AUTONOMOUS MOTION SYSTEM
Patent Information
- Application Number
- DE102024128709
- Authority / Receiving Office
- DE · DE
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-10-10
- Filing Date
- 2024-10-04
- Publication Date
- 2025-04-10
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
TECHNICAL FIELDThe disclosure herein relates to an autonomous motion system.BACKGROUNDU.S. patent application publication number US 2013 / 0 006 418 A1 describes an autonomous motion system. The autonomous moving system includes a work robot configured to perform an operation while autonomously moving in a work area, and a charging station configured to allow the work robot to dock thereon and charge the work robot. The work robot includes a work unit configured to perform the operation, a moving unit configured to move the work robot, a moving motor configured to drive the moving unit, a battery configured to be charged at the charging station and supply power to the moving motor, a control unit configured to control the moving motor, and a robot power receiver configured to receive power for charging the battery from the charging station while the work robot is docked to the charging station. The charging station includes a station power transmitter configured to supply the power for charging the battery to the robot power receiver, and a station plate placed on the ground. When the work robot is docked to the charging station and is in a non-chargeable state in which it is not possible to start charging to the battery, the control unit executes a docking retry process for moving the work robot by the moving unit and docking the work robot to the charging station again.SUMMARY OF THE DISCLOSUREIn autonomous motion systems such as the one described above, it is desirable that the docking retry process be efficiently performed. The disclosure herein provides a technology that enables a docking retry process to be efficiently performed.An autonomous movement system disclosed herein may include: a work robot configured to perform an operation (operation) while autonomously moving in a work area; and a charging station configured to charge the work robot and allow the work robot to dock thereto. The work robot may include: a work unit configured to perform the operation; a moving unit configured to move the work robot; a moving motor configured to drive the moving unit; a battery configured to be charged at the charging station and supply power to the moving motor; a control unit configured to control the moving motor; and a robot power receiver configured to receive (receive) power for charging the battery from the charging station while the work robot is docked to the charging station. The charging station may include: a station power transmitter configured to supply the power for charging the battery to the robot power receiver; and a station plate placed on a floor. When the work robot is docked to the charging station and is in a non-chargeable state in which charging to the battery (charging the battery) is not allowed to be started, the control unit may execute a docking retry process of moving the work robot by the moving unit and docking the work robot to the charging station again. As the work robot moves during the docking retry process, at least a portion of the work robot may overlap the station board as viewed in a direction perpendicular to the floor.According to the above configuration, while the work robot moves during the docking retry process, at least a part of the work robot remains to overlap (further overlaps) the station board. Thus, the distance the work robot moves is shorter compared to a distance the work robot would move when moving completely away from the station plate. Therefore, the docking retry process can be efficiently performed.BRIEF DESCRIPTION OF DRAWINGSFIG. 1 schematically illustrates an autonomous motion system 10 according to a first embodiment. FIG. 2 is a side view of a work robot 12 and a charging station 14 according to the first embodiment. FIG. 3 is a front view of the work robot 12 according to the first embodiment. FIG. 4 is a rear view of the work robot 12 according to the first embodiment. FIG. 5 is a plan view of the work robot 12 according to the first embodiment. FIG. 6 is an electric block diagram of the work robot 12 according to the first embodiment. FIG. 7 schematically shows a part of the autonomous movement system 10 near the charging station 14 according to the first embodiment. FIG. 8 shows an enlarged perspective view of a docking component 98 of the charging station 14 according to the first embodiment. FIG. 9 is a cross-sectional view of the work robot 12 and the charging station 14 in which the work robot 12 is docked to the charging station 14 in the autonomous moving system 10 according to the first embodiment. FIG. 10 shows current waveforms CW 1 of a first electric signal and current waveforms CW 2 of a second electric signal according to the first embodiment. FIG. 11 shows a waveform indicating magnetic field intensities inside and outside a working range WA according to the first embodiment. FIG. 12 shows a waveform indicating magnetic field intensities inside and outside a region surrounded by a station wire 20 according to the first embodiment. FIG. 13 is a flowchart of an autonomous control process according to the first embodiment. FIG. 14 is a flowchart of a docking process according to the first embodiment. FIG. 15 is a plan view of the work robot 12 and the charging station 14 after a retraction process of a docking retry process according to the first embodiment. FIG. 16 is a plan view of the work robot 12 and the charging station 14 after an advancing process of the docking retry process according to the first embodiment. FIG. 17 shows a flow diagram of a docking process according to a second embodiment.DESCRIPTION OF EMBODIMENTSRepresentative, non-limiting examples of the present disclosure will now be described in further detail with reference to the accompanying drawings. This detailed description is intended merely to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the present disclosure. Additionally, each of the additional features and teachings disclosed below may be utilized separately or in conjunction with other features and teachings to provide improved autonomous motion systems and methods of using and manufacturing the same.Moreover, combinations of features and steps disclosed in the following detailed description need not be necessary to practice the present disclosure in the broadest sense, and are instead taught merely to specifically describe representative examples of the present disclosure. In addition, various features of the representative examples described above and described below, as well as the various independent and dependent claims, may be combined to provide additional useful embodiments of the present teachings in ways that are not specifically and explicitly enumerated.All features disclosed in the specification and / or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure as well as for the purpose of restricting the claimed subject matter independently of the compositions of the features in the embodiments and / or the claims. Moreover, all ranges of values or statements of groups of objects are intended to disclose each possible intermediate value or object for the purpose of original written disclosure as well as for the purpose of limiting the claimed subject matter.In one or more embodiments, the robot power receiver may be a robot charging port configured to be electrically connected to the charging station when the working robot is docked to the charging station. The station power transmitter may be a station charging port configured to be electrically connected to the robot charging port. The docking retry process may include a disconnection process for disconnecting the working robot from the charging station. The robot charging port may be separated from the station charging port after the separation process.Electrical connection of the robot charging port to the station charging port may fail due to insertion of a foreign particle between the robot charging port and the station charging port. In the configuration above, since the robot charging port is separated from the station charging port, such foreign particles fall off from the interface between the robot charging port and the station charging port. Thus, the robot charging port can be electrically connected to the station charging port.In one or more embodiments, the control unit may be configured to drive the movement motor in the docking retry process at a predetermined number of revolutions.Control by the control unit can be made complicated if the number of revolutions of the moving motor is varied each time the docking retry process is executed. The configuration above suppresses complexity in control by the control unit.In one or more embodiments, during the docking retry process, a part of the work robot corresponding to 50% or more of a length of the work robot in a robot longitudinal direction may overlap the station plate when the work robot is viewed in the direction perpendicular to the floor.The configuration above allows a reduction in a moving distance of the working robot during the docking retry process.In one or more embodiments, when viewed in the direction perpendicular to the floor, the work robot may have a first surface. During the docking retry process, a part of the work robot corresponding to 50% or more of the first area of the work robot may overlap the station board when the work robot is viewed in the direction perpendicular to the floor.The configuration above allows a reduction in a moving distance of the working robot during the docking retry process.In one or more embodiments, the docking retry process may include: a retraction process for moving the work robot rearward; and an advancement process for moving the work robot forward after the retraction process.The configuration above facilitates docking of the work robot to the charging station as compared to a configuration in which the work robot rotates (turns) for docking to the charging station.In one or more embodiments, a retraction distance by which the working robot moves rearward in the retraction process may be equal to or more than 50 mm and equal to or less than 650 mm.The configuration above allows the work robot to dock from the charging station while suppressing the work robot from moving away from the station board.In one or more embodiments, the retraction distance may be equal to or more than 150 mm and equal to or less than 300 mm.The configuration above allows the work robot to dock from the charging station while suppressing the work robot from moving away from the charging station.In one or more embodiments, the autonomous movement system may further include an informing unit configured to inform a user. The control unit may be configured to execute the docking retry process once or more; and control (drive) the information unit when a number of executions of the docking retry process reaches a reference number.When the number of executions of the docking retry process reaches the reference number, an abnormality such as an abnormality between the robot power receiver and the station power transmitter often occurs. The configuration above can inform the user of such abnormality by the informing unit.In one or more embodiments, the control unit may be configured to stop the moving motor when the number of executions of the docking retry process reaches the reference number.The configuration above allows the work robot to be stopped until the user approaches the work robot.(First Embodiment) As shown in FIG. 1, an autonomous motion system 10 includes a work robot 12, a charging station 14, a limit wire (limit wire) 16, a guide wire 18, and a station wire 20. The work robot 12 is, for example, a lawn mower. The working robot 12 is placed on the floor for use. The work robot 12 mowed a lawn on the ground while autonomously moving within a work area WA surrounded by the boundary wire 16. Hereinafter, the longitudinal direction of the working robot 12 is referred to as a front-rear direction, the width direction of the working robot 12 is referred to as a right-left direction, and the direction perpendicular to the front-rear direction and the right-left direction is referred to as an up-down direction. The up-down direction is perpendicular to the ground.The longitudinal length of the working robot 12 is equal to or more than 500 mm and equal to or less than 1000 mm. As shown in FIG. 2, the work robot 12 includes a housing 24, a battery 26, a connection unit 28, a work motor 30, a work unit 32, a right motion motor 34 (see FIG. 4 ), a left motion motor 36 (see FIG. 4 ), a motion unit 38, a manipulation unit 40 (see FIG. 4 ), a display unit 42 (see FIG. 4 ), an informing unit 44 (see FIG. 4 ), a magnetism detection unit 46 (see FIG. 5 ), a collision detection unit 48 (see FIG. 5 ), and a control unit 50 (see FIG. 6 ).The battery 26 is accommodated in the case 24. The battery 26 is a secondary battery including a lithium ion battery. The battery 26 is not detachable from the housing 24.The terminal unit 28 is located near the front end of the housing 24. the housing 24 has a docking opening 24a. The docking hole 24 atransfiltrates a front end portion of the housing 24 in the front-rear direction. The docking opening 24 ais located at the center of the housing 24 in the right-left direction. As shown in FIG. 3, the connection unit 28 is visible to a user through the docking opening 24 ain the front view of the work robot 12. The connection unit 28 is located behind the docking opening 24 a. The connection unit 28 includes a first robot charging port 54, a first biasing member 56, a second robot charging port 58, a second biasing member 60, a robot communication port 62, and a third biasing member 64.The first robot charging port 54 corresponds to a robot power receiver. The first robot charging port 54 is electrically connected to the battery 26 (see FIG. 2 ). The first robot loading port 54 is supported by the housing 24 so as to be movable in the right-left direction. The first robot charging port 54 is biased leftward by the first biasing member 56. The first biasing member 56 is, for example, a compression spring.The second robot charging port 58 corresponds to a robot power receiver. The second robot charging port 58 is electrically connected to the battery 26 (see FIG. 2 ). The second robot charging port 58 is opposed to the first robot charging port 54 in the right-left direction. The second robot charging port 58 is supported by the housing 24 so as to be movable in the right-left direction. The second robot charging port 58 is biased rightward by the second biasing member 60. The first robot charging port 54 is biased toward the second robot charging port 58 by the first biasing member 56, and the second robot charging port 58 is biased toward the first robot charging port 54 by the second biasing member 60. The second biasing member 60 is, for example, a compression spring.The robot communication terminal 62 is electrically connected to the control unit 50 (see FIG. 6 ). The robot communication port 62 overlies each of the first robot charging port 54 and the second robot charging port 58. In the right-left direction, the robot communication port 62 is located at the center between the first robot charging port 54 and the second robot charging port 58. The robot communication port 62 is biased downward by the third biasing member 64. The third biasing member 64 is, for example, a compression spring.The working robot 12 is configured to dock to the charging station 14 (see FIG. 1 ) via the connection unit 28. When the work robot 12 is docked to the charging station 14, the first robot charging port 54 or the second robot charging port 58 receives power from an external power supply 100 via the charging station 14. The battery 26 is thus charged.As shown in FIG. 2, the engine 30 is supported by the housing 24. The work motor 30 is, for example, a brushless motor. The engine 30 operates using the power in the battery 26.The working unit 32 includes a substantially disk-shaped blade (a knife 32 a). The blade 32a is fixed to the output shaft of the work motor 30. The output shaft is inclined to the up-down direction. The blade 32a is rotated by the operation of the work motor 30. The lawn on the ground is thereby mowed.As shown in FIG. 4, the right moving motor 34 and the left moving motor 36 are supported by the housing 24. The right moving motor 34 and the left moving motor 36 are, for example, brushless motors. The right motion motor 34 and the left motion motor 36 operate using the power in the battery 26 (see FIG. 2 ).The moving unit 38 includes a right front auxiliary wheel 68, a left front auxiliary wheel 70, a right rear drive wheel 72, and a left rear drive wheel 74. The right front auxiliary wheel 68 and the left front auxiliary wheel 70 are mounted on the housing 24. The right front auxiliary wheel 68 and the left front auxiliary wheel 70 may each rotate about a rotation axis extending in the right-left direction and also pivot about a pivot axis extending in the up-down direction. The right rear drive wheel 72 is fixed to the output shaft of the right moving motor 34. The left rear drive wheel 74 is fixed to the output shaft of the left travel motor 36. The output shaft of the right moving motor 34 and the output shaft of the left moving motor 36 extend in the right-left direction. The right rear drive wheel 72 is rotated by the operation of the right moving motor 34, while the left rear drive wheel 74 is rotated by the operation of the left moving motor 36. Thus, the work robot 12 moves forward, moves rearward, and turns (turns, turns).The manipulation unit 40 is disposed on the outer surface of the housing 24. The user manipulates the manipulation unit 40 to switch the working robot 12 between an on state and an off state, set a working condition of the working robot 12, and so on, for example.The display unit 42 is, for example, a display. The display unit 42 displays various information. The manipulation unit 40 and the display unit 42 may be integrated as a touch screen.The informing unit 44 is, for example, a buzzer configured to emit sound. In a variant, the information unit 44 may be a light (a lamp) configured to emit light. The informing unit 44 emits, for example, sound when an abnormality occurs in the work robot 12.As shown in FIG. 5, the magnetism detection unit 46 is supported by the housing 24. The magnetism detection unit 46 includes a plurality of magnetic sensors 78 (in this embodiment, four magnetic sensors 78). The magnetic sensors 78 are, for example, search coils, Hall sensors, or the like. The magnetic sensors 78 each detect magnetic field intensity in the up-down direction.The plurality of magnetic sensors 78 includes a right front magnetic sensor 78 a, a left front magnetic sensor 78 b, a center front magnetic sensor 78 c, and a rear magnetic sensor 78 d. The right front magnetic sensor 78 a, the left front magnetic sensor 78 b, and the center front magnetic sensor 78 care located forward of the center of the housing 24 in the front-rear direction. the right front magnetic sensor 78 ais located on / in a right front portion of the housing 24. the left front magnetic sensor 78 bis located on / in a left front portion of the housing 24. a distance from the right front magnetic sensor 78 ato a center line CL is substantially equal to a distance from the left front magnetic sensor 78 bto the center line CL in the right-left direction. The center line CL extends in the front-rear direction and is located at the center of the housing 24 in the right-left direction. The center front magnetic sensor 78 cis located on / in a front portion of the housing 24. the rear magnetic sensor 78 dis located behind the center of the housing 24 in the front-rear direction.The housing 24 includes a base 24 b(see FIG. 2 ) and a bumper 24 cmovedly attached to the base 24 b, and the collision detection unit 48 is supported by the base 24 band the bumper 24 c. Typically, the bumper 24 cis in an initial position relative to the base 24 b. The docking hole 24 a(see FIG. 2 ) is located at the front end of the bumper 24 c. The collision detection unit 48 includes a plurality of collision detection sensors 80 (three collision detection sensors 80 in this embodiment). The collision detection sensors 80 each detect a collision of the housing 24 with an obstacle by detecting an offset of the bumper 24 cfrom the initial position. When the displacement of the bumper 24 cfrom the initial position is equal to or greater than a predetermined value (i.e., when the housing 24 collides with an obstacle, etc.), the collision detection sensors 80 switch to an on state (in which the collision detection sensors 80 detect the collision of the housing 24 with the obstacle), whereas when the displacement of the bumper 24 from the initial position is less than the predetermined value (i.e., when the housing 24 does not collide with an obstacle, etc.), the collision detection sensors 80 switch to an off state (in which the collision detection sensors 80 do not detect the collision of the housing 24 with an obstacle).The collision detection sensors 80 include a center collision detection sensor 80 a, a right collision detection sensor 80 b, and a left collision detection sensor 80 c. The center collision detection sensor 80 ais located directly above the center front magnetic sensor 78 c. The right collision detection sensor 80 bis located directly above the right movement motor 34. the left collision detection sensor 80 cis located directly above the left movement motor 36.As shown in FIG. 6, the control unit 50 is electrically connected to the battery 26, the first robot charging port 54, the second robot charging port 58, the robot communication port 62, the work motor 30, the right movement motor 34, the left movement motor 36, the manipulation unit 40, the display unit 42, the informing unit 44, the magnetism detection unit 46, and the collision detection unit 48. The control unit 50 includes a microcomputer (not shown) and a memory (not shown). The control unit 50 independently controls the rotation direction and rotation speed of the right moving motor 34 and the rotation direction and rotation speed of the left moving motor 36. For example, when the control unit 50 controls the right moving motor 34 and the left moving motor 36 to run in the forward direction and at the same speed, the work robot 12 moves forward. When the control unit 50 controls the right moving motor 34 and the left moving motor 36 to run in the reverse direction and at the same speed, the work robot 12 moves rearward. When the control unit 50 controls the right moving motor 34 to run in the forward direction and controls the left moving motor 36 to run in the reverse direction, the work robot 12 rotates on the spot. When the control unit 50 controls the right moving motor 34 and the left moving motor 36 to run at different speeds in the forward direction (or in the reverse direction), the work robot 12 moves forward (or rearward) while rotating. The control unit 50 autonomously controls the work robot 12 according to various programs stored in the memory. For example, the control unit 50 acquires signals from the manipulation unit 40 and the magnetism detection unit 46, and controls the work motor 30, the right movement motor 34, and the left movement motor 36 accordingly so that the work robot 12 grass the lawn while autonomously moving.As shown in FIG. 7, the charging station 14 is located partially inside the work area WA and partially outside the work area WA. The charging station 14 includes a station plate 84, a stand 86, a first station charging port 88 (see FIG. 8 ), a second station charging port 90 (see FIG. 8 ), a station communication port 92 (see FIG. 8 ), and a signal generator 94. The station plate 84 is placed on the floor. The station plate 84 is substantially rectangular in shape as viewed from above. The longitudinal length of the station plate 84 is, for example, equal to or more than 700 mm and equal to or less than 1200 mm. The longitudinal length of the station plate 84 is greater than the longitudinal length of the work robot 12 (see FIG. 5 ).The stand 86 is disposed on the station board 84. The post 86 includes a base 96 and a docking member 98. The base 96 extends upwardly from the station plate 84. The docking member 98 is configured to allow the working robot 12 to dock thereon (see FIG. 2 ). The docking member 98 protrudes from the base 96 in a direction away from the boundary wire 16. The protruding direction of the docking member 98 from the base 96 is substantially the same as the longitudinal direction of the station plate 84. the docking member 98 is substantially perpendicular to the base 96. the docking member 98 is substantially parallel to the ground. The docking component 98 is located within the working area WA. As shown in FIG. 8, the docking member 98 includes a bottom wall 98 afacing the floor, a top wall 98 bopposing the bottom wall 98 a, a first side wall 98 cconnecting the bottom wall 98 ato the top wall 98 b, a second side wall 98 dopposing the first side wall 98 c, and a contact portion 98 eprotruding upward from the top wall 98 b.The first station charging terminal 88, the second station charging terminal 90, and the station communication terminal 92 are electrically connected to the external power supply 100 (see FIG. 7 ). The first station charging port 88 and the second station charging port 90 each correspond to a station power transmitter. The first station charging port 88 is located in the first side wall 98 cof the docking member 98. the first station charging port 88 is partially exposed from the first side wall 98 c. The second station charging port 90 is located in the second side wall 98 dof the docking member 98. the second station charging port 90 is partially exposed from the second side wall 98 d. The station communication port 92 is located in the top wall 98b of the docking member 98. The first station charging port 88, the second station charging port 90, and the station communication port 92 extend in the protruding direction of the docking member 98.As shown in FIG. 9, when the charging station 14 has the working robot 12 docked thereto, the docking member 98 is located inside the docking opening 24 a(see FIG. 3 ), the upper wall 98 bof the docking member 98 faces the robot communication port 62 in the up-down direction, the first side wall 98 cof the docking member 98 faces the first robot charging port 54 in the right-left direction, the second side wall 98 dof the docking member 98 faces the second robot charging port 58 in the right-left direction, and the contact portion 98 e(see FIG. 8 ) of the stand 86 is in contact with the housing 24. In this state, the first station charging port 88 is in contact with the first robot charging port 54, the second station charging port 90 is in contact with the second robot charging port 58, and the station communication port 92 is in contact with the robot communication port 62. The contact between the first station charging port 88 and the first robot charging port 54 is maintained by pressing the first robot charging port 54 against the first station charging port 88 by the biasing force of the first biasing member 56 (see FIG. 3 ). The contact between the second station charging port 90 and the second robot charging port 58 is maintained by pressing the second robot charging port 58 against the second station charging port 90 by the biasing force of the second biasing member 60 (see FIG. 3 ). The contact between the station communication terminal 92 and the robot communication terminal 62 is maintained by pressing the robot communication terminal 62 against the station communication terminal 92 by the biasing force of the third biasing member 64. Thus, the first station charging port 88 is electrically connected to the first robot charging port 54, the second station charging port 90 is electrically connected to the second robot charging port 58, and the station communication port 92 is electrically connected to the robot communication port 62. In this state, a current flows from the first station charging port 88 to the first robot charging port 54 or from the second station charging port 90 to the second robot charging port 58, and thus power of the external power supply 100 (see FIG. 7 ) for charging the battery 26 (see FIG. 6 ) is supplied from the first station charging port 88 to the first robot charging port 54 or from the second station charging port 90 to the second robot charging port 58.As shown in FIG. 7, the signal generator 94 is accommodated in the base 96. The signal generator 94 is configured to supply a first electrical signal to the boundary wire 16 and the station wire 20. The signal generator 94 is further configured to provide a second electrical signal to the limit wire 16 and the guide wire 18. As shown in FIG. 10, a current waveform CW 1 of the first electric signal is different from a current waveform CW 2 of the second electric signal. For example, the pulse length and the number of pulses in the current waveform CW 1 of the first electric signal are different from the pulse length and the number of pulses in the current waveform CW 2 of the second electric signal. In a variant, the phase of the current waveform CW 1 of the first electrical signal may be different from the phase of the current waveform CW 2 of the second electrical signal. The first electrical signal and the second electrical signal are supplied alternately by the signal generator 98, for example. The first electric signal and the second electric signal are supplied by the signal generator 94 at predetermined intervals, for example.As shown in FIG. 1, the boundary wire 16 defines the working range WA. The boundary wire 16 is buried in the ground near the ground surface, for example. The limit wire 16 is electrically connected to the signal generator 94 (see FIG. 7 ) of the charging station 14 via the station wire 20. When a current flows in the boundary wire 16, a magnetic field surrounding the boundary wire 16 is generated according to Ampere's law. The direction of the magnetic field inside the working area WA is different from the direction of the magnetic field outside the working area WA. As shown in FIG. 11, the intensity of the magnetic field in the up-down direction on / immediately above the boundary wire 16 is zero, indicates a positive value within the working range WA, and indicates a negative value outside the working range WA. The intensity of the magnetic field depends on the distance from the boundary wire 16. The control unit 50 receives the intensity of the magnetic field from the magnetism detection unit 46 and determines whether the work robot 12 is located within the work area WA.For example, as shown in Fig. 1, the guide wire 18 is buried in the ground near the ground surface. The guidewire 18 is electrically connected to a first point 17 of the border wire 16. The first point 17 may be positioned at any location between one end and the other end of the border wire 16. Hereinafter, a portion of the boundary wire 16 between the one end and the first point 17 may be referred to as a first boundary wire portion 16 a, and another portion of the boundary wire 16 between the first point 17 and the other end may be referred to as a second boundary wire portion 16 b. The guide wire 18 is also electrically connected to the signal generator 94 (see FIG. 7 ) of the loading station 14. The guide wire 18 and the first boundary wire portion 16a define a guide region GA. When a current flows in the guide wire 18 and the first boundary wire portion 16 a, a magnetic field surrounding the guide wire 18 and the first boundary wire portion 16 ais generated according to Ampere's law. In this embodiment, the first electric signal is supplied when the current flows first through the first boundary wire portion 16a and then through the second boundary wire portion 16b, whereas the second electric signal is supplied when a current flows first through the first boundary wire portion 16a and then through the guide wire 18. The control unit 50 receives the intensity of the magnetic field from the magnetism detection unit 46 and determines whether the work robot 12 is located within the guidance area GA.As shown in FIG. 7, the station wire 20 is disposed on the station plate 84 of the charging station 14. The station wire 20 is electrically connected in series with the border wire 16. The station wire 20 is electrically connected to the signal generator 94 (see FIG. 7 ).The station wire 20 has a first loop portion 104 and a second loop portion 106 each having a loop shape. The first loop portion 104 and the second loop portion 106 are adjacent to each other. The docking component 98 of the charging station 14 lies on the boundary between the first loop section 104 and the second loop section 106. The first loop portion 104 and the second loop portion 106 are formed by winding the single station wire 20 more than once (e.g., twice). In the station wire 20, a current flows in the first loop portion 104 in a counterclockwise direction D 1 and flows in the second loop portion 106 in a clockwise direction D 2. As shown in FIG. 12, the intensity of the magnetic field in the up-down direction is zero in the vicinity of the boundary between the first loop portion 104 and the second loop portion 106, indicates a positive value within the first loop portion 104, and indicates a negative value within the second loop portion 106. The control unit 50 receives one or more intensities of the magnetic field from the magnetism detection unit 46 to determine whether the work robot 12 is located within the first loop portion 104 or within the second loop portion 106, and detect that the work robot 12 has traversed the station wire 20.(Autonomous Control Process) The control unit 50 executes an autonomous control process shown in FIG. 13. The autonomous control process is executed to cause the work robot 12 to perform a mowing operation within the work area WA, return the work robot 12 to the charging station 14, dock the work robot 12 to the charging station 14, and charge the work robot 12.In S 2 shown in FIG. 13, the control unit 50 executes a mowing process. Specifically, the control unit 50 controls the work motor 30, the right movement motor 34, and the left movement motor 36. This causes the working robot 12 to move within the working area WA while the blade 32a is rotated, so that the lawn is mowed within the working area WA.In S 4, the control unit 50 determines whether a return condition is satisfied. For example, the control unit 50 determines that the return condition is satisfied when the remaining amount of power in the battery 26 reaches a predetermined amount or less. Alternatively, the control unit 50 may determine that the return condition is satisfied when the current time is after a time set by the user or when an abnormality occurs at / in at least one of the work motor 30, the right moving motor 34, and the left moving motor 36. When the control unit 50 determines that the return condition is satisfied (YES in S 4), the process proceeds to S 6, whereas when the control unit 50 determines that the return condition is not satisfied (NO in S 4), the process returns to S 2.In S 6, the control unit 50 executes a return process. Specifically, the control unit 50 controls the right moving motor 34 and the left moving motor 36 so that the work robot 12 can reach the charging station 14 based on one or more magnetic field intensities detected by the magnetic sensors 78. At this time, the working robot 12 moves in a return direction D 3 along the guide wire 18 and the first boundary wire portion 16 aor moves in a return direction D 4 along the first boundary wire portion 16 aand the second boundary wire portion 16 b. As shown in FIG. 1, the return directions D 3, D 4 are each the counterclockwise direction when the work robot 12 is viewed from above. The control unit 50 continues to drive the work motor 30 until the work robot 12 reaches the charging station 14. That is, the working robot 12 moves while the blade 32a is rotated. Thus, the lawn within the work area WA is also mowed during the return process.In S 8, the control unit 50 performs a docking process shown in FIG. 14. In S 102 of the docking process shown in FIG. 14, the control unit 50 controls the right moving motor 34 and the left moving motor 36 based on one or more magnetic field intensities of the first loop portion 104 detected by the magnetic sensors 78 such that the work robot 12 can move along the first loop portion 104. The work robot 12 moves clockwise along the first loop portion 104.In S 104, the control unit 50 determines whether the work robot 12 has reached a central position of the charging station 14 based on one or more magnetic field intensities of the first loop portion 104 detected by the magnetic sensors 78. The central position of the charging station 14 is the position at which the magnetic field intensity of the station wire 20 is zero, i.e., the boundary between the first loop portion 104 and the second loop portion 106. When the control unit 50 determines that the work robot 12 has reached the central position of the charging station 14 (YES in S 104), the process proceeds to S 106, whereas when the control unit 50 determines that the work robot 12 has not reached the central position of the charging station (NO in S 104), the process returns to S 102.In S 106, the control unit 50 controls the right moving motor 34 and the left moving motor 36 so as to adjust the orientation of the work robot 12. Consequently, the docking opening 24 ais located directly above the boundary between the first loop portion 104 and the second loop portion 106 so as to be opposite the docking member 98 of the charging station 14.In S 108, the control unit 50 controls the right moving motor 34 and the left moving motor 36 to run in the forward direction and at the same speed so that the work robot 12 moves forward along the boundary between the first loop portion 104 and the second loop portion 106. The working robot 12 thus approaches the docking member 98.In S 110, the control unit 50 determines whether at least one of the collision detection sensors 80 is in the on state. That at least one of the collision detection sensors 80 is in the ON state in S 110 means that the docking member 98 is in contact with the front end of the housing 24 (the bumper 24 c) and faces the docking opening 24 a. When the control unit 50 determines that at least one of the collision detection sensors 80 is in the ON state (YES in S 110), the process proceeds to S 112, whereas when the control unit 50 determines that all the collision detection sensors 80 are in the OFF state (NO in S 110), the process returns to S 108.In S 112, the control unit 50 controls the right moving motor 34 and the left moving motor 36 to rotate by a predetermined number of revolutions in the forward direction and at the same rotational speed so that the work robot 12 can move forward. When the right moving motor 34 and the left moving motor 36 rotate the predetermined number of revolutions in the forward direction and at the same speed without the working robot 12 colliding with an obstacle, the working robot 12 moves forward a first distance. The first distance is, for example, equal to or more than 50 mm and equal to or less than 650 mm. For example, the first distance may be equal to or more than 150 mm and equal to or less than 300 mm. For example, the first distance is 200 mm. The first distance is larger than the length of the docking member 98 in the protruding direction. When the right moving motor 34 and the left moving motor 36 are rotated by the predetermined number of revolutions in the forward direction and at the same rotational speed, the docking member 98 is inserted into the docking hole 24 aand the front end of the housing 24 is pressed against the contact portion 98 eof the docking member 98.In S 114 shown in FIG. 14, the control unit 50 determines whether the work robot 12 is in a non-chargeable state in which charging to the battery 26 is not possible to be started at the charging station 14. For example, the working robot 12 is in the non-chargeable state when foreign particles such as lawns cut by the blade 32 aare stuck between the first station charging port 88 and the first robot charging port 54 and / or between the second station charging port 90 and the second robot charging port 58 and / or between the station communication port 92 and the robot communication port 62. The control unit 50 determines that the work robot 12 is in the non-chargeable state when the work robot 12 cannot communicate with the charging station 14 (when the second station charging port 90 is not electrically connected to the second robot charging port 58 and / or the station communication port 92 is not electrically connected to the robot communication port 62). In one variation, the control unit 50 may determine that the work robot 12 is in the non-rechargeable state when the first station charging port 88 is not electrically connected to the first robot charging port 54 and / or the second station charging port 90 is not electrically connected to the second robot charging port 58. When the control unit 50 determines that the work robot 12 is not in the non-chargeable state (NO in S 114), the process proceeds to S 10 in FIG. 13, whereas when the control unit 50 determines that the work robot 12 is in the non-chargeable state (YES in S 114), the process proceeds to S 116. A sequence executed after YES in S 114 (i.e., S 116 to S 122 and S 108 to S 114) corresponds to a docking retry process.In S 116, the control unit 50 determines whether the number of retries is equal to a reference number. The number of retries indicates how many times the docking retry process has been performed. Thus, the number of retries is zero when the docking retry process is executed for the first time. The control unit 50 resets the number of retries to zero each time the work robot 12 is charged at the charging station 14. The reference number is an integer equal to or greater than 1. for example, the reference number is 1. when the control unit 50 determines that the number of retries is equal to the reference number (YES in S 116), the process proceeds to S 118, whereas when the control unit 50 determines that the number of retries is less than the reference number (NO in S 116), the process proceeds to S 120.In S 118, the control unit 50 switches a docking failure flag from off to on. The docking failure flag is stored in the memory of the control unit 50. Then, the process proceeds to S 10 in FIG. 13.In S 120, the control unit 50 controls the right moving motor 34 and the left moving motor 36 to rotate by a predetermined number of revolutions in the reverse direction (reverse direction) and at the same rotational speed so that the work robot 12 can move rearward. As a result, the working robot 12 moves backward a second distance along the boundary between the first loop portion 104 and the second loop portion 106 to separate from the docking member 98. The second distance is, for example, equal to or more than 15 mm and equal to or less than 650 mm. For example, the second distance may be equal to or more than 150 mm and equal to or less than 300 mm. For example, the second distance is 200 mm. The second distance is larger than the length of the docking member 98 in the protruding direction. For example, the second distance is substantially equal to the first distance. The retracting process for moving the work robot 12 rearward in S 120 corresponds to a separating process for separating the work robot 12 from the docking member 98. when the work robot 12 moves rearward the second distance, the first robot charging port 54 separates from the first station charging port 88, the second robot charging port 58 separates from the second station charging port 90, and the robot communication port 62 separates from the station communication port 92. thereby, the foreign particles such as lawn parts cut by the blade 32 afall from the first robot charging port 54 and / or the second robot charging port 58 and / or the robot communication port 62 and / or the first station charging port 88 and / or the second station charging port 90 and / or the station communication port 92. Further, the docking member 98 comes out of the docking hole 24a. Thus, the work robot 12 docks off the charging station 14.As shown in FIG. 15, after the work robot 12 moves the second distance backward, a part of the work robot 12 corresponding to 50% or more of the longitudinal length of the work robot 12 overlaps the station board 84 when the work robot 12 is viewed in the downward direction perpendicular to the floor. That is, as the work robot 12 moves rearward, the part of the work robot 12 corresponding to 50% or more of the longitudinal length further overlaps the station board 84 when the work robot 12 is viewed in the downward direction. The work robot 12 has a first surface when the work robot 12 is viewed in the downward direction. After the work robot 12 moves backward the second distance, a part of the work robot 12 corresponding to 50% or more of the first area overlaps the station plate 84 when the work robot 12 is viewed in the downward direction perpendicular to the ground. That is, as the work robot 12 moves rearward, the part of the work robot 12 corresponding to 50% or more of the first area further overlaps the station board 84 when the work robot 12 is viewed in the downward direction.In S 122 shown in FIG. 14, the control unit 50 increases the number of retries by 1.In the following sequence from S 108 to S 114, the working robot 12 moves forward again along the boundary between the first loop portion 104 and the second loop portion 106. Consequently, the docking member 98 is inserted into the docking hole 24a, and the front end of the housing 24 is pressed against the contact portion 98e of the docking member 98. Thus, the work robot 12 docks on the charging station 14. The advancing process for moving the work robot 12 forward in S 108 to S 114 corresponds to an approaching process for moving the work robot 12 closer to the docking member 98. as shown in FIG. 16, after the work robot 12 has moved forward, the entire work robot 12 overlaps the station board 84 when the work robot 12 is viewed in the downward direction. That is, as the work robot 12 moves forward, the part of the work robot 12 corresponding to 50% or more of the longitudinal length of the work robot 12 further overlaps the station board 84 when the work robot 12 is viewed in the downward direction. Further, as the work robot 12 moves forward, the part of the work robot 12 corresponding to 50% or more of the first area further overlaps the station board 84 when the work robot 12 is viewed in the downward direction.S 10 shown in FIG. 13 is executed after NO in S 114 and also after S 118 shown in FIG. 14. In S 10, the control unit 50 determines whether the docking failure flag is turned off. When the control unit 50 determines that the docking failure flag is turned off (YES in S 10), the process proceeds to S 12, whereas when the control unit 50 determines that the docking failure flag is not turned off, i.e., that the docking failure flag is turned on (NO in S 10), the process proceeds to S 14.In S 12, the control unit 50 executes a charging process. The battery 26 is thereby charged. Thereafter, the control unit 50 ends the autonomous control process.In S 14, the control unit 50 stops the right moving motor 34 and the left moving motor 36, and thus the work robot 12 is stopped. Further, the control unit 50 controls the informing unit 44. the sound from the informing unit 44 informs the user of occurrence of abnormality in the work robot 12.(Effects) The autonomous moving system 10 according to this embodiment includes the work robot 12 configured to perform an operation while autonomously moving in the work area WA; and the charging station 14 configured to charge the work robot 12 and allow the work robot 12 to dock thereto. The work robot 12 includes the work unit 32 configured to perform the operation; the moving unit 38 configured to move the work robot 12; the right moving motor 34 and the left moving motor 36 (examples of moving motors) configured to drive the moving unit 38; the battery 26 configured to be charged at the charging station 14 and supply power to the right moving motor 34 and the left moving motor 36; the control unit 50 configured to control the right moving motor 34 and the left moving motor 36; and the first robot charging port 54 (an example of robot power receiver) configured to receive power for charging the battery 26 from the charging station 14 while the work robot 12 is docked to the work station 14. The charging station 14 includes the first station charging port 88 (an example of station power transmitters) configured to supply the power for charging the battery 26 to the first robot charging port 54; and the station plate 84 placed on the ground. When the work robot 12 is docked to the charging station 14 and is in the non-chargeable state in which it is not possible to start charging to the battery 26, the control unit 50 performs the docking retry process of moving the work robot 12 by the moving unit 38 and docking the work robot 12 to the charging station 14 again. As the work robot 12 moves during the docking retry process, at least a part of the work robot 12 overlaps the station board 84 as viewed in the direction perpendicular to the ground.According to the configuration above, while the work robot 12 moves during the docking retry process, at least a part of the work robot 12 remains to overlap the station board 84. Thus, the distance that the work robot 12 moves is shorter compared to a distance that the work robot 12 would move when moving completely away from the station plate 84. Therefore, the docking retry process can be efficiently performed.The first robot charging port 54 is electrically connected to the charging station 14 when the working robot 12 is docked to the charging station 14. The first station charging port 88 is electrically connected to the first robot charging port 54. The docking retry process includes the disconnection process for disconnecting the work robot 12 from the charging station 14. the first robot charging port 54 is disconnected from the first station charging port 88 after the disconnection process.Electrical connection of the first robot charging port 54 to the first station charging port 88 may fail due to insertion of a foreign particle between the first robot charging port 54 and the first station charging port 88. In the above configuration, the first robot charging port 54 is separated from the first station charging port 88, so that a foreign particle falls off from the interface between the first robot charging port 54 and the first station charging port 88. Thus, the first robot charging port 54 can be electrically connected to the first station charging port 88.The control unit 50 controls the right moving motor 34 and the left moving motor 36 in the docking retry process by a predetermined number of revolutions.Control by the control unit 50 can be made complicated if the number of revolutions of the right moving motor 34 and the left moving motor 36 is varied each time the docking retry process is executed. The above configuration suppresses complexity in control by the control unit 50.During the docking retry process, a part of the work robot 12 corresponding to 50% or more of the longitudinal length of the work robot 12 overlaps the station board 84 when the work robot 12 is viewed in the direction perpendicular to the floor.The configuration above allows a reduction in a moving distance of the working robot 12 during the docking retry process.As viewed in the direction perpendicular to the floor, the work robot 12 has the first surface. During the docking retry process, a part of the work robot 12 corresponding to 50% or more of the first area overlaps the station board 84 when the work robot 12 is viewed in the direction perpendicular to the ground.The configuration above allows a reduction in a moving distance of the working robot 12 during the docking retry process.The docking retry process includes the retraction process for moving the working robot 12 rearward; and the advancement process for moving the working robot 12 forward after the retraction process.The configuration above facilitates docking of the work robot 12 to the charging station 14 as compared to a configuration in which the work robot 12 rotates to dock to the charging station 14.A retraction distance by which the work robot 12 moves rearward in the retraction process is equal to or more than 50 mm and equal to or less than 650 mm.The configuration above allows the work robot 12 to dock from the charging station 14 while suppressing the work robot 12 from moving away from the station plate 84.The retraction distance is equal to or more than 150 mm and equal to or less than 300 mm.The configuration above allows the work robot 12 to dock from the charging station 14 while suppressing the work robot 12 from moving away from the station plate 84.The autonomous moving system 10 further includes the informing unit 44 configured to inform the user. The control unit 50 is configured to execute the docking retry process once or more; and control the informing unit 44 when the number of executions of the docking retry processes reaches the reference number.When the number of executions of docking retry processes reaches the reference number, an abnormality such as an abnormality occurs between the first robot charging port 54 and the first station charging port 88. The configuration above can inform the user of such abnormality through the informing unit 44.The control unit 50 is configured to stop the right moving motor 34 and the left moving motor 36 when the number of executions of the docking retry processes reaches the reference number.The configuration above allows the work robot 12 to be stopped until the user approaches the work robot 12.(Second Embodiment) For a second embodiment, differences from the first embodiment will be described. As shown in FIG. 17, in a docking process according to the second embodiment, the control unit 50 executes S220 and S222 in place of S120 in the docking process according to the first embodiment.In S220, the control unit 50 controls the right moving motor 34 and the left moving motor 36 in the reverse direction and at the same speed so that the work robot 12 can move rearward. Accordingly, the working robot 12 moves rearward along the boundary between the first loop portion 104 and the second loop portion 106 to separate from the docking member 98. When the work robot 12 moves rearward, the first robot charging port 54 separates from the first station charging port 88, the second robot charging port 58 separates from the second station charging port 90, and the robot communication port 62 separates from the station communication port 92.In S222, the control unit 50 determines whether a retraction completion condition is satisfied. For example, the control unit 50 determines that the retraction completion condition is satisfied when a position detection sensor determines that the first robot charging port 54, the second robot charging port 58, and the robot communication port 62 have returned to their initial positions. In a variant, the work robot 12 includes a switch configured to be pressed by the charging station 14 when the docking member 98 of the charging station 14 is located in the docking opening 24 aof the work robot 12, and the control unit 50 determines that the retraction completion condition is satisfied when the switch is not pressed. In another variation, the work robot 12 includes a switch configured to be pressed by the charging station 14 when the first robot charging port 54 is not electrically connected to the first station charging port 88 and the second robot charging port 58 is not electrically connected to the second station charging port 90, and the control unit 50 determines that the retraction completion condition is satisfied when the switch is pressed. In still another variation, the charging station 14 includes a permanent magnet, the working robot 12 includes a Hall sensor configured to oppose the permanent magnet when the docking member 98 of the charging station 14 is located in the docking opening 24 aof the working robot 12, and the control unit 50 determines that the retraction completion condition is satisfied when a magnetic field intensity detected by the Hall sensor is equal to or less than a predetermined value. In still another variation, the charging station 14 includes a permanent magnet, the working robot 12 includes a Hall sensor configured to oppose the permanent magnet when the first robot charging terminal 54 is not electrically connected to the first station charging terminal 88 and the second robot charging terminal 58 is not electrically connected to the second station charging terminal 90, and the control unit 50 determines that the retraction completion condition is satisfied when a magnetic field intensity detected by the Hall sensor is equal to or more than a predetermined value. When the control unit 50 determines that the retraction completion condition is satisfied (YES in S222), the process proceeds to S122, whereas when the control unit 50 determines that the retraction completion condition is not satisfied (NO in S222), the process returns to S220.(Variations) In one embodiment, the work robot 12 may be a cleaning device configured to remove foreign particles such as dust from a floor (floor). The cleaning device may remove foreign particles from a floor by rotating a brush and / or by sucking the foreign particles.In one embodiment, the battery 26 of the work robot 12 may be removable from the housing 24.In an embodiment, the moving unit 38 of the work robot 12 may include a crawler instead of the right front auxiliary wheel 68, the left front auxiliary wheel 70, the right rear drive wheel 72, and the left rear drive wheel 74.In one embodiment, the docking process may include a turning process for turning the work robot 12.In an embodiment, the charging station 14 may include a transmitter coil for wirelessly charging the work robot 12 instead of the first station charging port 88, the second station charging port 90, and the station communication port 92. The transmitter coil may be located in the base 96, in the docking component 98, or on the station plate 84. The work robot 12 may include a receiver coil for wirelessly charging via the transmitter coil. The receiver coil may be located in the housing 24 or in the connector unit 28. If the transmitter coil of the charging station 14 is located on the station plate 84, the receiver coil may be located on the lower surface of the housing 24 so as to be opposed to the transmitter coil on the station plate 84.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedUS 2013 / 0 006 418 A1
[0002]
Claims
An autonomous moving system (10) comprising: a work robot (12) configured to perform an operation while autonomously moving in a work area (WA); and a charging station (14) configured to charge the work robot (12) and allow the work robot (12) to dock thereon, wherein the work robot (12) comprises: a work unit (32) configured to perform the operation; a moving unit (38) configured to move the work robot (12); a moving motor (34, 36) configured to drive the moving unit (38); a battery (26) configured to be charged at the charging station (14) and supply power to the moving motor (34, 36); a control unit (50) configured to control the moving motor (34, 36); and a robot power receiver (54) configured to receive power for charging the battery (26) from the charging station (14) while the working robot (12) is docked to the charging station (14), the charging station (14) comprising: a station power transmitter (88) configured to supply the power for charging the battery (26) to the robot power receiver (54); A station board (84) placed on a ground when the work robot (12) is docked to the charging station (14) and is in a non-chargeable state in which charging to the battery (26) is not possible to be started, the control unit (50) performs a docking retry process for moving the work robot (12) by the moving unit (38) and re-docking the work robot (12) to the charging station (14), and while the work robot (12) moves during the docking retry process, at least a part of the work robot (12) overlaps the station board (84) as viewed in a direction perpendicular to the ground.The autonomous motion system (10) of claim 1, wherein the robot power receiver (54) is a robot charging port (54) configured to be electrically connected to the charging station (14) when the work robot (12) is docked to the charging station (14), the station power transmitter (88) is a station charging port (88) configured to be electrically connected to the robot charging port (54), the docking retry process comprises a disconnection process for disconnecting the work robot (12) from the charging station (14), and the robot charging port (54) is disconnected from the station charging port (88) after the disconnection process.The autonomous motion system (10) according to claim 1 or 2, wherein the control unit (50) is configured to drive the motion motor (34, 36) at a predetermined number of revolutions in the docking retry process.The autonomous moving system (10) according to any one of claims 1 to 3, wherein during the docking retry process, a part of the work robot (12) corresponding to 50% or more of a length of the work robot (12) in a robot longitudinal direction overlaps the station board (84) when the work robot (12) is viewed in the direction perpendicular to the ground.The autonomous moving system (10) according to any one of claims 1 to 4, wherein the work robot (12) has a first surface as viewed in the direction perpendicular to the ground, and during the docking retry process, a part of the work robot (12) corresponding to 50% or more of the first surface of the work robot (12) overlaps the station board (84) when the work robot (12) is viewed in the direction perpendicular to the ground.The autonomous moving system (10) according to any one of claims 1 to 5, wherein the docking retry process comprises: a retraction process for moving the working robot (12) rearward; and an advancement process for moving the working robot (12) forward after the retraction process.The autonomous moving system (10) according to claim 6, wherein a retraction distance by which the working robot (12) moves rearward in the retraction process is equal to or more than 50 mm and equal to or less than 650 mm.The autonomous motion system (10) of claim 7, wherein the retraction distance is equal to or greater than 150 mm and equal to or less than 300 mm.The autonomous moving system (10) according to any one of claims 1 to 8, further comprising an informing unit (44) configured to inform a user, wherein the control unit (50) is configured to: execute the docking retry process once or more; and control the informing unit (44) when a number of executions of the docking retry process reaches a reference number.The autonomous motion system (10) according to claim 9, wherein the control unit (50) is configured to stop the motion motor (34, 36) when the number of executions of the docking retry process reaches the reference number.