1. check physical write protect on usb drive
It is quite clear that your disk is 1) full and 2) damaged.
OPTION 1: Repair
* restore the file system running "dosfsck -a /dev/sdb1"
The -a option will automatically repair the errors to make the filesystem consistent again. Lost clusters will be converted to files and keep taking space. Perhaps also space will be freed. After running the disk check, run "df -h /dev/sdb1" again to check the free space. Chances are it will already be more than 1% (I added the -h swicht, means "human readable) to have sizes displayed in kB, MB). After that, clean up the drive, deleting what isn't necessary.
OPTION 2. Reformat altogether
sudo umount /dev/sdb1
sudo mkfs -t vfat /dev/sda1
Warning: You are probably aware that reformatting destroys all data on the disk !
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