Compact Autonomous Coverage Robot

• US 20080276407A1
• Filed: 05/09/2008
• Published: 11/13/2008
• Est. Priority Date: 05/09/2007
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Mammen, Jeffrey W., Schnittman, Mark, Dubrovsky, Zivthan A., Solochek, Aaron
• Granted Patent: US 8,239,992 B2
• Time in Patent Office: Days
• US Class Current: 15/319
• 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 forward and rearward portions, the forward portion of the chassis defining a substantially rectangular shape;

a drive system carried by the chassis and configured to maneuver the robot over a cleaning surface;

a cleaning assembly mounted on the forward portion of the chassis;

a bin disposed adjacent the cleaning assembly and configured to receive debris agitated by the cleaning assembly;

a bin cover 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;

a body attached to the chassis;

a handle disposed on an upper portion of the body; and

a bin cover release configured to control movement of the bin cover between its first and second positions, the bin cover release being actuatable from substantially near the handle.

2. The autonomous coverage robot of claim 1, wherein the bin cover release is configured to move between a first, locking position which locks the bin cover in its first, closed position and a second, disengaged position which allows the bin cover to move to its second, open position.

3. The autonomous coverage robot of claim 2, wherein the bin cover release comprises a spring biased latch.

4. The autonomous coverage robot of claim 3, wherein the bin cover release further comprises a button disposed on the handle and configured to actuate the latch, thereby allowing actuation of the bin cover release while holding the handle.

5. The autonomous coverage robot of claim 1, wherein the cleaning assembly comprises a first roller brush rotatably mounted substantially near a front edge of the chassis.

6. The autonomous coverage robot of claim 5, wherein the cleaning assembly comprises a second roller brush rotatably mounted substantially parallel to and rearward of the first roller brush, the first and second roller brushes rotate in opposite directions.

7. The autonomous coverage robot of claim 6, wherein the bin is disposed rearward of the first and second roller brushes and forward of the drive system.

8. The autonomous coverage robot of claim 6, wherein each roller brush comprises right and left end brushes extending from respective ends of the roller brush beyond a lateral extend of the body, each end brush extending at angle φ

of between 0° and

about 90°

from a longitudinal axis defined by the roller brush.

9. The autonomous coverage robot of claim 1, wherein the cleaning assembly comprises a front roller brush rotatably mounted substantially near the front edge of the chassis, and right and left side roller brushes rotatably mounted orthogonal to the front brush substantially near the respective right and left side edges of the chassis.

10. The autonomous coverage robot of claim 9, wherein the bin is disposed rearward of the front roller brush and substantially between the right and left side roller brushes and forward of the drive system.

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

12. The autonomous coverage robot of claim 1, wherein the drive system comprises right and left differentially driven drive wheels rotatably mounted to the rearward portion of the chassis, the drive system being capable of maneuvering the robot to pivot in place.

13. The autonomous coverage robot of claim 12, wherein the rearward portion of the chassis defines a substantially semi-circular shape and the axes of the right and left drive wheels are disposed on or rearward of a center axis defined by the rearward portion of the chassis.

14. The autonomous coverage robot of claim 1, wherein the chassis and the body together have a length of less than 23 cm and a width of less than 19 cm.

15. The autonomous coverage robot of claim 1, further comprising at least one proximity sensor carried by a dominant side of the robot, the at least one proximity sensor responsive to an obstacle substantially near the body, the controller configured to alter a drive direction in response to a signal received from the at least one proximity sensor.

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

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

18. The autonomous coverage robot of claim 1, further comprising an idler wheel disposed on the bin cover.

19. The autonomous coverage robot of claim 18, wherein the rearward portion of the chassis defines a substantially semi-circular shape and the idler wheel is position at least ⅓

the radius of the substantially semi-circular shaped rearward portion forward of the drive wheels.

20. The autonomous coverage robot of claim 18, wherein the idler wheel comprises a stasis detector comprising:

a magnet disposed in or on the idler wheel; and

a magnet detector disposed adjacent the idler wheel for detecting the magnet as the idler wheel rotates.

26. The autonomous coverage robot of claim 1, further comprising a bumper guide configured to confine body movements to along two directions.

27. The autonomous coverage robot of claim 26, wherein the bumper guide comprises two orthogonal grooves defined by the body and configured to receive a guide pin disposed on the chassis.

28. The autonomous coverage robot of claim 1, wherein the cleaning assembly comprises a first roller brush rotatably mounted substantially near a front edge of the chassis.

29. The autonomous coverage robot of claim 28, wherein the cleaning assembly comprises a second roller brush rotatably mounted substantially parallel to and rearward of the first roller brush, the first and second roller brushes rotate in opposite directions.

30. The autonomous coverage robot of claim 29, further comprising a bin disposed rearward of the first and second roller brushes and forward of the drive system, the bin configured to receive debris agitated by the cleaning assembly.

31. The autonomous coverage robot of claim 29, wherein each roller brush comprises right and left end brushes extending from respective ends of the roller brush beyond a lateral extend of the body, each end brush extending at angle φ

of between 0° and

about 90°

from a longitudinal axis defined by the roller brush.

21. An autonomous coverage robot comprising:

a chassis having forward and rearward portions;

a drive system carried by the rearward portion of the chassis and configured to maneuver the robot over a cleaning surface;

a controller in communication with the drive system, the controller configured to maneuver the robot to pivot in place;

a cleaning assembly mounted on the forward portion of the chassis;

a bump sensor in communication with the controller and configured to detect movement in multiple directions; and

a body flexibly attached to the chassis and substantially covering the chassis, wherein contact with the body is translated to the bump sensor for detection;

wherein the controller is configured to alter a drive direction of the robot in response to a signal received from the bump sensor; and

wherein the bump sensor comprises;

a sensor base;

a sensor shroud positioned adjacent the sensor base and connected to the body;

an emitter housed by the sensor shroud, the emitter emitting a signal onto the sensor base; and

at least three detectors carried by the sensor base and configured to detect the emitted signal;

wherein movement of the sensor shroud causes movement of the emitted signal over the detectors.

22. The autonomous coverage robot of claim 21, wherein the bump sensor detects 360 degrees of movement of the body about the bump sensor.

23. The autonomous coverage robot of claim 21, wherein the bump sensor comprises four detectors arranged in a rectangular configuration with respect to each other.

24. The autonomous coverage robot of claim 21, wherein the sensor shroud defines an orifice through which the emitter emits its signal onto the sensor base.

25. The autonomous coverage robot of claim 24, wherein the emitter comprises an infrared light emitter and the detectors comprise infrared light detectors, the orifice collimating the emitted signal onto the sensor base.

32. The autonomous coverage robot of claim 21, wherein the cleaning assembly comprises a front roller brush rotatably mounted substantially near the front edge of the chassis, and right and left side roller brushes rotatably mounted orthogonal to the front brush substantially near the respective right and left side edges of the chassis.

33. The autonomous coverage robot of claim 32, further comprising a bin disposed rearward of the front roller brush and substantially between the right and left side roller brushes and forward of the drive system, the bin configured to receive debris agitated by the cleaning assembly.

34. The autonomous coverage robot of claim 21, wherein, the forward portion defining a substantially rectangular shape and the rearward portion of the chassis defines an arcuate shape.

35. The autonomous coverage robot of claim 21, wherein the drive system comprises right and left differentially driven drive wheels rotatably mounted to the rearward portion of the chassis, the drive system being capable of maneuvering the robot to pivot in place.

36. The autonomous coverage robot of claim 21, further comprising at least one proximity sensor carried by a dominant side of the robot, the at least one proximity sensor responsive to an obstacle substantially near the body, the controller configured to alter a drive direction in response to a signal received from the at least one proximity sensor.

37. The autonomous coverage robot of claim 21, further comprising at least one cliff sensor carried by a forward portion of the body and arranged substantially near a front edge of the body, the at least one cliff sensor responsive to a potential cliff forward of the robot, the drive system configured to alter a drive direction in response to a signal received from the cliff sensor indicating a potential cliff.

38. The autonomous coverage robot of claim 21, further comprising at least one cliff sensor carried by a rearward portion of the body and arranged substantially near the rear edge of the body, the at least one cliff sensor responsive to a potential cliff rearward of the robot, the drive system configured to alter a drive direction in response to a signal received from the cliff sensor indicating a potential cliff.

39. An autonomous coverage robot comprising:

a chassis having forward and rearward portions, the forward portion defining a substantially rectangular shape and the rearward portion defining an arcuate shape;

a drive system carried by the rearward portion of the chassis and configured to maneuver the robot over a cleaning surface, the drive system comprising right and left drive wheels differentially driven by corresponding right and left motors;

a controller in communication with the drive system, the controller configured to maneuver the robot to pivot in place;

a cleaning assembly mounted on the forward portion of the chassis;

an accelerometer in communication with the controller, the controller controlling the drive system in response to a signal received from the accelerometer.

40. The autonomous coverage robot of claim 39, wherein the controller alters a drive direction of the robot in response to a signal received from the accelerometer indicating an abrupt speed change.

41. The autonomous coverage robot of claim 39, wherein the controller alters a drive direction of the robot in response to a signal received from the accelerometer indicating stasis of the robot.

42. The autonomous coverage robot of claim 39, wherein the controller reduces a drive speed of the robot in response to a signal received from the accelerometer indicating a maximum speed.

43. The autonomous coverage robot of claim 42, wherein the maximum speed is between about 200 mm/s and about 400 mm/s.

44. The autonomous coverage robot of claim 39, wherein the cleaning assembly comprises a first roller brush rotatably mounted substantially near a front edge of the chassis.

45. The autonomous coverage robot of claim 44, wherein the cleaning assembly comprises a second roller brush rotatably mounted substantially parallel to and rearward of the first roller brush, the first and second roller brushes rotate in opposite directions.

46. The autonomous coverage robot of claim 45, further comprising a bin disposed rearward of the first and second roller brushes and forward of the drive system, the bin configured to receive debris agitated by the cleaning assembly.

47. The autonomous coverage robot of claim 45, wherein each roller brush comprises right and left end brushes extending from respective ends of the roller brush beyond a lateral extend of the body, each end brush extending at angle φ

of between 0° and

about 90°

from a longitudinal axis defined by the roller brush.

48. The autonomous coverage robot of claim 39, wherein the cleaning assembly comprises a front roller brush rotatably mounted substantially near the front edge of the chassis, and right and left side roller brushes rotatably mounted orthogonal to the front brush substantially near the respective right and left side edges of the chassis.

49. The autonomous coverage robot of claim 48, further comprising a bin disposed rearward of the front roller brush and substantially between the right and left side roller brushes and forward of the drive system, the bin configured to receive debris agitated by the cleaning assembly.

50. The autonomous coverage robot of claim 49, wherein the chassis and the body together have a length of less than 23 cm and a width of less than 19 cm.

51. The autonomous coverage robot of claim 39, further comprising at least one proximity sensor carried by a dominant side of the robot, the at least one proximity sensor responsive to an obstacle substantially near the body, the controller configured to alter a drive direction in response to a signal received from the at least one proximity sensor.

52. The autonomous coverage robot of claim 39, further comprising at least one cliff sensor carried by a forward portion of the body and arranged substantially near a front edge of the body, the at least one cliff sensor responsive to a potential cliff forward of the robot, the drive system configured to alter a drive direction in response to a signal received from the cliff sensor indicating a potential cliff.

53. The autonomous coverage robot of claim 39, further comprising at least one cliff sensor carried by a rearward portion of the body and arranged substantially near the rear edge of the body, the at least one cliff sensor responsive to a potential cliff rearward of the robot, the drive system configured to alter a drive direction in response to a signal received from the cliff sensor indicating a potential cliff.

54. An autonomous coverage robot comprising:

a chassis having forward and rearward portions, the forward portion defining a substantially rectangular shape, the rearward portion defining an arcuate shape;

a drive system carried by the rearward portion of the chassis and configured to maneuver the robot over a cleaning surface, the drive system comprising right and left drive wheels differentially driven by corresponding right and left motors;

a controller in communication with the drive system, the controller configured to maneuver the robot to pivot in place;

a cleaning assembly mounted on the forward portion of the chassis, the cleaning assembly comprising;

a first roller brush rotatably mounted substantially near a front edge of the chassis; and

a second roller brush rotatably mounted substantially parallel to and rearward of the first roller brush, the first and second roller brushes rotating in opposite directions;

a bin disposed rearward of the cleaning assembly and configured to receive debris agitated by the cleaning assembly;

a bin cover 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;

a bin cover release configured to control movement of the bin cover between its first and second positions;

a handle disposed on the chassis, wherein the bin cover release is actuatable from substantially near the handle;

a body flexibly attached to the chassis and substantially covering the chassis, the body being movable in relation to the handle and the chassis; and

a bump sensor in communication with the controller and configured to detect movement in multiple directions, wherein contact with the body is translated to the bump sensor for detection;

wherein the controller is configured to alter a drive direction of the robot in response to a signal received from the bump sensor.

55. The autonomous coverage robot of claim 54, wherein the bump sensor comprises:

a sensor base;

a sensor shroud position adjacent the sensor base and connected to the body;

an emitter housed by the sensor shroud, the emitter emitting a signal onto the sensor base; and

at least three detectors carried by the sensor base and configured to detect the emitted signal;

wherein movement of the sensor shroud causes movement of the emitted signal over the detectors.

56. The autonomous coverage robot of claim 54, further comprising a bumper guide configured to confine body movements to along two directions.

57. The autonomous coverage robot of claim 56, wherein the bumper guide comprises two orthogonal grooves defined by the body and configured to receive a guide pin disposed on the chassis.

58. The autonomous coverage robot of claim 54, wherein the chassis and the body together have a length of less than 23 cm and a width of less than 19 cm.

59. The autonomous coverage robot of claim 58, wherein the drive wheels are disposed less than 9 cm rearward of the cleaning assembly.

60. The autonomous coverage robot of claim 54, further comprising an idler wheel disposed on the bin cover.

61. The autonomous coverage robot of claim 60, wherein the rearward portion of the chassis defines a substantially semi-circular shape and the idler wheel is position at least ⅓

the radius of the substantially semi-circular shaped rearward portion forward of the drive wheels.

62. The autonomous coverage robot of claim 54, further comprising a power source disposed in the rearward portion of the chassis substantially between the right and left wheels.

63. The autonomous coverage robot of claim 62, wherein the power source is disposed adjacent and rearward of the bin.

64. The autonomous coverage robot of claim 54, wherein the cleaning assembly further comprises a brush motor configured to drive the first and second roller brushes, the brush motor being disposed substantially near a forward edge of the chassis.

65. The autonomous coverage robot of claim 54, wherein the first roller brush is disposed substantially near a forward edge of the chassis.

66. The autonomous coverage robot of claim 54, further comprising at least one proximity sensor carried by a dominant side of the robot, the at least one proximity sensor responsive to an obstacle substantially near the body, the controller configured to alter a drive direction in response to a signal received from the at least one proximity sensor.

67. The autonomous coverage robot of claim 54, further comprising at least one cliff sensor carried by a forward portion of the body and arranged substantially near a front edge of the body, the at least one cliff sensor responsive to a potential cliff forward of the robot, the drive system configured to alter a drive direction in response to a signal received from the cliff sensor indicating a potential cliff.

68. The autonomous coverage robot of claim 67, further comprising right and left front cliff sensors disposed at the respective right and left corners of a forward portion of the robot.

69. The autonomous coverage robot of claim 54, further comprising at least one cliff sensor carried by a rearward portion of the body and arranged substantially near the rear edge of the body, the at least one cliff sensor responsive to a potential cliff rearward of the robot, the drive system configured to alter a drive direction in response to a signal received from the cliff sensor indicating a potential cliff.

70. The autonomous coverage robot of claim 69, further comprising right and left rear cliff sensors disposed directly rearward of the respective right and left drive wheels.