Autonomous floor-cleaning robot

• US 9,622,635 B2
• Filed: 05/21/2014
• Issued: 04/18/2017
• 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:
  US14/283,968
• Publication Number:
  US 20140250613A1
• Time in Patent Office: 1,063 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 robot comprising:

a robot housing having a forward portion;

a motor drive housed in the robot housing and configured to maneuver the robot on a floor surface;

at least two independently driven drive wheels moveably attached to the robot housing and biased toward the floor surface, each of the drive wheels being independently moveable downwardly;

a plurality of cliff sensors disposed forward of the wheels and spaced from each other, each cliff sensor comprising an emitter positioned to direct emissions toward a floor surface and a detector configured to receive emitter emissions reflected off of the floor surface, each cliff sensor responsive to a cliff in the floor surface and configured to send a signal when a cliff in the floor surface is detected;

at least one side brush driven about a nonhorizontal axis and comprising at least one brush arm having a plurality of bristles, at least a portion of the at least one side brush extending beyond a peripheral edge of the robot housing, and at least a portion of the at least one brush arm periodically intersecting a path between at least one of the plurality of cliff sensors and the floor surface; and

a controller in communication with the plurality of cliff sensors and the motor drive, configured to redirect movement of the robot when a cliff in the floor surface is detected.

2. The robot of claim 1, further comprising an obstacle detection sensor including an emitter and detector configured to detect the proximity of the robot to an obstacle and transmit a detection signal to the controller.

3. The robot of claim 2, wherein the obstacle detection sensor is substantially adjacent the forward portion of the robot housing.

4. The robot of claim 1, wherein the controller is configured to initiate a collision avoidance routine that navigates the robot about objects as the robot is maneuvered across the floor surface.

5. The robot of claim 1, wherein the plurality of cliff sensors are substantially equally spaced from one another along the forward portion of the robot housing.

6. The robot of claim 1, wherein the at least two drive wheels are moved to an extended position when the robot is removed from the floor surface.

7. The robot of claim 1, wherein free ends of the bristles of the at least one side brush define a locus that intersects a peripheral edge of one of the at least two independently driven drive wheels.

8. The robot of claim 1, further comprising a wheel drop sensor in communication with each drive wheel that is configured to sense when a drive wheel moves downwardly and send a signal indicating downward movement of the drive wheel.

9. The robot of claim 8, wherein the wheel drop sensor senses when the drive wheel pivots downwardly.

10. The robot of claim 8, wherein the wheel drop sensor senses when the drive wheel extends downwardly.

11. The autonomous coverage robot of claim 8, wherein the wheel drop sensor senses when the drive wheel extends in a direction away from the robot housing.

12. The robot of claim 8, wherein the controller is in communication with each of the wheel drop sensors.

13. A robot comprising:

a robot housing having a forward portion;

a motor drive housed in the robot housing;

at least two independently driven drive wheels moveably attached to the robot housing, each of the drive wheels being moveable downwardly;

a plurality of cliff sensors disposed forward of the wheels, each cliff sensor configured to send a signal when a cliff in the floor surface is detected;

at least one side brush, comprising at least one brush arm that includes a plurality of bristles, and at least a portion of the at least one brush arm periodically intersecting a path between at least one of the plurality of cliff sensors and the floor surface; and

a controller in communication with the plurality of cliff sensors and the motor drive, configured to redirect movement the robot when a cliff in the floor surface is detected.

14. The autonomous coverage robot of claim 13, wherein the plurality of cliff sensors are substantially evenly positioned along the forward portion of the robot housing.

15. The autonomous coverage robot of claim 13, wherein the controller is configured to initiate a collision avoidance routine that navigates the robot about objects as the robot moves across the floor surface.

16. The autonomous coverage robot of claim 13, wherein the at least one side brush is mounted in a recess in the robot housing in front of one of the drive wheels and adjacent the peripheral edge of the robot housing.

17. The autonomous coverage robot of claim 13, further comprising a bumper extending along a portion of the robot housing, the bumper having a bumper sensor responsive to movement of the bumper relative to the robot housing.

18. The autonomous coverage robot of claim 13, further comprising an obstacle detection sensor including an emitter and detector configured to detect the proximity of the robot to an obstacle and transmit a detection signal to the controller.

19. The autonomous coverage robot of claim 13, wherein the at least two drive wheels are moved to an extended position when the robot is removed from the floor surface.

20. The autonomous coverage robot of claim 13, wherein free ends of the bristles of the at least one side brush define a locus that intersects a peripheral edge of one of the at least two independently driven drive wheels.

21. The autonomous coverage robot of claim 13, further comprising a wheel drop sensor in communication with each drive wheel that is configured to sense when a drive wheel moves downwardly and send a signal indicating downward movement of the drive wheel.

22. The autonomous coverage robot of claim 21, wherein the wheel drop sensor senses when the drive wheel pivots in a direction away from the robot housing.

23. The autonomous coverage robot of claim 21, wherein the wheel drop sensor senses when the drive wheel extends in a direction away from the robot housing.

24. The autonomous coverage robot of claim 21, wherein the controller is in communication with each of the wheel drop sensors.