The invention relates to an autonomous vacuum cleaner. It finds particular application in conjunction with a robotic vacuum having a controller module, a cleaning head module, and an interconnecting hose and will be described with particular reference thereto. However, it is to be appreciated that the invention is also amenable to other applications, such as, for example, a single module robotic vacuum cleaner.
Generally, there are two standard types of vacuum cleaners: upright and canister. Uprights tend to be more popular in the United States because they are easier to manipulate and less expensive to manufacture. Conversely, the principal advantage of canister vacuums, which are more popular in Europe, is that, while the canister may be more cumbersome, the cleaning head is smaller.
It is well known that robots and robot technology can automate routine household tasks, eliminating the need for humans to perform these repetitive and time-consuming tasks. Currently, technology and innovation are both limiting factors in the capability of household cleaning robots. Computer processing power, battery life, electronic sensors, such as cameras, and efficient electric motors are all either just becoming available, cost effective, or reliable enough to use in autonomous consumer robots.
Much of the work on robotic vacuum cleaner technology has centered on navigation and obstacle detection and avoidance. The path of a robot determines its success at cleaning the entire available floor surface of a room, while navigating around obstacles such as furniture, and dictates whether or not it will get stuck. Some proposed systems have two sets of orthogonal drive wheels to enable the robot to move directly between any two points to increase its maneuverability. Many robotic vacuums also include methods for detecting and avoiding obstacles. Some known robotic vacuum cleaners have mounted the suction nozzle on a pivoting or transverse sliding arm so as to increase the reach of the robot. Recently, several patents and published patent applications have disclosed self-propelled and autonomous vacuum cleaners.
For example, U.S. Pat. No. 6,226,830 to Hendriks et al. and assigned to Philips Electronics discloses a self-propelled canister-type vacuum cleaner. The canister includes an electric motor, a caster wheel, two drive wheels, a controller, and at least one touch or proximity sensor. The controller controls at least the direction of at least one of the drive wheels. The vacuum cleaner also includes a conventional cleaning head and a hose assembly connecting the cleaning head to the canister. As a user operates the vacuum cleaner and controls the cleaning head, the sensors in the canister detect obstacles and the controller controls the canister to avoid the obstacles.
U.S. Pat. No. 6,370,453 to Sommer discloses an autonomous service robot for automatic suction of dust from floor surfaces. The robot is controlled so as to explore the adjacent area and to detect potential obstacles using special sensors before storing them in a data field. The displacement towards a new location is then carried out using the stored data until the whole accessible surface has been covered. One of the main constituent members of the robot includes an extensible arm that rests on the robot and on which contact and range sensors are arranged. When the robot is used as an automatic vacuum cleaner, airflow is forced into the robot arm. When one or more circular rotary brushes are provided at the front end of the arm, the cleaning effect is enhanced.
U.S. Pat. No. 6,463,368 to Feiten et al. discloses a self-propelled vacuum cleaner. The vacuum cleaner includes a pivotable arm and a cable to connect to an electrical receptacle for power. The arm includes a plurality of tactile sensors to recognize obstacles by touching the obstacle with the arm. The vacuum cleaner also includes a processor and a memory connected via a bus. An identified and traversed path is stored in an electronic map in the memory. Every obstacle identified on the path is entered in the map. The vacuum cleaner includes a cable drum for winding up the cable. The cable drum includes a motor to drive the cable drum for unwinding or winding the cable. The vacuum cleaner also includes a steering mechanism, wheels, and a motor for driving the vacuum cleaner along the path.
PCT Published Patent Application No. WO 02/074150 to Personal Robotics discloses a self-propelled canister vacuum cleaner. In one embodiment, the vacuum cleaner is autonomous. In another embodiment, the self-propelled vacuum cleaner is powered by standard utility power via a power cord. The canister vacuum cleaner includes a cleaning head module, a vacuum fan module (i.e., canister), and a hose assembly connecting the cleaning head module with the vacuum fan module. The vacuum fan module includes a controller that performs navigation and control functions for both the vacuum fan module and the cleaning head module. Alternatively, the controller may be separated from the vacuum fan module and the cleaning head module, and can be mobile. The vacuum fan module and the cleaning head module each include a drive mechanism for propulsion. The cleaning head module includes a cleaning brush assembly that can be motorized or air driven. The cleaning head module may also include a microcontroller that communicates with the controller.
U.S. patent application Ser. No. 10/423,588, filed Apr. 25, 2003 which is assigned to the assignee of this application and incorporated herein by reference also discloses a self-propelled canister vacuum cleaner. The vacuum portion is removable to provide a portable vacuum cleaner.
However, the current two component robotic vacuum cleaners lack a free-floating nozzle section to provide a cleaning head that is more versatile. Additionally, current robotic canister-like vacuum cleaners do not make the cleaning head as compact as possible with improved bumpers. Accordingly, a need exists to overcome the aforementioned shortcomings and others while providing a better and more advantageous design.
Thus, there is a particular need for an improved autonomous vacuum cleaner. The invention contemplates a robotic vacuum cleaner that overcomes the above- mentioned shortcomings as well as others.
In one aspect of the invention, an autonomous vacuum cleaner includes a first module, a hose connected at a first end to the first module and a second module spaced from the first module and connected to a second end of the hose. The first module includes a suction source. The hose is in fluid communication with the suction source. The second module includes a drive housing including a drive system to propel the second module and a nozzle section pivotally mounted to the drive housing. The nozzle section includes a suction opening in fluid communication with the hose.
In another aspect of the invention, an autonomous vacuum cleaner includes a first module housing a suction source and a dirt container. The autonomous vacuum cleaner further includes a hose connected at a first end to the first module and a second module space from the first module and connected to a second end of the hose. The second module includes a suction opening in fluid communication with the hose, a drive system to propel the second module and at least one bumper attached to the second module by an attachment arm.
Benefits and advantages of the invention will become apparent to those of ordinary skill in the art upon reading and understanding the description of the invention provided herein.
The invention is described in more detail in conjunction with a set of accompanying drawings, wherein:
While the invention is described in conjunction with the accompanying drawings, the drawings are for purposes of illustrating an exemplary embodiment of the invention and are not to be construed as limiting the invention to such embodiments. It is understood that the invention may take form in various components and arrangements of components beyond those provided in the drawings and the following associated description.
With reference to
The vacuum module 20 is carried by the transport module 22 and is in fluidic communication with the cleaning head 14 via the hose 16. If used, the remote control 18 would be in operative communication with the controller 12 and the controller would be in operative communication with the cleaning head module 14. The controller 12 can communicate with the cleaning head 14 via data lines (not shown) in the hose. In one embodiment, one data line could provide directional information to the cleaning head 14 and a second data line could provide sensor information from the cleaning head to the controller. Also, a power line could extend through the hose or on the hose to provide power to the cleaning head. Alternatively, both power and information can be sent over the same line. In another embodiment, the controller 12 could communicate with the cleaning head 14 via an RF emitting device in communication with a receiver in the cleaning head. In yet another embodiment, the controller and the cleaning head can communicate via infrared receivers and transmitters.
The controller 12 and the cleaning head 14 cooperate by moving in tandem across a surface area to vacuum dirt and dust from the surface. Typically, the cleaning head 14 acts as a slave to the controller 12, which is the master, for robotic cleaning operations. Since the cleaning head 14 is separate from the controller 12 in a tandem configuration, the cleaning head 14 can be significantly smaller than the controller 12 and smaller than known one-piece robotic vacuum cleaners. This arrangement allows the small cleaning head 14 to access and clean small or tight areas, including under and around furniture. In one embodiment, the vacuum portion 20 can be removed from the transport module 22 for use as a vacuum or blower for manual operations. Furthermore, the hose 16 can stretch up to three times its unstretched length, thus allowing the cleaning head to access areas well away from the controller.
The controller 12 can perform mapping localization, planning and control for the robotic vacuum 10. If used, the remote control 18 would allow a user to control the direction the robotic vacuum moves throughout the surface area. While the user is performing this function, the controller 12 can learn and map a floor plan for the surface area including any existing stationary objects.
With reference to
The vacuum module 20 includes a vacuum inlet 30, a dirt receptacle 32, a primary filter 34, a motor 36, a fan 38, an air exhaust outlet 40 and a secondary filter 42. The motor 36 and the fan 38 are operatively engaged when the motor 36 is powered. The fan 38 creates an airflow path pulling a suction at the suction inlet 24 by blowing air through the air exhaust outlet 40. Air is drawn into the airflow path at the suction inlet 24. Thus a suction airflow path is created between the suction inlet 24 and the fan 38. The motor and fan assembly is only one possible suction source contemplated by the invention. Other conventional suction sources, such as a pump or the like could be substituted. The vacuum or lower pressure in the suction airflow path draws dirt and dust particles in the suction inlet 24. The dirt and dust particles are retained in the dirt receptacle 32. The dirt receptacle 32 may be dirt cup or canister or a disposable bag, depending on whether a bag-less or bagged configuration is implemented.
Additionally, as shown in
With reference to
Referring to
A gear reduction assembly 98 mounts to the axle 86 and a driven wheel 102 attaches to the gear reduction assembly. The gear reduction assembly comprises a plurality of conventional gears and components that can reduce the high RPM output of the motor to lower the RPM translated to the driven wheel 102. A gear reduction assembly housing 108 encloses the gear reduction assembly 98 and attaches to the mounting frame 82. The driven wheel 102 also includes a rim 104 mounted to a hub 106 received by the wheel. Accordingly, the motor 72 drives the driven wheel 102, and the gear reduction assembly 98 decreases the high RPM output of the motor to a lower RPM for driving the wheel. With reference to
As also seen in
Connected to each wheel 102 and 114 can be an odometer (not shown). Each odometer can include an encoder (not shown) that communicates with the controller 12 or other control circuitry on the autonomous vacuum cleaner to calculate how far each wheel has traveled by multiplying the circumference of the wheel by the number of rotations of the wheel. Such information can be used for positioning of the cleaning head.
Each driven wheel 102 and 114 can also be driven independently of the other. For example, if the left driven wheel 102 is propelled forward at a faster speed than the right driven wheel 114, the cleaning head will turn along an arc to the right. Also, the driven wheels can be propelled in opposite directions such that the cleaning head 14 can rotate about its geometric center 116 (
As best viewed in
Accordingly, the left driven wheel 102, the right driven wheel 114 and the omni wheel 122 are situated about 120( apart from one another thus forming a triangular configuration. Mounted to the base plate 66 of the drive housing 60, a skid plate 124, having an opening 126 with the omni wheel protruding through it, protects the omni wheel. The skid plate 124 mounts to the base plate 66 via conventional fasteners 128. In an alternative embodiment, more than one omni wheel can be provided on the cleaning head. Furthermore, conventional casters can be provided additionally to the omni wheel or in lieu thereof.
With reference back to
With continued reference to
The right bumper 152 attaches in much the same manner as the left bumper 148. Attachment arms 176 and 178 attach the right bumper to the mounting wall 146 and the attachment is the same as for the left bumper. For the sake of brevity, description of the attachment is not provided.
The bumpers 148 and 152 resiliently attach to the mounting wall 146. Wire form springs 182 and 184 provide the resiliency for the bumpers. For the sake of brevity only the left bumper spring 182 will be described, since the springs are mirror images of one another. The left wire form spring 182 is positioned resting on the mounting wall 146 and having a first leg 186 abut against a rear wall 188 (best viewed in
With reference to
With reference back to
As shown in
With reference once more to
A left upper bumper 242 attaches to the rear of the chassis 64. The left upper bumper 242 includes hoops 244 to receive a pin 246 to pivotally attach the left upper bumper to the chassis. The pin 246 is received in an opening (not visible) in the chassis 64 at the rear side of the left drive housing portion 132 (
A right upper bumper 266 also mounts to the chassis 64 and communicates with a sensor 268 in much the same manner as left upper bumper 242 and left sensor 248. Therefore, for the sake of brevity, its description will not be supplied.
With reference to
The brushroll 25 includes a flange 296 that the belt engages. The flange 296 is received in a housing 298 that is a part of the lower nozzle portion 272. The housing 298 protects the belt from dust and dirt that is sucked into the brushroll chamber 27.
With reference once more to
The nozzle section 62 includes a left corner bumper 320, a right corner bumper 322 and a front bumper 324 positioned between the left corner bumper and the right corner bumper. The corner bumpers 320 and 322 each have a scalloped or serrated edge 326 and 328 respectively. The front bumper 324 also includes a scalloped edge 332 at one end that complements the scalloped edge 326 of the left front bumper and a scalloped edge 334 at the other end that complements the scalloped edge 328 of the right front bumper 322. The scalloped edges allow the bumpers to cover more ground. In other words, if the cleaning head module 14 contacts an obstruction near a corner of the cleaning head both the front bumper 324 and a corner bumper 320 or 322 can transmit a signal to the drive motors so that the cleaning head can move to avoid the obstruction in the future.
The left corner bumper 330 attaches to the upper nozzle portion 274 via an attachment arm 336. The attachment arm attaches to the upper nozzle portion 274 via a fastener 338 received in an opening 342 in the upper nozzle portion and an opening 344 in the attachment arm. The attachment arm pivotally attaches to the left corner bumper via a fastener 346 received in an opening 348 in a flange 352 of the bumper and an opening 354 in the attachment arm. A sensor 356 mounts to the upper nozzle portion 274 via a fastener 358 received in an opening 362 in the sensor and an opening 364 in the upper nozzle portion. A shutter 366 mounts to the left corner bumper 320 via a fastener 368 received in an opening 372 in the bumper and an opening 374 in the shutter. The shutter can fit into a recess 376 in the sensor 356 to activate the sensor. A spring 378 can bias the shutter 366 away from the recess 376 until the bumper contacts an object. At one end the spring attaches to a projection 382 of the upper nozzle portion. At an opposite end of the spring, it attaches to a projection 384 on the shutter. Likewise, the right corner bumper 332 attaches to the upper nozzle portion in much the same manner as the left corner bumper, and for the sake of brevity a detailed description of the attachment is not provided.
The front bumper 324 attaches to the upper nozzle portion 274 via attachment arms 392 and 394. The first or left attachment arm 392 includes a cylinder 396 that receives a post 398 mounted to a rear side of the front bumper. Similarly, the second or right attachment arm includes a cylinder 402 that receives a post 404 mounted to a rear side of the front bumper. The attachment arm 392 is received in a left recess 406 in the upper nozzle portion 274. A spring 408 is also received in the recess to bias the front bumper 324. A left front shutter 412 is interposed between the spring 408 and the attachment arm 392. Accordingly, when the bumper 324 contacts an object causing the attachment arm 392 to displace, the shutter pivots forward. This is shown in
With reference again to
With continued reference to
While the invention has been described in conjunction with a preferred embodiment, it is evident that many alternatives and modifications and variations will be apparent to those skilled in the art. Accordingly, the embodiments of the invention and the preceding description are intended to be illustrative, rather than limiting, of the spirit and scope of the invention. More specifically, it is intended that the invention embrace all alternatives, modifications, and variations of the exemplary embodiments described herein that fall within the spirit and scope of the appended claims or the equivalents thereof.