Autonomous floor-cleaning robot

• US 10,420,447 B2
• Filed: 04/14/2017
• Issued: 09/24/2019
• Est. Priority Date: 01/24/2001
• Status: Expired due to Term

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Jones, Joseph L., Mack, Newton E., Nugent, David M., Sandin, Paul E.
• Primary Examiner(s): Scruggs, Robert J
• Application Number:
  US15/487,680
• Publication Number:
  US 20170215673A1
• Time in Patent Office: 893 Days
• CPC Class Codes: A47L 11/282 having rotary tools
• 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 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 2201/06 Control of the cleaning action for autonomous devices; Automatic detection of the surface condition before, during or after cleaning
• CPC Class Codes: A47L 5/30 with driven dust-loosening tools, e.g. rotating brushes
• CPC Class Codes: A47L 5/34 with height adjustment of nozzles or dust-loosening tools
• CPC Class Codes: A47L 7/02 with driven tools for special purposes with floor-polishing tools A47L11/20
• CPC Class Codes: A47L 9/009 Carrying-vehicles; Arrangements of trollies or wheels; Means for avoiding mechanical obstacles
• CPC Class Codes: A47L 9/0411 driven by electric motor
• CPC Class Codes: A47L 9/0477 Rolls
• CPC Class Codes: A47L 9/0494 Height adjustment of dust-loosening tools
• CPC Class Codes: A47L 9/1409 Rigid filtering receptacles dust collecting receptacles for cyclones A47L9/1683
• CPC Class Codes: A47L 9/2826 the condition of the floor
• CPC Class Codes: A47L 9/2852 Elements for displacement of the vacuum cleaner or the accessories therefor, e.g. wheels, casters or nozzles
• CPC Class Codes: A47L 9/2894 Details related to signal transmission in suction cleaners
• CPC Class Codes: A47L 9/32 Handles

Abstract

An autonomous floor-cleaning robot comprising a housing infrastructure including a chassis, a power subsystem; for providing the energy to power the autonomous floor-cleaning robot, a motive subsystem operative to propel the autonomous floor-cleaning robot for cleaning operations, a command and control subsystem operative to control the autonomous floor-cleaning robot to effect cleaning operations, and a self-adjusting cleaning head subsystem that includes a deck mounted in pivotal combination with the chassis, a brush assembly mounted in combination with the deck and powered by the motive subsystem to sweep up particulates during cleaning operations, a vacuum assembly disposed in combination with the deck and powered by the motive subsystem to ingest particulates during cleaning operations, and a deck adjusting subassembly mounted in combination with the motive subsystem for the brush assembly, the deck, and the chassis that is automatically operative in response to an increase in brush torque in said brush assembly to pivot the deck with respect to said chassis. The autonomous floor-cleaning robot also includes a side brush assembly mounted in combination with the chassis and powered by the motive subsystem to entrain particulates outside the periphery of the housing infrastructure and to direct such particulates towards the self-adjusting cleaning head subsystem.

Claims

1. A floor-cleaning robot comprising:

a housing having a substantially round perimeter;

motors operably connected to wheels to move the floor-cleaning robot across a floor surface;

a spring biased displaceable bumper configured for displacement with respect to the housing responsive to obstacles encountered by the floor-cleaning robot;

a sensor responsive to displacement of the spring biased displaceable bumper;

a controller in electrical communication with both the sensor and the motors and configured to control the motors to maneuver the robot to travel away from the encountered obstacles across the floor surface during a floor-cleaning operation;

a vacuum assembly;

a driven cleaning brush, rotatable about an axis substantially parallel to an underside of the housing, the driven cleaning brush being positioned to brush the floor surface as the floor-cleaning robot is moved across the floor surface to brush surface debris towards the vacuum assembly;

a first cliff detector that detects a falling edge of the floor surface, the first cliff detector being located on a side of the floor-cleaning robot forward of the wheels; and

a driven side brush, comprising;

a hub;

a plurality of resilient brush arms extending outwardly from the hub; and

bristles at a distal end of each brush arm of the plurality of resilient brush arms, a portion of the driven side brush extending beyond the substantially round perimeter and positioned to brush floor surface debris from beyond the substantially round perimeter toward a projected path of the driven cleaning brush;

wherein the first cliff detector is located on the same side as the driven side brush, behind the driven side brush, and forward of the wheels.

2. The floor-cleaning robot of claim 1,

wherein the first cliff detector is located on a right side of the floor-cleaning robot forward of the wheels;

and

the floor-cleaning robot further comprises a second cliff detector that detects a falling edge of the floor surface, the second cliff detector being located on a left side of the floor-cleaning robot forward of the wheels,

wherein the wheels comprise a left wheel and a right wheel, and at least a portion of the driven cleaning brush is positioned between the left wheel and the right wheel.

3. The floor-cleaning robot of claim 2, further comprising:

a nose-wheel subassembly adjacent to a forward edge of the housing; and

a third cliff detector proximate to the nose-wheel subassembly.

4. The floor-cleaning robot of claim 1, wherein the controller is configured to move the robot in a wall-following mode to maneuver the robot along a wall in a direction that places the driven side brush against the wall.

5. The floor-cleaning robot of claim 1, wherein the controller is configured to operate the floor-cleaning robot in any of a plurality of modes, the plurality of modes comprising:

a spot-coverage mode whereby the floor-cleaning robot provides coverage of a spot on the floor, an obstacle following mode whereby the floor-cleaning robot travels adjacent to an obstacle, and a bounce mode whereby the floor-cleaning robot travels substantially in a direction away from an obstacle after detecting an obstacle.

6. The floor-cleaning robot of claim 1, further comprising a removable dust cartridge positioned to receive and collect particulates including the floor surface debris.

7. The floor-cleaning robot of claim 1, further comprising a first resilient blade extending from the underside of the housing rearward of the driven cleaning brush and having a distal edge configured to wipe the floor surface.

8. The floor-cleaning robot of claim 1, wherein the driven side brush is configured to rotate about an axis substantially perpendicular to the floor surface.

9. The floor-cleaning robot of claim 1 in which the wheels comprise a left wheel and a right wheel, and at least a portion of the driven cleaning brush is positioned between the left wheel and the right wheel.

10. A floor-cleaning robot comprising:

a housing having a substantially round perimeter;

motors operably connected to wheels to move the floor-cleaning robot across a floor surface;

a spring biased displaceable bumper configured for displacement with respect to the housing responsive to obstacles encountered by the floor-cleaning robot;

a sensor responsive to displacement of the spring biased displaceable bumper;

a controller in electrical communication with both the sensor and the motors and configured to control the motors to maneuver the robot to travel away from the encountered obstacles across the floor surface during a floor-cleaning operation;

a vacuum assembly;

a driven cleaning brush, rotatable about an axis substantially parallel to an underside of the housing, the driven cleaning brush being positioned to brush the floor surface as the floor-cleaning robot is moved across the floor surface to brush surface debris towards the vacuum assembly;

a first cliff detector that detects a falling edge of the floor surface, the first cliff detector being located on a side of the floor-cleaning robot forward of the wheels; and

a driven side brush, comprising;

a hub; and

bristles coupled to the hub and extending beyond the perimeter and positioned to brush floor surface debris from beyond the perimeter toward a projected path of the driven cleaning brush along the floor surface;

wherein the first cliff detector is located on the same side as the driven side brush, behind the driven side brush, and forward of the wheels.

11. The floor-cleaning robot of claim 10,

wherein the first cliff detector is located on a right side of the floor-cleaning robot forward of the wheels;

and

the floor-cleaning robot further comprises a second cliff detector configured to detect a falling edge of the floor surface, the second cliff detector being located on a left side of the floor-cleaning robot forward of the wheels,

wherein the wheels comprise a left wheel and a right wheel, and at least a portion of the driven cleaning brush is positioned between the left wheel and the right wheel.

12. The floor-cleaning robot of claim 11, further comprising:

a nose-wheel subassembly adjacent to a forward edge of the housing; and

third cliff detector proximate to the nose-wheel subassembly.

13. The floor-cleaning robot of claim 10, wherein the controller is configured to move the floor-cleaning robot in a wall-following mode to maneuver the floor-cleaning robot along a wall in a direction that places the driven side brush against the wall.

14. The floor-cleaning robot of claim 10, wherein the controller is configured to operate the floor-cleaning robot in any of a plurality of modes, the plurality of modes comprising:

a spot-coverage mode whereby the floor-cleaning robot provides coverage of a spot on the floor, an obstacle following mode whereby the floor-cleaning robot travels adjacent to an obstacle, and a bounce mode whereby the floor-cleaning robot travels substantially in a direction away from an obstacle after detecting an obstacle.

15. The floor-cleaning robot of claim 10, wherein the driven side brush further comprises resilient brush arms extending outwardly from the hub, wherein the bristles comprise multiple sets of bristles connected to a distal end of each brush arm.

16. The floor-cleaning robot of claim 10 in which the wheels comprise a left wheel and a right wheel, and at least a portion of the driven cleaning brush is positioned between the left wheel and the right wheel.

17. A self-propelled floor-cleaning robot comprising a housing defining a substantially round housing perimeter, the robot comprising:

a spring biased displaceable bumper configured for displacement with respect to the housing responsive to obstacles encountered by the self-propelled floor-cleaning robot;

a sensor responsive to displacement of the spring biased displaceable bumper;

a right wheel module;

a left wheel module;

a vacuum system operable to ingest particulates;

a driven side brush, comprising;

a hub;

bristles extending beyond the perimeter and positioned to brush floor surface debris from beyond the perimeter toward a location inside the perimeter;

a removable dust cartridge in communication with the vacuum system, and operable to store the particulates collected by the self-propelled floor-cleaning robot;

a first cliff detector located on a right side of the self-propelled floor-cleaning robot forward of the right wheel module; and

a second cliff detector located on a left side of the self-propelled floor-cleaning robot forward of the left wheel module, at least one of the first and second cliff detectors located behind the side brush assembly;

a third cliff detector located forward of the first and second cliff detectors and forward of the side brush assembly; and

a controller in electrical communication with a motor drive and the sensor and configured to control the motor drive to maneuver the self-propelled floor-cleaning robot about obstacles encountered and located on the floor surface.

18. The floor-cleaning robot of claim 17, wherein the driven side brush further comprises resilient brush arms extending outwardly from the hub, wherein the bristles comprise multiple sets of bristles connected to a distal end of each brush arm.

19. The floor-cleaning robot of claim 17, further comprising a driven cleaning brush disposed within the housing perimeter and positioned to engage the floor surface.

20. The floor-cleaning robot of claim 19, wherein the driven cleaning brush is rotatable about an axis substantially parallel to the floor surface and wherein the driven side brush rotatable about an axis substantially perpendicular to the floor surface.

21. The floor-cleaning robot of claim 17, further comprising a carrying handle hingedly coupled to the housing structure such that upon the self-propelled floor-cleaning robot being picked up by the carrying handle, an aft end of the self-propelled floor-cleaning robot lies below the forward end of the self-propelled floor-cleaning robot.

22. The floor-cleaning robot of claim 17, wherein the controller is configured to move the self-propelled floor-cleaning robot in a wall-following mode to maneuver the self-propelled floor-cleaning robot along a wall in a direction that places the driven side brush against the wall.