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The frontier exploration module (http://wiki.ros.org/frontier_exploration) is built as a plugin to the basic ros navigation stack, and works with gmapping to explore an unknown area. See the launch files for usecases.

If you're having reliability/repeatability issues, try testing the exploration algorithm in gazebo first, to determine whether the error source is high or low level. It could be anything from the exploration planner, to your navigation stack setup, to issues with your sensor setup.