Compact autonomous coverage robot

• US 10,070,764 B2
• Filed: 10/24/2016
• Issued: 09/11/2018
• Est. Priority Date: 05/09/2007
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Schnittman, Mark Steven, Dubrovsky, Zivthan A., Mammen, Jeffrey W., Solochek, Aaron
• Primary Examiner(s): JENNINGS, MICHAEL DEANGILO
• Application Number:
  US15/331,965
• Publication Number:
  US 20170079499A1
• Time in Patent Office: 687 Days
• Field of Search: 15 411, 15 521, 153404, 31856812
• CPC Class Codes: A47L 11/125 with supply of cleaning agents
• CPC Class Codes: A47L 11/145 with supply of cleaning agents
• CPC Class Codes: A47L 11/161 with supply of cleaning agents
• CPC Class Codes: A47L 11/201 with supply of cleaning agents
• CPC Class Codes: A47L 11/282 having rotary tools
• CPC Class Codes: A47L 11/292 having rotary tools A47L11/30 takes precedence
• CPC Class Codes: A47L 11/30 by suction
• CPC Class Codes: A47L 11/302 having rotary tools
• CPC Class Codes: A47L 11/34 Machines for treating carpets in position by liquid, foam, or vapour, e.g. by steam
• CPC Class Codes: A47L 11/4011 Regulation of the cleaning machine by electric means; Control systems and remote control systems therefor
• CPC Class Codes: A47L 11/4025 Means for emptying
• CPC Class Codes: A47L 11/4041 Roll shaped surface treating tools
• CPC Class Codes: A47L 11/4044 Vacuuming or pick-up tools; Squeegees
• CPC Class Codes: A47L 11/4061 Steering means; Means for avoiding obstacles; Details related to the place where the driver is accommodated
• CPC Class Codes: A47L 11/4066 Propulsion of the whole machine
• CPC Class Codes: A47L 11/408 Means for supplying cleaning or surface treating agents
• CPC Class Codes: A47L 2201/00 Robotic cleaning machines, i.e. with automatic control of the travelling movement or the cleaning operation
• CPC Class Codes: A47L 2201/04 Automatic control of the travelling movement; Automatic obstacle detection
• CPC Class Codes: A47L 9/00 Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
• CPC Class Codes: A47L 9/0477 Rolls
• CPC Class Codes: A47L 9/0488 : Combinations or arrangements of several tools, e.g. edge cleaning tools
• CPC Class Codes: A47L 9/2805 : Parameters or conditions being sensed
• CPC Class Codes: B60L 15/2036 : Electric differentials, e.g. for supporting steering vehicles
• CPC Class Codes: B60L 2200/40 : Working vehicles
• CPC Class Codes: B60L 2220/44 : Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 2240/12 : Speed
• CPC Class Codes: B60L 2240/421 : Speed
• CPC Class Codes: B60L 2240/423 : Torque
• CPC Class Codes: B60L 2250/16 : by display
• CPC Class Codes: B60L 2260/32 : Auto pilot mode
• CPC Class Codes: B60L 2270/145 : Structure borne vibrations
• CPC Class Codes: B60L 50/52 : characterised by DC-motors
• CPC Class Codes: B60L 53/14 : Conductive energy transfer
• CPC Class Codes: G05D 1/0225 : involving docking at a fixed facility, e.g. base station or loading bay parking aids B62D15/027
• CPC Class Codes: G05D 1/0227 : using mechanical sensing means, e.g. for sensing treated area
• CPC Class Codes: G05D 1/0242 : using non-visible light signals, e.g. IR or UV signals
• CPC Class Codes: G05D 1/0255 : using acoustic signals, e.g. ultra-sonic singals sonar systems designed for anti-collision purposes G01S15/93
• CPC Class Codes: Y02P 90/60 : Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles

Abstract

An autonomous coverage robot includes a chassis having forward and rearward portions and a drive system carried by the chassis. The forward portion of the chassis defines a substantially rectangular shape. The robot includes a cleaning assembly mounted on the forward portion of the chassis and a bin disposed adjacent the cleaning assembly and configured to receive debris agitated by the cleaning assembly. A bin cover is pivotally attached to a lower portion of the chassis and configured to rotate between a first, closed position providing closure of an opening defined by the bin and a second, open position providing access to the bin opening. The robot includes a body attached to the chassis and a handle disposed on an upper portion of the body. A bin cover release is actuatable from substantially near the handle.

Claims

1. An autonomous coverage robot comprising:

a chassis having a forward portion and a rearward portion;

a drive system for maneuvering the autonomous coverage robot over a cleaning surface, the drive system comprising drive wheels;

a cleaning assembly for agitating debris on the cleaning surface;

a bin that receives debris agitated by the cleaning assembly;

a pivotally attached bin cover configured to rotate between a first, closed position providing closure of a bin opening and a second, open position providing access to the bin opening, the pivotally attached bin cover comprising a bottom portion of the bin that swings open about a hinge;

a bin cover latch configured to lock the bin cover in the first, closed position and to disengage to allow the bin cover to move to the second, open position; and

a bin cover release for actuating the bin cover latch, the bin cover release allowing actuation of the bin cover latch while holding a handle positioned on the upper portion of the autonomous coverage robot.

2. The autonomous coverage robot according to claim 1, wherein the bin is configured for debris evacuation from below into a base station receptacle when the autonomous coverage robot is stopped at a home position on the base station.

3. The autonomous coverage robot according to claim 1, wherein the forward portion of the chassis further comprises a capacitance sensor for detecting an object.

4. The autonomous coverage robot according to claim 1, wherein the rearward portion of the chassis defines an arcuate shape.

5. The autonomous coverage robot according to claim 4, further comprising an idler wheel, wherein the cleaning assembly is mounted forward of the idler wheel.

6. The autonomous coverage robot according to claim 5, wherein the idler wheel is positioned at least ⅓

of a radius of the arcuate shape of the rearward portion from the drive wheels.

7. The autonomous coverage robot according to claim 1, wherein the cleaning assembly comprises a first roller brush having a cylindrical body, the first roller brush rotatably mounted substantially near and substantially parallel to a front edge of the forward portion of the chassis and a second roller brush having a cylindrical body positioned adjacent the first roller brush and substantially parallel to the first roller brush.

8. The autonomous coverage robot according to claim 7, wherein the cylindrical body of the first roller brush and the second roller brush comprises flexible flaps attached along a length of the cylindrical body.

9. The autonomous coverage robot according to claim 7, wherein the cleaning assembly comprises at least one side brush mounted orthogonally to the first roller brush.

10. The autonomous coverage robot according to claim 1, wherein the cleaning assembly comprises a vacuum for directing the debris into the bin.

11. The autonomous coverage robot according to claim 1, wherein the bin cover latch is a spring biased latch.

12. The autonomous coverage robot according to claim 1, wherein the bin cover release is a button that releases the bin cover latch when pressed downwardly.

13. The autonomous coverage robot according to claim 1, further comprising a plurality of sensors for obstacle avoidance and detection and a controller in communication with the plurality of sensors and the drive system, the controller configured to alter a drive direction of the autonomous coverage robot via the drive system in response to detection of an obstacle via one or more sensors of the plurality of sensors.

14. The autonomous coverage robot according to claim 13, wherein the plurality of sensors includes a plurality of bump sensors disposed at corners of the forward portion of the autonomous coverage robot, each bump sensor in the plurality of bump sensors comprising a sensor base and a sensor shroud positioned adjacent the sensor base, connected to the chassis, and movable with respect to the sensor base, an emitter housed by the sensor shroud, and one or more detectors carried by the sensor base.

15. The autonomous coverage robot according to claim 14, wherein the plurality of sensors includes a light based clearance sensor for detecting overhead objects within 2 feet of the autonomous coverage robot.

16. The autonomous coverage robot according to claim 1, further comprising at least one cliff sensor carried by the forward portion of the chassis and arranged substantially near a front edge of the autonomous coverage robot, the at least one cliff sensor responsive to a potential cliff forward of the autonomous coverage robot, the drive system configured to alter a drive direction of the autonomous coverage robot in response to a signal received from the cliff sensor indicating the potential cliff.

17. The autonomous coverage robot according to claim 1, further comprising at least one cliff sensor carried by the rearward portion of the chassis and arranged substantially near a rear edge of the autonomous coverage robot, the at least one cliff sensor responsive to a potential cliff rearward of the autonomous coverage robot, the drive system configured to alter a drive direction of the autonomous coverage robot in response to a signal received from the cliff sensor indicating the potential cliff.

18. The autonomous coverage robot of claim 1 in which the bin is removably secured to the chassis rearward of the cleaning assembly.

19. An autonomous coverage robot comprising:

a chassis having a forward portion and a rearward portion, the forward portion of the chassis defining a substantially rectangular shape;

a drive system for maneuvering the autonomous coverage robot over a cleaning surface, the drive system comprising drive wheels;

a cleaning assembly for agitating debris on the cleaning surface;

a bin that receives debris agitated by the cleaning assembly;

a pivotally attached bin cover configured to rotate between a first, closed position providing closure of a bin opening and a second, open position providing access to the bin opening;

a bin cover latch configured to lock the bin cover in the first, closed position and to disengage to allow the bin cover to move to the second, open position; and

a bin cover release for actuating the bin cover latch, the bin cover release allowing actuation of the bin cover latch while holding a handle positioned on the upper portion of the autonomous coverage robot.

20. The autonomous coverage robot of claim 19 in which the bin is removably secured to the chassis rearward of the cleaning assembly.

21. The autonomous coverage robot of claim 19 in which the bin is configured for debris evacuation from below into a base station receptacle when the autonomous coverage robot is positioned on the base station.

22. The autonomous coverage robot of claim 19, further comprising a plurality of sensors for obstacle avoidance and detection and a controller in communication with the plurality of sensors and the drive system, the controller configured to alter a drive direction of the autonomous coverage robot via the drive system in response to detection of an obstacle via one or more sensors of the plurality of sensors.

23. The autonomous coverage robot of claim 22 in which the plurality of sensors includes a plurality of bump sensors disposed at corners of the forward portion of the autonomous coverage robot, each bump sensor in the plurality of bump sensors comprising a sensor base and a sensor shroud positioned adjacent the sensor base, connected to the chassis, and movable with respect to the sensor base, an emitter housed by the sensor shroud, and one or more detectors carried by the sensor base.

24. The autonomous coverage robot of claim 23 in which the plurality of sensors includes a light based clearance sensor for detecting overhead objects within 2 feet of the autonomous coverage robot.

25. The autonomous coverage robot of claim 19, further comprising at least one cliff sensor carried by the rearward portion of the chassis and arranged substantially near a rear edge of the autonomous coverage robot, the at least one cliff sensor responsive to a potential cliff rearward of the autonomous coverage robot, the drive system configured to alter a drive direction of the autonomous coverage robot in response to a signal received from the cliff sensor indicating the potential cliff.

26. An autonomous coverage robot comprising:

a chassis having a forward portion and a rearward portion;

a drive system for maneuvering the autonomous coverage robot over a cleaning surface, the drive system comprising drive wheels;

a cleaning assembly for agitating debris on the cleaning surface, the cleaning assembly for agitating debris on the cleaning surface mounted on the forward portion of the chassis;

a bin that receives debris agitated by the cleaning assembly;

a pivotally attached bin cover configured to rotate between a first, closed position providing closure of a bin opening and a second, open position providing access to the bin opening;

a bin cover latch configured to lock the bin cover in the first, closed position and to disengage to allow the bin cover to move to the second, open position; and

a bin cover release for actuating the bin cover latch, the bin cover release allowing actuation of the bin cover latch while holding a handle positioned on the upper portion of the autonomous coverage robot.

27. The autonomous coverage robot according to claim 26, wherein the bin is removably secured to the chassis rearward of the cleaning assembly.

28. The autonomous coverage robot of claim 26 in which the bin is configured for debris evacuation from below into a base station receptacle when the autonomous coverage robot is position on the base station.

29. The autonomous coverage robot of claim 26, further comprising a plurality of sensors for obstacle avoidance and detection and a controller in communication with the plurality of sensors and the drive system, the controller configured to alter a drive direction of the autonomous coverage robot via the drive system in response to detection of an obstacle via one or more sensors of the plurality of sensors.

30. The autonomous coverage robot of claim 29 in which the plurality of sensors includes a plurality of bump sensors disposed at corners of the forward portion of the autonomous coverage robot, each bump sensor in the plurality of bump sensors comprising a sensor base and a sensor shroud positioned adjacent the sensor base, connected to the chassis, and movable with respect to the sensor base, an emitter housed by the sensor shroud, and one or more detectors carried by the sensor base.

31. The autonomous coverage robot of claim 30 in which the plurality of sensors includes a light based clearance sensor for detecting overhead objects within 2 feet of the autonomous coverage robot.

32. The autonomous coverage robot of claim 26, further comprising at least one cliff sensor carried by the rearward portion of the chassis and arranged substantially near a rear edge of the autonomous coverage robot, the at least one cliff sensor responsive to a potential cliff rearward of the autonomous coverage robot, the drive system configured to alter a drive direction of the autonomous coverage robot in response to a signal received from the cliff sensor indicating the potential cliff.