searching for a signal from the docking station 14. In one embodiment, the robot 12 may use a random movement behavior when searching, and the robot 12 may move randomly around the floor surface. If a wall is detected during the random movement, input from the wall following sensor 104 may be used to control the robot 12 to closely follow along the wall without contacting the wall. This may, for example, guide the robot 12 around the perimeter of the room and may allow the robot to pass through the room faster than if it were to move randomly. In other embodiments, the robot 12 may only use a random movement behavior when searching.

[0161] The robot 12 searches until a long docking signal LL, CL, RL is detected at step 310. It should be noted that the robot 12 may continue cleaning until a long docking signal is detected, rather than stopping cleaning after returning to a docking event.

[0162] Once the long docking signal LL, CL, RL is detected, the controller 30 may determine whether this is the first time the docking signal has been seen at step 312. This may include determining whether a particular receiver 116 has seen a particular docking signal or combination of docking signals, or whether a particular combination of receivers 116 has seen a particular docking signal or combination of docking signals.

[0163] If the robot 12 has not previously seen the detected docking signal, the method 300 proceeds to step 314 and the TOF sensor 94 may be turned off. As described above, due to potential interference from sunlight and other infrared sources, both the TOF sensor 94 and the docking station transmitter 124 operate at the same frequency. Although it is counterintuitive to turn off the TOF sensor 94 because it is used for navigation, if the TOF sensor 94 remains on, the robot 12 will essentially not see the docking station's signal and may crash into the docking station 14. Once the robot 12 is within range of the docking station signal, the robot 12 relies on the passive infrared receiver 116 instead of using the TOF sensor 94 to navigate. In the case where the receiver 116 covers the front, sides, and back of the robot 12 (see Figure 6 ), by tracking which receiver 116 detects a signal from a particular transmitter 124, the robot 12 can accurately determine its position relative to the docking station 14.

[0164] At step 316, the robot 12 rotates until at least one long docking signal LL, CL, RL is detected by both center receivers 116CR, 116CL. The robot 12 may perform a zero radius turn at the location where the long docking signal was detected at step 310. A zero radius turn may be performed by operating one drive wheel 64 in a forward direction ( Figure 3) and operating the other drive wheel 64 in the opposite direction. The robot 12 can turn left or right depending on whether the long docking signal is detected on the right or left side of the robot 12. Once at least one long docking signal is detected by both center receivers 116CR, 116CL, the robot 12 stops rotating.

[0165] Next, at step 318, the robot 12 drives forward until at least one short docking signal LS, CS, RS is detected. The robot 12 then determines where its charging contacts 82 are approximately positioned relative to the docking station 14 and, if necessary, performs appropriate maneuvers to position the charging contacts 82 toward the docking station 14. The relative position of the charging contacts 82 can be approximately calculated by determining which receiver 116 detected the center short docking signal CS from the docking station 14.

[0166] In the illustrated embodiment, the controller 30 determines at step 320 whether one of the rear receivers 116RR, 116RL detects the center short docking signal CS, and if so, the method proceeds to Fig.23 If not, the controller 30 determines at step 322 whether one of the side receivers 116SR, 116SL detects the center short docking signal CS, and if so, rotates 90 degrees, or substantially 90 degrees, to position the robot's charging contacts 82 toward the docking station 14 at step 324. For example, if the right side receiver 116SR detects the center short docking signal CS, the robot 12 turns left, and if the left side receiver 116SL detects the center short docking signal CS, the robot turns right. In either case, the robot 12 can perform a zero radius turn at this location.

[0167] If not detected by either side receiver 116SR, 116SL, the controller 30 determines at step 326 whether the center short docking signal CS is detected by one of the front receivers 116CR, 116CL, and if so, rotates 180 degrees, or substantially 180 degrees, to position the robot's charging contacts 82 toward the docking station 14 at step 328. For example, if the center short docking signal CS is detected by the center right receiver 116CR, the robot 12 turns left, and if the center short docking signal CS is detected by the center left receiver 116CL, the robot 12 turns right. In either case, the robot 12 can perform a zero radius turn at this location. If the center short docking signal CS is not detected by any receiver after step 326, the robot 12 can drive out and begin searching for a long docking signal again, returning to step 308.

[0168] Once the center short docking signal CS is detected and the charging contacts 82 of the robot are positioned toward the docking station 14, the method proceeds to step 336, and the robot 12 performs a scan to calculate the heading to the docking station 14. The calculated heading to the docking station 14 may be a position where the robot is substantially aligned with the docking station 14, so that the robot 12 can be driven back to cooperate with the docking station 14, and the position where the robot 12 can leave the docking station 14 at the beginning of a planned cleaning or after charging. Performing a scan may include rotating left and right from the current position of the robot by a predetermined angle, such as rotating ±90 degrees, alternatively rotating ±45 degrees, alternatively rotating ±20 degrees. The robot 12 may perform a zero radius turn for the scan.

[0169] Once the heading is calculated, the robot 12 rotates to that heading at step 338. Next, the robot 12 more accurately determines where its charging contacts 82 are located relative to the docking station 14 and, if necessary, performs appropriate maneuvers to align the charging contacts 82 with the docking station 14. The relative position of the charging contacts 82 can more accurately determine which rear receiver 116RR, 116RL detects the center short docking signal CS from the docking station 14.

[0170] In the illustrated embodiment, the controller 30 determines at step 340 whether the center short docking signal CS is detected by the left rear receiver 116RL but not the right rear receiver 116RR, and if so, the method proceeds to step 342, where the robot 12 makes an arcuate movement to the left. If not, the controller 30 determines at step 344 whether the center short docking signal CS is detected by the right rear receiver 116RR but not the left rear receiver 116RL, and if so, the method proceeds to step 346, where the robot 12 makes an arcuate movement to the right. To make an arcuate movement to the left or right, the robot 12 can move by operating one drive wheel 64 at a first speed in the opposite direction ( Figure 3 ) and operating the other drive wheel 64 in the opposite direction at a second speed different from the first speed to drive backward, thereby causing a turn greater than a zero radius. Depending on whether the robot 12 is moving in an arc to the left or right, the second speed may be greater than or less than the first speed to move the robot 12 to the left or right. These steps 340 to 346 are looped until the center short docking signal CS is detected by both rear receivers 116RR and 116RL. Once both rear receivers 116RR, 116RL detect the center short docking signal CS, the method proceeds to step 348.

[0171] At step 348, the robot 12 returns to the docking station 14. The robot 12 may move straight from its current position back to the docking station 14. For example, the robot 12 may operate the two drive wheels 64 in opposite directions ( Figure 3). The robot 12 may move in the reverse direction until the robot's charging contacts 82 make positive electrical contact with the docking station charging contacts 122.

[0172] In step 350, once the robot 12 reaches the docking station 14, the robot 12 performs a back-and-forth rotation or nuzzling to determine when it is "square" to the docking station 14, that is, when the charging contacts 82, 122 are aligned. To perform the nuzzling, the robot 12 rotates in one direction until it reaches a first position in which its charging contacts 82 do not contact the docked charging contacts 122. At this point, the robot 12 records a loss of charge. The robot 12 then rotates in the opposite direction until it reaches a second position in which its charging contacts 82 again do not contact the docked charging contacts 122. At this point, the robot 12 again records a loss of charge. The controller 30 then determines a midpoint position between the first position and the second position. The midpoint position can be a position at or near the middle of the first position and the second position, or equidistant from each of the first position and the second position. Finally, the robot 12 rotates to the midpoint position to complete step 350.

[0173] At step 352, the controller 30 determines whether the robot 12 has been successfully docked and the battery 80 is charging. If so, docking is complete and the method 300 ends. If not, at step 354, the controller 30 determines whether a predetermined number X of docking attempts have been made without success. In one example, the predetermined number X may be three attempts. If a predetermined number X of docking attempts have been made without success, the method proceeds to step 356 and the robot 12 issues a docking error notification. The docking error notification may be a visual notification on the display 86 or elsewhere on the robot 12, or an audible notification from the robot 12. Additionally or alternatively, the docking station 14 may issue a docking error notification.

[0174] If less than the predetermined number X of docking attempts have been made, the method proceeds to step 358, where the controller 30 determines whether any docking signal has been detected within a threshold time and whether the return distance traveled by the robot at step 348 is less than a threshold distance. In one embodiment, the threshold time may be 10 to 20 seconds, and the threshold distance may be 500 mm or less. If both the time and distance values ​​are within their respective thresholds, the method returns to step 350, and the robot 12 retries the rubbing maneuver to attempt to establish a charge. If either threshold is met or exceeded, the method returns to step 308 ( Fig.21 ) and start searching for a docking signal again.

[0175] In some embodiments, the robot 12 may use data from a previous docking to navigate to the docking station 14, rather than relying on a docking signal. This may shorten the amount of time it takes for the robot 12 to successfully dock, and may conserve battery life. Fig.21 If, at step 312, the robot 12 has previously seen the detected docking signal, the method 300 may proceed to step 330, such as Fig. 22 As shown, and using a docking action lookup table to navigate toward the docking station 14. The docking action lookup table can be an array or matrix of data that pairs the robot's receiver 116 with docking signals previously detected by the receiver 116, and the value returned is the action taken given the combination of the detected signal and the one or more receivers that detected the signal. The data that makes up the lookup table can be historical data saved from one or more previous dockings. The docking action lookup table can be stored in the memory 68 of the robot 12 and accessed by the controller 30.

[0176] The robot 12 navigates using the docking motion lookup table until a short docking signal LS, CS, RS is detected at step 332. The TOF sensor 94 may be turned off before or during step 332. Once a short docking signal is detected, the controller 30 continues to use the docking motion lookup table to navigate toward the docking station 14 at step 334. The method may then proceed to step 320 ( Fig.21 ), wherein the robot 12 determines which receiver 116 detected the center short docking signal CS, and the method 300 can continue as previously described.

[0177] Figures 29 to 34 The robot 12 is shown according to Figure 21 to Figure 23 An example of a docking method for docking with the docking station 14. Fig.29 The overall path P of the robot 12 to the docking station 14 is generally shown. Fig.30 The robot 12 is shown searching and detecting a long docking signal, which in this example is shown as a left long docking signal LL, in accordance with steps 308 to 310 of the method 300, and then rotating in accordance with step 316 until the long docking signal LL is detected by the center receiver 116CR or the front receiver 116CL. Fig.31 The robot 12 is shown driving according to steps 318 to 328 of the method 300 until a short docking signal is detected, which in this example is shown as a left short docking signal LS, and then turns to a center short signal CS. Fig.31 , the robot 12 detects the center short signal CS on the left receiver 116SL and therefore turns right approximately 90 degrees. Fig.31 Also shown in dashed lines is a second robot 12 ′ which, in the example shown, detects the right short signal RS on the right receiver 116SR and therefore turns approximately 90 degrees to the right. Fig.32 The robot 12 is shown scanning the center short signal CS to calculate a heading to the docking station 14 and rotating to the calculated heading according to steps 336 to 338 of the method 300 . Fig.33 The robot 12 is shown returning to the docking station 14 in accordance with steps 340 through 348 of the method 300 while making arcuate motions to the left or right as needed to maintain the center short docking signal CS within range of the rear receivers 116RR, 116RL. Fig.34 The robot 12 is shown executing steps 318 to 352 of the method 300, including driving toward the docking station 14 in (a), turning to position its charging contacts 82 toward the docking station 14 in (b), returning to the docking station 14 in (c) to (d), performing rubbing in (e) to (f), and completing docking in (g).

[0178] Fig.24 1 is a flow chart illustrating one embodiment of a method 400 for re-docking a robot 12 at a docking station 14 after a loss of charge. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, may include additional or intervening steps, or the described steps may be split into multiple steps without departing from the invention.

[0179] After successful docking, the robot 12 may lose charging contact with the docking station 14, for example if the robot 12 or the docking station 14 is bumped. Once successfully docked, the robot 12 may continuously or intermittently monitor whether the robot 12 remains docked. At step 402, if the robot 12 is docked, the controller 30 next determines at step 404 whether the battery is charging or has lost charge.

[0180] If charge has been lost, the method proceeds to step 406, where the robot is driven a predetermined distance D away from the docking station 14. The predetermined distance D may be a distance that will keep the robot 12 within the range of the short docking signals LS, CS, RS. In one example, the predetermined distance D may be in the range of one to three feet (approximately 0.3m to 0.9m), alternatively in the range of one to two feet (approximately 0.3m to 0.6m), and alternatively in the range of 12-18 inches (approximately 0.3m to 0.46m). To drive away from the docking station 14, the robot 12 may operate both drive wheels 64 in a forward direction ( Figure 3 ) for a predetermined time or number of re-estimates.

[0181] Next, at step 408, the robot 12 performs a scan to attempt to detect the center short docking signal CS. Performing a scan may include turning left and right by a predetermined angle from the robot's current position, such as ±90 degrees, alternatively ±45 degrees, alternatively ±20 degrees. The robot 12 may perform a zero radius turn to perform the scan.

[0182] During the scan, at step 410, the robot 12 monitors the detection of the center short docking signal CS by one of the rear receivers 116RR, 116RL. If the center short docking signal CS is detected by either rear receiver 116RR, 116RL during the scan, then at step 412, the robot 12 calculates a path that will move the center of the robot 12 to the current position of the rear receiver 116RR, 116RL that detected the center short docking signal CS. The calculated path may include rotation instructions, such as the direction to rotate the robot 12 (e.g., left or right) and the degree of rotation. The path may additionally or alternatively include translation instructions, such as how far to drive the robot 12 backward or how far to drive the robot 12 forward. For Figure 6 For the illustrated embodiment of the robot 12 , in which the rear receivers 116RR, 116RL are positioned substantially near the outer edge of the robot 12 , the path may be an overall translation of less than half the width of the robot 12 .

[0183] At step 414, the robot 12 may continue scanning while monitoring for detection of a center short docking signal CS. If at step 414, the scan is completed without finding a center short docking signal CS, the method 400 proceeds to step 416 and determines whether any docking signals were detected during the scan. If no docking signals were detected, the method 400 may proceed to step 424 and the robot 12 issues a docking error notification. The docking error notification may be a visual notification on the display 86 or elsewhere on the robot 12, or an audible notification issued from the robot 12. Additionally or alternatively, the docking station 14 may issue a docking error notification.

[0184] If one or more docking signals are detected during the scan, the method 400 may proceed to step 418 and estimate a path that will move the center of the robot to align with the center of the docking station 14. The path may be estimated based on which side of the robot more docking signals were detected during the scan. Based on which receivers detected the docking signals, the robot 12 may estimate its orientation relative to the docking station 14, and the estimated path may be a predetermined path based on the estimated orientation of the robot that may reliably align the robot 12 with the center of the docking station 14.

[0185] The estimated path may include rotation instructions, such as the direction (e.g., left or right) and degree of rotation of the robot 12. The path may additionally or alternatively include translation instructions, such as how far to backdrive the robot 12 or how far to drive the robot 12 forward.

[0186] From the path calculation at step 412 or the path estimation at step 418, the method 400 proceeds to step 420 and the robot 12 executes the path. If the path includes both rotation instructions and translation instructions, the robot 12 may first execute the rotation instructions and then the translation instructions. After executing the path, the robot 12 should be in a position where the center of the robot is aligned with the docking station 14.

[0187] Next, at step 422, the robot 12 turns to position its charging contacts 82 toward the docking station 14. Because the robot 12 should be centered on the docking station 14, at step 422, the robot 12 may rotate ±180 degrees, or substantially 180 degrees.

[0188] Method 400 then proceeds to step 348 of docking method 300 ( Fig.23 ), and begins the final docking procedure to attempt to reestablish charging.

[0189] Fig.25 is a flow chart illustrating one embodiment of a method 500 for low power charging of a robot 12 via a docking station. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, may include additional or intervening steps, or the steps described may be divided into multiple steps without departing from the invention.

[0190] In one embodiment, when the robot 12 is docked, the docking station 14 is configured to operate in a wake-up mode and a sleep mode, and wherein the docking station is further configured to enter the sleep mode and stop charging the battery 80 after fully charging the battery 80, and resume charging the battery 80 after switching from the sleep mode to the wake-up mode. In such an embodiment, the docking station 14 may also be configured to resume the sleep mode once the battery 80 is fully charged (i.e., fully charged).

[0191] After the battery 80 of the robot 12 is fully charged, it will slowly discharge even when the robot 12 is idling on the docking station 14. In one embodiment, instead of just continuously "charging" the battery 80, the docking station 14 can optionally enter a sleep mode and periodically wake up to charge the battery 80. The sleep mode can last for a predetermined period of time, also referred to herein as the sleep time. That is, after the sleep time has passed to allow the battery 80 to be fully charged, the docking station 14 will wake up from the sleep mode.

[0192] Optionally, the user can select the length of the sleep time. For example, the docking station 14 may have a default sleep time, such as one hour or another time period, and the user may optionally change the sleep time from the default setting. Energy-saving conscious users may, for example, select a sleep time that is longer than the default time. In one embodiment, the docking station 14 may operate at least in a high-power charging mode with a first sleep time or a low-power charging mode with a second sleep time that is longer than the first sleep time. In a non-limiting example, the first sleep time may be one hour, and the second sleep time may be 30 hours. The docking station 14 may have an additional charging mode between the high-power mode and the low-power mode, and accordingly, it has a sleep time between the first sleep time and the second sleep time. The charging mode may be selected by a user on the docking station 14, or using a mobile device that is operably in communication with the docking station 14, such as a smart phone or a tablet computer.

[0193] In one embodiment, the user may perform a sequence of events on the docking station 14, such as by pressing one of the charging contacts 122P, 122N a predetermined number of times within a predetermined time period (e.g., pressing the upper charging contact 122P three times within two seconds) to cycle the sleep time between the first sleep time and the second sleep time or between the modes.

[0194] If the robot 12 is successfully docked at step 502, the docking signal is turned off at step 504. For example, the transmitter 124 may be disabled.

[0195] The docking station 14 is initially in wake-up mode at step 506. In wake-up mode, full power is applied to the charging contacts 122 at step 508. With full power applied from the docking station contacts 122 to the charging contacts 82 of the robot, the battery 80 is charged at a first higher rate and the battery 80 is charged from the A / C power outlet 16 ( Figure 1 ) or other household power sources to draw more energy.

[0196] Next, the robot 12 determines whether the remaining power level of the battery 80 is at or above a threshold. The threshold may be >99% capacity (i.e., fully charged). If so, the docking station 14 may go to sleep. In the illustrated embodiment, to determine whether the remaining power level of the battery 80 is at or above a threshold, the robot 12 may sample the voltage on its charging contacts 82 at step 510. If the voltage is below the full battery threshold, the docking station 14 continues to charge the robot 12 in wake mode (i.e., at full power). If the voltage is at or above the full battery threshold, the docking station 14 may go to sleep.

[0197] At step 514, the docking station 14 starts a sleep timer, and the docking station 14 ends the sleep mode at step 516. In the sleep mode, the docking station 14 applies low power to the charging contacts 122 at step 518. With low power applied from the docking station contacts 122 to the charging contacts 82 of the robot, the battery 80 charges more slowly, thereby saving energy.

[0198] In sleep mode, the docking station 14 may monitor whether the robot 12 remains docked. In one example, if the activation switch 168 remains closed, the docking station 14 assumes that the robot 12 is docked. If the robot 12 undocks, such as if the activation switch 168 is open, the method 500 ends. If the robot 12 remains docked when the sleep timer expires at step 522, the method 500 returns to step 510, and the robot 12 determines whether the remaining power level of the battery 80 is at or above a threshold, such as by sampling the voltage on its charging contacts 82. If the voltage is at or above the full battery threshold, the docking station 14 restarts the sleep timer at step 514, and the docking station 14 may remain asleep at step 514. If the voltage is below the full battery threshold, the docking station 14 may wake up at step 506, and may apply full power at step 508. Upon re-entering the wake-up mode, the system 10 may alert the user that the robot 12 is charging at full power, such as by illuminating an indicator light on the robot 12 or docking station 14, displaying an icon on the user interface of the robot 12, or sounding an audible alarm.

[0199] Fig.26 is a flow chart illustrating one embodiment of a method 600 for docking station avoidance performed by the robot 12. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, may include additional or intervening steps, or the described steps may be separated into multiple steps without departing from the invention.

[0200] At step 602, the robot is cleaning. During cleaning, the vacuum motor 50 and / or the brush motor 60 may be activated.

[0201] At step 604, the robot 12 detects the long docking signal LL, CL, RL. This signals to the robot 12 that the docking station 14 is nearby. The robot 12 then takes steps to avoid the docking station 14. Before starting the avoidance steps, at step 606, the robot 12 may optionally stop cleaning. This may save battery life while the robot 12 navigates around and / or away from the docking station 14. Stopping cleaning may include turning off the vacuum motor 50 and / or the brush motor 60.

[0202] The method 600 proceeds to step 608 and the TOF sensor 94 may be turned off. The robot 12 now relies on the passive infrared receiver 116 and the docking signal to avoid the docking station 14.

[0203] Various avoidance behaviors may be performed by the robot 12. In the illustrated embodiment, at step 610, the robot 12 drives straight and determines whether at least one no-entry signal KO is detected by the front receivers 116CR, 116CL. If so, it may be assumed that the robot 12 is driving straight toward the docking station. Alternatively, the robot 12 may drive straight until at least one no-entry signal KO is detected or until the robot encounters an obstacle.

[0204] At step 612, if the entry block signal KO is detected, the robot 12 rotates 180 degrees, or substantially 180 degrees, to turn away from the docking station 14. Alternatively, the robot 12 may rotate 180 degrees ± n degrees, where n is a randomly generated number from 0 to 20. Using a randomly generated number can prevent the robot 12 from repeatedly jamming the drive in the same pattern. The robot 12 then resumes cleaning at step 622.

[0205] If, at step 610, no stop entry signal is detected by the front receivers 116CR, 116CL, the method 600 proceeds to step 614, and the robot 12 turns left and determines whether at least one stop entry signal KO is detected by the front left receiver 116CL. When turning left, the robot 12 may perform a zero radius turn of approximately 90 degrees up to 180 degrees. If a stop entry signal KO is detected by the front left receiver 116CL, it may be assumed that the docking station 14 is on the left side of the robot 12. At step 616, the robot 12 turns right 90 degrees or substantially 90 degrees so as to turn away from the docking station 14. Alternatively, the robot 12 may rotate 90 degrees ± n degrees, where n is a randomly generated number from 0 to 20. The robot 12 then resumes cleaning at step 622.

[0206] If, at step 614, no stop entry signal is detected by the front left receiver 116CL, the method 600 proceeds to step 618, and the robot 12 turns right and determines whether at least one stop entry signal KO is detected by the front right receiver 116CR. When turning right, the robot 12 may perform a zero radius turn of approximately 90 degrees up to 180 degrees. If a stop entry signal KO is detected by the front right receiver 116CR, it may be assumed that the docking station 14 is on the right side of the robot 12. At step 620, the robot 12 turns left 90 degrees, or substantially 90 degrees, to turn away from the docking station 14. Alternatively, the robot 12 may rotate 90 degrees ± n degrees, where n is a randomly generated number from 0 to 20. The robot 12 then resumes cleaning at step 622.

[0207] It should be noted that during the avoidance method 600, there may be a situation where the robot turns left and the stop entry signal KO is detected by the front right receiver 116CR, or the robot turns right and the stop entry signal KO is detected by the front left receiver 116CL. This situation is illogical and may be caused by the reflection of the stop entry signal KO from a nearby object. As such, the robot 12 may ignore this input.

[0208] Fig. 27 is a flow chart illustrating one embodiment of a method 700 for obstacle response during docking performed by the robot 12. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it is understood that the steps may be performed in a different logical order, additional or intermediate steps may be included, or the described steps may be separated into multiple steps without departing from the invention.

[0209] During docking or re-docking, for example when following Figure 21 to Figure 24 When performing the method outlined in FIG. 7 , the robot 12 may encounter an obstacle. The obstacle response method 700 is one embodiment of a process that the robot 12 may follow in order to effectively avoid obstacles and restore docking with minimal time and / or battery life spent.

[0210] At step 702, the robot 12 follows at least one docking signal transmitted by the docking station 14 to dock or re-dock with the docking station 14. At step 704, if the robot 12 successfully docks while following the docking signal, the method 700 ends. If not, the robot 12 continues to follow the docking signal. If an obstacle is detected by the robot 12 while following the docking signal at step 706, the method 700 proceeds to step 708, and the robot 12 temporarily ignores all docking signals from the docking station 14.

[0211] In one embodiment, obstacles may be detected based on input from a collision sensor 102 or a steep wall sensor 106. For the purposes of the obstacle response method 700, an obstacle may include any obstacle recorded on one of the collision sensors 102 or an excessive drop or steep wall recorded on one of the steep wall sensors 106. It should be noted that in at least some embodiments, the TOF sensor 94 may be turned off for docking or re-docking. Thus, when the robot 12 follows the docking signal at step 702, the TOF sensor 94 does not provide input for obstacle detection. In other embodiments where at least one distance sensor 94 does not include a TOF sensor, input from the distance sensor 94 may be used to detect obstacles.

[0212] Next, while ignoring all docking signals, the robot 12 performs obstacle avoidance behavior at step 710. The obstacle avoidance behavior may be selected by the controller 30 based on input from one or more sensors that detect an obstacle. For example, the robot 12 may change direction (e.g., reverse and / or turn) or begin a wall following routine. During step 710, the robot 12 may modify, update, or change the obstacle avoidance behavior based on updated input from one or more sensors regarding encountered obstacles or new obstacles.

[0213] The robot 12 may continue to ignore all docking signals and perform obstacle avoidance behaviors at step 712 until the obstacle is avoided. The controller 30 may determine that the obstacle has been avoided based on the sensor input. Once the obstacle has been avoided, the method 700 may proceed to step 702 and the robot 12 may continue to follow the docking signal from the docking station 14. It should be noted that in some embodiments, if the obstacle avoidance behavior has moved the robot 12 out of range of all docking signals, the robot 12 may need to search for a docking signal once the obstacle has been avoided, as described above with respect to the docking method 300 ( Fig.21 ) as described in step 308.

[0214] Fig.28 is a flow chart illustrating one embodiment of a method 800 for approach docking performed by the robot 12. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, may include additional or intervening steps, or the described steps may be divided into multiple steps without departing from the invention.

[0215] A return to docking event may sometimes occur when the robot 12 is already within range of the short-range docking signal. For example, a user may set the robot 12 to approach the docking station 14 and command the robot 12 to dock. Normally, the proximity of the docking station 14 may make it difficult for the robot to follow the previously described docking method 300. In step 802, after a return to docking event, if the robot first detects the short docking signals LS, CS, RS in step 804, i.e., before detecting the long docking signals, the robot 12 will follow the proximity docking method 800. In step 806, the TOF sensor 94 may be turned off. The robot 12 now relies on the passive infrared receiver 116 and the short docking signals LS, CS, RS to dock with the docking station 14. The method then proceeds to step 320 of the normal docking method 300 ( Fig.21 ), wherein the robot 12 determines which receiver 116 detected the center short docking signal CS, and docking can continue as previously described.

[0216] To the extent not yet described, the different features and structures of the various embodiments of the present invention can be used in combination with each other as needed, or can be used alone. An autonomous floor cleaning system, robot or docking station is shown here as having the described features does not mean that all these features must be used in combination, but is done here for the simplicity of description. The disclosed docking station can be provided independently of the disclosed robot, and vice versa. It should be noted that although methods 300, 400, 500, 600, 700, 800 are described with respect to system 10, robot 12 and docking station 14, methods 300, 400, 500, 600, 700, 800 are also applicable to other robots and docking stations. In addition, although a variety of methods are disclosed herein, one of the disclosed methods can be performed independently, or more than one of the disclosed methods (including any combination of the methods disclosed herein) can be performed by a robot or docking station. Therefore, the various features of different embodiments can be mixed and matched in various cleaning equipment configurations as needed to form new embodiments, regardless of whether the new embodiments are explicitly described.

[0217] The above description relates to general and specific embodiments of the present disclosure. However, various changes and variations may be made without departing from the spirit and broader aspects of the present disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. Therefore, the present disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the present disclosure or limiting the scope of the claims to the specific elements shown or described in conjunction with these embodiments. Any reference to a singular element, such as the use of the article "one", "the", "the" or "said" should not be interpreted as limiting the element to the singular.

[0218] Likewise, it should also be understood that the appended claims are not limited to the expressions and specific components or methods described in the detailed description, which may vary between specific embodiments falling within the scope of the appended claims. With respect to any Markush group relied upon herein to describe specific features or aspects of various embodiments, different, special and / or unexpected results may be obtained from each member of the corresponding Markush group independent of all other Markush members. Each member of the Markush group may be relied upon individually and / or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

Claims

1. A docking station for an autonomous floor cleaner, characterized in that The docking station comprises: a housing having a bottom side on which the docking station rests; charging contacts disposed on the housing, the charging contacts being configured to charge a battery of the autonomous floor cleaner; a docking signal transmitter within the housing configured to transmit an optical signal detectable by the autonomous floor cleaner, wherein the housing includes a portion aligned with the docking signal transmitter, the portion being one of transparent and translucent to allow the transmitted optical signal to pass through the portion; and a shield within the housing, the shield comprising a plurality of opaque shells, each of the plurality of opaque shells surrounding one of the docking signal transmitters; at least one of the plurality of opaque housings comprises a wall surrounding one of the docking signal transmitters and an aperture in the wall through which light can be emitted, the aperture defining a direction and angle of an emission zone for one of the docking signal transmitters, The shield includes a plurality of walls and a plurality of apertures, wherein a first aperture of the plurality of apertures is narrower than a second aperture of the plurality of apertures, the first aperture defining a first emission region, the first emission region being narrower than a second emission region defined by the second aperture, The first aperture is axially aligned with a first one of the docking signal transmitters so that a signal from the first one of the docking signal transmitters can be emitted straight from the docking station in the first emission region; and the second aperture being offset from a second one of the docking signal transmitters so that a signal from the second one of the docking signal transmitters can be transmitted from the docking station at an angle in the second transmission zone; and The second emission region intersects with the first emission region.

2. The docking station according to claim 1, characterized in that: The docking signal transmitter includes an infrared transmitter that radiates at least one of infrared light and near-infrared light, and the wall includes an inner surface that reflects at least one of the infrared light and the near-infrared light.

3. The docking station according to claim 2, characterized in that: The wall includes a concave interior surface that directs reflected light back toward one of the docking signal transmitters.

4. The docking station according to claim 3, characterized in that: The wall includes a convex outer surface.

5. The docking station according to claim 4, characterized in that: The shroud includes an extension extending radially from the wall adjacent the aperture.

6. The docking station according to claim 1, characterized in that The docking station includes a printed circuit board assembly having circuitry for supplying appropriate voltage and current to the autonomous floor cleaner via the charging contacts when the autonomous floor cleaner is docked, wherein the docking signal transmitter is electrically connected to and controlled by the printed circuit board assembly.

7. The docking station according to claim 6, characterized in that: The docking station includes a seal between the printed circuit board assembly and the shroud, wherein the seal is opaque to a wavelength of light emitted by the docking signal transmitter.

8. The docking station according to any one of claims 1 to 7, characterized in that: The aperture is defined by a first edge of the wall and a second edge of the wall, the first edge and the second edge being spaced apart to define a width of the aperture, wherein the first edge of the aperture is aligned with one of the docking signal transmitters to provide a clear outer edge to the emission area, and the second edge of the aperture is offset from one of the docking signal transmitters.

9. The docking station according to any one of claims 1 to 7, characterized in that: The docking signal transmitter is capable of transmitting at least one long-range docking signal and at least one short-range docking signal, the at least one short-range docking signal having a shorter range than the at least one long-range docking signal.

10. The docking station according to any one of claims 1 to 7, characterized in that: The docking station includes a no-entry signal transmitter within the housing, the no-entry signal transmitter configured to transmit a no-entry signal detectable by the autonomous floor cleaner, wherein the no-entry signal transmitter is not surrounded by the shield.

11. The docking station according to any one of claims 1 to 7, characterized in that: The docking station comprises: a spring biasing the charging contact to a neutral position corresponding to a condition where the autonomous floor cleaner is not docked with the docking station, the charging contact being movable to a contact position corresponding to a condition where the autonomous floor cleaner is docked with the docking station; and an activation switch to control the supply of power to the charging contacts, the activation switch being configured to be actuated by at least one of the charging contacts being in the contact position; Wherein, the housing comprises a rear block, and the charging contact is located on the rear block.

12. A docking station for an autonomous floor cleaner, characterized in that The docking station comprises: a housing having a bottom side on which the docking station rests; charging contacts disposed on the housing, the charging contacts being configured to charge a battery of the autonomous floor cleaner; A plurality of docking signal transmitters within the housing are configured to transmit optical signals detectable by the autonomous floor cleaner, the plurality of docking signal transmitters comprising: a central transmitter configured to transmit at least one optical signal within a first transmission area; a right transmitter disposed on a side of the central transmitter and configured to transmit at least one optical signal within a second transmission area; and a left transmitter, disposed on a side of the central transmitter and configured to transmit at least one optical signal within a third transmitting area; The shield in the housing comprises: a central shield segment surrounding the central emitter and defining a first light chamber, the central shield segment comprising an opaque first wall surrounding the central emitter and a first aperture in the first wall through which light can be emitted, the first aperture defining a direction and angle of the first emission area; a right shield segment surrounding the right emitter and defining a second light chamber, the right shield segment comprising an opaque second wall surrounding the right emitter and a second aperture in the second wall through which light can be emitted, the second aperture defining a direction and angle of the second emission area; and a left shield segment surrounding the left emitter and defining a third light chamber, the left shield segment comprising an opaque third wall surrounding the left emitter and a third aperture in the third wall through which light can be emitted, the third aperture defining a direction and angle of the third emission area, The first aperture is axially aligned with the central transmitter so that a signal from the central transmitter can be emitted straight from the docking station in the first transmission area; The second aperture is offset from the right transmitter so that the second transmission zone intersects the first transmission zone and the third transmission zone and enables signals from the right transmitter to be transmitted from the docking station at an angle in the second transmission zone; and The third aperture is offset from the left transmitter such that the third transmission zone intersects the first transmission zone and the second transmission zone and enables signals from the left transmitter to be transmitted from the docking station at an angle in the third transmission zone.

13. The docking station according to claim 12, characterized in that The first aperture is narrower than the second aperture and the third aperture, and the first emission area is narrower than the second emission area and the third emission area.

14. The docking station according to claim 12, characterized in that The docking station includes at least one no-entry signal transmitter configured to transmit a no-entry signal detectable by the autonomous floor cleaner, wherein the at least one no-entry signal transmitter is not surrounded by the shield.

15. A method for docking an autonomous floor cleaner with a docking station according to claim 1 or 12, the autonomous floor cleaner having a plurality of distance sensors configured to detect obstacles, the method comprising: recording a return to docking event at the autonomous floor cleaner; searching for a docking signal transmitted by the docking station; upon detecting a first docking signal transmitted by the docking station, turning off the plurality of distance sensors of the autonomous floor cleaner; receiving, with at least one passive receiver of the autonomous floor cleaner, at least one other docking signal transmitted by the docking station; driving the autonomous floor cleaner toward the docking station based on the at least one other docking signal received by the at least one passive receiver; manipulating the autonomous floor cleaner to align charging contacts on the autonomous floor cleaner with charging contacts on the docking station; as well as The autonomous floor cleaner is docked with the docking station.

16. The method according to claim 15, comprising: upon determining that charging contact between the autonomous floor cleaner and the docking station is lost, driving the autonomous floor cleaner away from the docking station; realigning the autonomous floor cleaner with the docking station based on at least one short-range docking signal received by the at least one passive receiver; as well as Re-docking the autonomous floor cleaner with the docking station.

17. The method according to claim 15 or 16, comprising: charging a battery of the autonomous floor cleaner; entering a sleep mode of the docking station and reducing power applied to the charging contacts of the docking station; as well as The docking station is awakened after a sleep time and full power is applied to the charging contacts of the docking station.

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