Autonomous floor cleaning robot

• US 9,167,946 B2
• Filed: 08/06/2007
• Issued: 10/27/2015
• 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): Redding, David A
• Application Number:
  US11/834,647
• Publication Number:
  US 20080000042A1
• Time in Patent Office: 3,004 Days
• Field of Search: 153/19, 153/403, 153/404, 153/53, 153/84, 153/39, 153/272, 153/64, 153/66, 153/56, 153/59
• US Class Current: 1/1
• 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. An autonomous floor-cleaning robot comprising:

a housing infrastructure including a chassis having forward and rearward ends;

a single removable collection cartridge carried by the chassis;

a motive subsystem drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly powered by the motive subsystem to that sweeps up particulates during cleaning operations;

a vacuum assembly powered by the motive subsystem that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet rearward of the brush assembly, the vacuum inlet including a first compliant blade having a generally rectangular configuration and a lateral dimension that defines a predetermined width of the vacuum inlet, wherein the first compliant blade extends beyond a lateral dimension of the brush assembly and is positioned to graze a surface to be cleaned; and

a replaceable filter retained in a chamber of the cartridge;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein the collection cartridge comprises a curved arcuate sidewall substantially continuing with an external sidewall of the housing infrastructure, the housing infrastructure having a structural envelope defining a generally cylindrical shape generally symmetrical along a forward portion of the housing infrastructure.

2. The autonomous floor-cleaning robot of claim 1 wherein the vacuum inlet further comprises a second blade spaced apart from the first blade to form a gap therebetween and having a generally rectangular configuration that is complementary to the configuration of the first blade, wherein the first and second blades in combination define the vacuum inlet having the predetermined width and gap.

3. The autonomous floor-cleaning robot of claim 2 further comprising a plurality of protrusions between the first blade and the second blade to form the predetermined gap of the vacuum inlet.

4. The autonomous floor-cleaning robot of claim 1 wherein a free lateral edge of the first blade has a castellated configuration to mitigate the pushing of particulates by the vacuum inlet during cleaning operations, the castellated configuration defining a plurality of castellated segments along the free lateral edge.

5. The autonomous floor-cleaning robot of claim 1 wherein the first blade is angled forwardly with respect to the housing.

6. The autonomous floor-cleaning robot of claim 1 wherein the vacuum inlet extends beyond the lateral dimensions of the brush assembly.

7. The autonomous floor-cleaning robot of claim 1 wherein the removable cartridge includes first and second chambers for receiving particulate.

8. The autonomous floor-cleaning robot of claim 7 wherein the first chamber is configured to receive particulate swept up by the brush assembly.

9. The autonomous floor-cleaning robot of claim 8 wherein the second chamber is configured to receive particulate drawn in by the vacuum assembly.

10. The autonomous floor-cleaning robot of claim 1 wherein a sidewall of the cartridge is configured to define part of or continuation of a rear external sidewall of the housing.

11. The autonomous floor-cleaning robot of claim 1 wherein the removable cartridge further comprise a plurality of baffled projection configured to remove debris entrained in the brush assembly.

12. The autonomous floor-cleaning robot of claim 1 wherein a back wall of the removable cartridge defines a baffle for angularly deflecting particulates swept up by the brush assembly.

13. The autonomous floor-cleaning robot of claim 1, wherein a portion of the removable cartridge defines a vacuum inlet and a part of or continuation of the housing.

14. The autonomous floor-cleaning robot of claim 1 wherein the brush assembly includes a flapper brush comprising angled pliable segments.

15. The autonomous floor-cleaning robot of claim 1 wherein the vacuum assembly further comprising a vacuum chamber, vacuum channel and an impeller.

16. The autonomous floor-cleaning robot of claim 1 wherein the cartridge comprises guide ribs for distributing air inflowing through the vacuum inlet across a floor portion of the cartridge.

17. The autonomous floor-cleaning robot of claim 1 wherein a portion of the cartridge is at least partially transparent to permit visual determination of a filling or clogging status of the cartridge.

18. The autonomous floor-cleaning robot of claim 1 further comprising a side-brush assembly configured to direct particulates towards the main brush.

19. The autonomous floor-cleaning robot of claim 18 wherein the side-brush assembly comprises opposed brush arms configured to allow passage of detection signals through the brush path.

20. The autonomous floor-cleaning robot of claim 1 wherein the brush assembly is height positionable by a self-adjusting deck assembly.

21. The autonomous floor-cleaning robot of claim 20 wherein the self-adjusting deck assembly is configured to self-adjust as a function of torque applied to the brush assembly.

22. The autonomous floor-cleaning robot of claim 1 further comprising a cliff detector forward of the brush assembly.

23. The autonomous floor-cleaning robot of claim 1 wherein the first blade is configured to graze a surface to be cleaned.

24. An autonomous floor-cleaning robot comprising:

a housing infrastructure including a chassis having forward and rearward ends;

a single removable collection cartridge carried by the chassis;

a motive subsystem drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly powered by the motive subsystem to that sweeps up particulates during cleaning operations;

a vacuum assembly powered by the motive subsystem that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet rearward of the brush assembly, the vacuum inlet including a first compliant blade having a generally rectangular configuration and a lateral dimension that defines a predetermined width of the vacuum inlet, wherein the first compliant blade extends beyond a lateral dimension of the brush assembly and is positioned to graze a surface to be cleaned; and

a replaceable filter retained in a chamber of the cartridge;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein the particles are collected into a first chamber and the replaceable filter is retained in a second chamber of the cartridge.

25. An autonomous floor-cleaning robot comprising:

a housing infrastructure including a chassis having forward and rearward ends;

a single removable collection cartridge carried by the chassis;

a motive subsystem drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly powered by the motive subsystem to that sweeps up particulates during cleaning operations;

a vacuum assembly powered by the motive subsystem that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet rearward of the brush assembly, the vacuum inlet including a first compliant blade having a generally rectangular configuration and a lateral dimension that defines a predetermined width of the vacuum inlet, wherein the first compliant blade extends beyond a lateral dimension of the brush assembly and is positioned to graze a surface to be cleaned; and

a replaceable filter retained in a chamber of the cartridge;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein the replaceable filter is configured for snap-fit insertion adjacent a floor portion of the cartridge.

26. An autonomous floor-cleaning robot comprising:

a housing infrastructure including a chassis having forward and rearward ends;

a single removable collection cartridge carried by the chassis;

a motive subsystem drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly powered by the motive subsystem to that sweeps up particulates during cleaning operations;

a vacuum assembly powered by the motive subsystem that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet rearward of the brush assembly, the vacuum inlet including a first compliant blade having a generally rectangular configuration and a lateral dimension that defines a predetermined width of the vacuum inlet, wherein the first compliant blade extends beyond a lateral dimension of the brush assembly and is positioned to graze a surface to be cleaned; and

a replaceable filter retained in a chamber of the cartridge;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein the brush assembly includes a flapper brush comprising angled pliable segments, the flapper brush is configured to counter-rotate with respect to a main brush of the brush assembly.

27. An autonomous floor-cleaning robot comprising:

a housing infrastructure including a chassis having forward and rearward ends;

a single removable collection cartridge carried by the chassis;

a motive subsystem drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly powered by the motive subsystem to that sweeps up particulates during cleaning operations;

a vacuum assembly powered by the motive subsystem that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet rearward of the brush assembly, the vacuum inlet including a first compliant blade having a generally rectangular configuration and a lateral dimension that defines a predetermined width of the vacuum inlet, wherein the first compliant blade extends beyond a lateral dimension of the brush assembly and is positioned to graze a surface to be cleaned; and

a replaceable filter retained in a chamber of the cartridge;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein the brush assembly includes counter-rotating, asymmetric brushes.

28. An autonomous floor-cleaning robot comprising:

a housing including a chassis;

a single removable cartridge carried by the chassis;

a drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly that sweeps up particulates during cleaning operations; and

a vacuum assembly that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet having a first blade that defines a generally rectangular configuration and has a lateral dimension that defines a predetermined width of the vacuum inlet and is less than a width of the housing;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge; and

wherein the collection cartridge comprises a curved arcuate sidewall substantially continuing with an external sidewall of the housing infrastructure, the housing infrastructure having a structural envelope defining a generally cylindrical shape generally symmetrical along a forward portion of the housing infrastructure.

29. The autonomous floor-cleaning robot of claim 28 wherein the housing is substantially circular and the sidewall of the cartridge is configured to define an arcuate portion of the external sidewall of the housing.

30. The autonomous floor-cleaning robot of claim 28 wherein a portion of the removable cartridge defines a vacuum inlet and a part of or continuation of the housing.

31. The autonomous floor-cleaning robot of claim 28 wherein the brush assembly includes a flapper brush comprising angled pliable segments.

32. The autonomous floor-cleaning robot of claim 28 wherein a portion of the cartridge is at least partially transparent to permit visual determination of a filling or clogging status of the cartridge.

33. The autonomous floor-cleaning robot of claim 28 further comprising a side-brush assembly configured to direct particulates towards the main brush.

34. The autonomous floor-cleaning robot of claim 28 wherein the side-brush assembly comprises opposed brush arms configured to allow passage of detection signals through the brush path.

35. The autonomous floor-cleaning robot of claim 28 wherein the brush assembly is height positionable by a self-adjusting deck assembly.

36. The autonomous floor-cleaning robot of claim 28 further comprising a cliff detector forward of the brush assembly.

37. The autonomous floor-cleaning robot of claim 28 wherein the first blade is configured to graze a surface to be cleaned.

38. An autonomous floor-cleaning robot comprising:

a housing including a chassis;

a single removable cartridge carried by the chassis;

a drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly that sweeps up particulates during cleaning operations; and

a vacuum assembly that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet having a first blade that defines a generally rectangular configuration and has a lateral dimension that defines a predetermined width of the vacuum inlet and is less than a width of the housing;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein a sidewall of the cartridge comprises a curved arcuate member configured to define part of or a continuation of an external sidewall of the housing; and

wherein the flapper brush is configured to counter-rotate with respect to a main brush of the brush assembly.

39. An autonomous floor-cleaning robot comprising:

a housing including a chassis;

a single removable cartridge carried by the chassis;

a drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly that sweeps up particulates during cleaning operations; and

a vacuum assembly that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet having a first blade that defines a generally rectangular configuration and has a lateral dimension that defines a predetermined width of the vacuum inlet and is less than a width of the housing;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein a sidewall of the cartridge comprises a curved arcuate member configured to define part of or a continuation of an external sidewall of the housing; and

wherein the brush assembly includes counter-rotating, asymmetric brushes.

40. An autonomous floor-cleaning robot comprising:

a housing including a chassis;

a single removable cartridge carried by the chassis;

a drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly that sweeps up particulates during cleaning operations; and

a vacuum assembly that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet having a first blade that defines a generally rectangular configuration and has a lateral dimension that defines a predetermined width of the vacuum inlet and is less than a width of the housing;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge;

wherein a sidewall of the cartridge comprises a curved arcuate member configured to define part of or a continuation of an external sidewall of the housing; and

wherein the self-adjusting deck assembly is configured to self-adjust as a function of torque applied to the brush assembly.

41. An autonomous floor-cleaning robot comprising:

a housing infrastructure including a chassis having forward and rearward ends;

a single removable collection cartridge carried by the chassis;

a motive subsystem drive assembly operative to propel the autonomous floor-cleaning robot forward for cleaning operations;

a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations;

a brush assembly powered by the motive subsystem to that sweeps up particulates during cleaning operations;

a vacuum assembly powered by the motive subsystem that collects particulates during cleaning operations, the vacuum assembly including a vacuum inlet rearward of the brush assembly, the vacuum inlet including a first compliant blade having a generally rectangular configuration and a lateral dimension that defines a predetermined width of the vacuum inlet; and

a replaceable filter retained in a chamber of the cartridge and configured for snap-fit insertion adjacent a floor portion of the cartridge;

wherein both the brush assembly sweeps and the vacuum inlet collects particles into the single removable cartridge; and

wherein the collection cartridge comprises a curved arcuate sidewall substantially continuing with an external sidewall of the housing infrastructure, the housing infrastructure having a structural envelope defining a generally cylindrical shape generally symmetrical along a forward portion of the housing infrastructure.