Modular Robot

• US 10,524,629 B2
• Filed: 08/18/2014
• Issued: 01/07/2020
• Est. Priority Date: 12/02/2005
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Won, Chikyung, Burnett, Scott Thomas, Hickey, Stephen A., Kapoor, Deepak Ramesh, Dubrovsky, Zivthan A., Svendsen, Selma, Rizzari, Robert, Sandin, Paul E.
• Primary Examiner(s): Redding, David
• Application Number:
  US14/461,733
• Publication Number:
  US 20140352103A1
• Time in Patent Office: 1,968 Days
• Field of Search: 15319, 15339
• CPC Class Codes: A47L 11/24 Floor-sweeping machines, motor-driven
• CPC Class Codes: A47L 11/40 Parts or details of machines not provided for in groups A47L11/02 - A47L11/38, or not restricted to one of these groups, e.g. handles, arrangements of switches, skirts, buffers, levers
• 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 11/4013 Contaminants collecting devices, i.e. hoppers, tanks or the like
• CPC Class Codes: A47L 11/4041 Roll shaped surface treating 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 11/4072 Arrangement of castors or wheels
• 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 5/30 with driven dust-loosening tools, e.g. rotating brushes
• CPC Class Codes: A47L 9/009 Carrying-vehicles; Arrangements of trollies or wheels; Means for avoiding mechanical obstacles
• CPC Class Codes: A47L 9/0466 Rotating tools
• CPC Class Codes: A47L 9/12 Dry filters
• CPC Class Codes: A47L 9/2857 User input or output elements for control, e.g. buttons, switches or displays
• CPC Class Codes: A47L 9/2894 Details related to signal transmission in suction cleaners
• CPC Class Codes: A47L 9/30 Arrangement of illuminating devices
• CPC Class Codes: B25J 9/0003 Home robots, i.e. small robots for domestic use
• 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 2250/10 by alarm
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2260/32 : Auto pilot mode
• CPC Class Codes: B60L 50/52 : characterised by DC-motors
• 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 1/0234 : using optical markers or beacons optical beacons per se G01S1/70
• 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: G05D 1/0272 : comprising means for registering the travel distance, e.g. revolutions of wheels measuring distance traversed on the ground by vehicles, e.g. using odometers G01C22/00
• CPC Class Codes: G05D 1/0274 : using mapping information stored in a memory device navigation using map-matching G01C21/30
• CPC Class Codes: G05D 1/028 : using a RF signal
• CPC Class Codes: H04L 1/16 : in which the return channel carries supervisory signals, e.g. repetition request signals
• 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: Y10S 901/01 : Mobile robot
• CPC Class Codes: Y10S 901/50 : Miscellaneous

Abstract

A coverage robot including a chassis, multiple drive wheel assemblies disposed on the chassis, and a cleaning assembly carried by the chassis. Each drive wheel assembly including a drive wheel assembly housing, a wheel rotatably coupled to the housing, and a wheel drive motor carried by the drive wheel assembly housing and operable to drive the wheel. The cleaning assembly including a cleaning assembly housing, a cleaning head rotatably coupled to the cleaning assembly housing, and a cleaning drive motor carried by cleaning assembly housing and operable to drive the cleaning head. The wheel assemblies and the cleaning assembly are each separately and independently removable from respective receptacles of the chassis as complete units.

Claims

1. A coverage robot comprising:

a chassis;

a battery carried by the chassis;

a cleaning assembly carried by the chassis, the cleaning assembly comprising;

a cleaning head configured to collect debris from a work surface; and

a cleaning drive motor operable to drive the cleaning head;

a cleaning bin arranged to collect debris removed from the work surface by the cleaning head; and

a data module comprising a recording device configured to record a distance driven by the coverage robot and configured to record how often the robot has been used.

2. The robot of claim 1, further comprising:

a removable caster wheel assembly; and

a side brush disposed rearward of the caster wheel assembly.

3. The robot of claim 2, further comprising:

multiple drive wheel assemblies disposed rearward of the caster wheel assembly; and

at least one proximity sensor disposed rearward of the caster wheel assembly.

4. The robot of claim 1 wherein the coverage robot further comprises at least one proximity sensor configured to detect an absence of an adjacent floor surface.

5. The robot of claim 1 wherein the cleaning bin further comprises a bin cover spring actuator that biases a bin cover in the open position and a latch to hold the biased bin cover in the closed position.

6. The robot of claim 1, wherein the cleaning bin comprises:

a bin housing defining a debris cavity and a filter cavity, the debris cavity configured to collect debris removed from a work surface by the cleaning head;

a bin filter disposed in the filter cavity, the filter configured to substantially inhibit particulate from entering a vacuum fan adjacent the filter cavity; and

a bin cover attached to the bin housing and configured to move between a bin closed position and a bin open position, exposing the filter cavity and the bin filter for servicing.

7. The robot of claim 2, wherein the caster wheel

is configured to turn about a vertical axis and roll about a horizontal axis.

8. The robot of claim 2, wherein the caster wheel assembly is separately and independently removable from a receptacle of the chassis as a complete unit.

9. The robot of claim 2, wherein the caster wheel assembly further comprises a wheel-floor proximity sensor.

10. The robot of claim 1, wherein the cleaning assembly further comprises a power connector disposed on an outer surface of the cleaning assembly housing and configured to mate with a corresponding chassis power connector within its respective receptacle as the cleaning assembly is placed within the receptacle, to establish an electric power connection to the cleaning assembly.

11. The robot of claim 1, wherein the data module is further configured to record usage of at least one constituent part of the robot.

12. The robot of claim 11, wherein the data module is further configured to record a life span of at least one constituent part of the robot.

13. The robot of claim 12, wherein the at least one constituent part of the robot comprises at least one of a drive wheel, a caster wheel, and a side brush.

14. The robot of claim 12, wherein the at least one constituent part of the robot comprises a main brush.

15. The robot of claim 1, wherein the data module is configured to send a signal comprising information representing that at least one constituent part of the robot needs to be replaced.

16. The robot of claim 1, wherein the robot is configured to present an indication that at least one constituent part of the robot needs to be replaced.

17. The robot of claim 1, wherein the robot is configured to send a signal over a local network, the signal comprising an indication that at least one constituent part of the robot needs to be replaced.

18. The robot of claim 1, wherein the robot is configured to output an audible message that at least one constituent part of the robot needs to be replaced.

19. The robot of claim 1, wherein the data module is further configured to record when at least one constituent part of the robot is changed.

20. The robot of claim 2, further comprising charging contacts positioned on either side of the caster wheel assembly.

21. The robot of claim 1, wherein the cleaning drive motor is positioned rearward of the cleaning head in the cleaning assembly.

22. The robot of claim 2, further comprising:

multiple drive wheel assemblies disposed rearward of the caster wheel assembly; and

at least one proximity sensor disposed forward of the drive wheel assemblies.

23. The robot of claim 2, further comprising:

multiple drive wheel assemblies disposed rearward of the caster wheel assembly; and

at least one proximity sensor disposed rearward of the caster wheel assembly and forward of the drive wheel assemblies.