Compact autonomous coverage robot

• US 8,839,477 B2
• Filed: 12/19/2012
• Issued: 09/23/2014
• 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): Carter, Monica S.
• Assistant Examiner(s): JENNINGS, MICHAEL DEANGILO
• Application Number:
  US13/719,784
• Publication Number:
  US 20130117952A1
• Time in Patent Office: 643 Days
• Field of Search: 15/411, 15/521, 15/46, 153/19, 153/404, 318/568.12, 318/568.16, 700/23, 700/258
• US Class Current: 15/41.1
• 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, when viewed from above an outer peripheral shape of the forward portion defining a substantially rectangular shape and an outer peripheral shape of the rear-ward portion defining an arcuate shape;

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

right and left differentially driven drive wheels;

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

bump sensors disposed at the forward corners of the chassis, with at least one bump sensor disposed on each side of each corner such that bump sensors on a lateral side of the robot detect bumps independently of bump sensors on a front side of the robot, thus allowing the robot to determine a direction and/or location of a collision.

2. The autonomous coverage robot of claim 1, wherein the rearward portion has a semi-circular profile defined by a profile circle that extends into the forward portion and has a center axis.

3. The autonomous coverage robot of claim 2, wherein the right and left drive wheels are positioned on or near the center axis of the profile circle such that the robot can turn in place without catching the rearward portion of the chassis on an obstacle.

4. The autonomous coverage robot of claim 3, wherein sides of the bumper are flat to allow the robot to skim along a wall.

5. The autonomous coverage robot of claim 1, comprising a bumper flexibly coupled to the chassis by one or more elastic elements, wherein the bump sensors are configured to detect movement of the bumper.

6. The autonomous coverage robot of claim 5, wherein the bumper covers a front portion and side portions of the forward portion of the chassis, and the bump sensors are configured to detect movement of the bumper in a direction normal to the front portion and in a direction normal to the side portions.

7. The autonomous coverage robot of claim 1, wherein the robot is configured to assume that an object it has bumped into is a wall and turn to follow the wall;

and

wherein the robot is configured to, after turning, drive straight along the wall and slightly turns into the wall so as to skim along the wall.

8. The autonomous coverage robot of claim 1 comprising a proximity sensor, wherein the robot is configured to semi-passively wall follow including:

detecting an object, assumed to be a wall, by either the bump sensor or the proximity sensor,

turning to align the dominant side of the robot with the assumed wall,

driving along the wall while turning slightly into the wall so as to skim along the wall,

maintaining contact with the wall by sensing contact with the wall via the bump sensor or the proximity sensor.

9. The autonomous coverage robot of claim 1, wherein a power source, preferably a battery, is positioned between the right and left drive wheels to place the center of gravity of the robot forward of a first transverse axis defined by the right and left drive wheels.

10. The autonomous coverage robot of claim 1, wherein the robot has a navigational sensor system in communication with the controller that allows the robot to be aware of its surroundings and environment and react in prescribed manners or behaviors according to its sensed perception of its surroundings and environment, the navigational sensor system including one or more cliff sensors, a stasis detector, a proximity sensor, the bump sensors, and/or an omni-directional receiver.

11. The autonomous coverage robot of claim 10, wherein the stasis detector indicates whether the robot is moving or stationary.

12. The autonomous coverage robot of claim 10, wherein

the stasis detector includes a stasis wheel with a magnet either embedded in or disposed on the wheel;

and

the stasis wheel acts as a third wheel.

13. The autonomous coverage robot of claim 1, comprising

at least one forward cliff sensor carried by the forward portion and arranged substantially near a front edge of the forward portion, the at least one forward cliff sensor configured to detect a potential cliff forward of the robot, wherein the drive system is configured to alter a drive direction in response to a signal received from the forward cliff sensor;

and

at least one rearward cliff sensor carried by a rearward portion and arranged substantially near the rear edge of the rearward portion, the at least one rearward 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 rearward cliff sensor.

14. The autonomous coverage robot of claim 1, wherein 1 the drive system is carried by the rearward portion of the chassis and includes right and left drive wheels differentially driven by corresponding right and left motors, and the autonomous coverage robot further includes

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

and

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

15. The autonomous coverage robot of claim 14, wherein the cleaning assembly comprises a roller brush rotatably mounted substantially near a front edge of the chassis.

16. The autonomous coverage robot of claim 14, wherein the controller is configured to alter a drive direction of the robot in response to a signal received from the accelerometer indicating an abrupt speed change.

17. The autonomous coverage robot of claim 14, wherein the controller is configured to alter a drive direction of the robot in response to a signal received from the accelerometer indicating stasis of the robot.

18. The autonomous coverage robot of claim 14, wherein the controller is configured to reduce a drive speed of the robot in response to a signal received from the accelerometer indicating a maximum speed.

19. The autonomous coverage robot of claim 18, wherein the maximum speed is between about 200 mm/s and about 400 mm/s.

20. The autonomous coverage robot of claim 1, wherein the bump sensor comprises four detectors arranged in a rectangular configuration with respect to each other.

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

22. The autonomous coverage robot of claim 1, wherein the right and left drive wheels are disposed less than 9 cm rearward of the cleaning assembly.

23. The autonomous coverage robot of claim 1, 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 chassis, the controller configured to alter a drive direction in response to a signal received from the at least one proximity sensor.

24. The autonomous coverage robot of claim 1, comprising right and left front cliff sensors disposed at the respective right and left corners of the forward portion of the chassis, the right and left front cliff sensors 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 right and left front cliff sensors indicating a potential cliff.

25. The autonomous coverage robot of claim 1, wherein the cleaning assembly comprises

a roller brush rotatably mounted within the chassis along a front edge of the chassis, and

a side brush mounted adjacent to the front edge so as to extend beyond the chassis.

26. The autonomous coverage robot of claim 1, wherein the cleaning assembly comprises

a roller brush rotatably mounted within the chassis along a front edge of the chassis, and

a side brush mounted adjacent to the front edge so as to extend beyond the chassis.

27. The autonomous coverage robot of claim 1, comprising:

a proximity sensor along a lateral side of the chassis, wherein the autonomous robot performs a first obstacle following based on the detection of a wall parallel to the lateral side of the chassis by the proximity sensor, and a second obstacle following based on detections of an obstacle by the bump sensor, in which the robot (i) in combination, backs up and turns in place to deactivate the bump sensor and to position to perform an obstacle following arc and (ii) the arc follows about the obstacle so that the lateral side of the chassis is arced about the obstacle.