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This likely means that the robot is not localized properly in the map. The "Polygon lies outside of map bounds" error means that the costmap is trying unsuccessfully to rasterize the footprint of the robot into a grid. This normally occurs when the robot is positioned at (0, 0) in the grid before being localized. Have you made sure to set the initial pose for AMCL using rviz as described here: http://www.ros.org/wiki/navigation/Tutorials/Using%20rviz%20with%20the%20Navigation%20Stack?