Patent Grant
10376120
This disclosure relates to floor-traversing robots, and more particularly to protecting internal components of such robots from liquid damage.
Modern-day autonomous robots can perform numerous desired tasks in unstructured environments without continuous human guidance. Many kinds of floor-traversing robots, for example, are autonomous to some degree with respect to navigation, and therefore may encounter unexpected hazards during unsupervised autonomous missions. Hazards resulting in a liquid (water, coffee, or juice, for example) being spilled on the robot may be particularly problematic if the liquid comes into contact with the electronics autonomously controlling the robot.
In one aspect of the present disclosure, an autonomous floor-traversing robot includes: a wheeled body including a chassis and at least one motorized wheel configured to propel the chassis across a floor, the chassis defining an interior compartment disposed beneath a chassis ceiling; a cover extending across at least a central area of the chassis ceiling; and a graspable handle connected to the chassis and located outside the cover so as to be accessible from above the robot, the handle arranged to enable lifting of the robot. The chassis ceiling defines a primary drainage channel outside the cover configured to catch liquid from an outer surface of the cover and conduct the liquid away from the central area.
In some embodiments, the handle is pivotally coupled to the chassis and extends over a mounting bay defined in the chassis ceiling. In some examples, a floor of the mounting bay includes one or more drainage gutters to direct liquid from within the mounting bay out of the robot.
In some embodiments, the handle is mounted to the chassis at a position offset from the robot's center of gravity, such that the robot tilts when lifted.
In some embodiments, the chassis ceiling defines at least one secondary drainage channel extending beneath the cover and configured to conduct away from the central area. In some examples, the secondary drainage channel extends from a corner of a mounting bay retaining the handle. In some examples, the secondary drainage channel is defined by a plurality of struts extending integrally from a surface of the chassis ceiling to support the cover atop the chassis. In some examples, the secondary drainage channel defines an arcuate path leading across the chassis without traversing the central area. In some implementations, the arcuate path of the secondary drainage channel leads to a downwardly sloped egress region near a back end of the chassis. In some applications, the egress region leads to an opening to the interior of a cleaning bin of the robot. In some examples, the secondary drainage channel is downwardly sloped along a radial direction from the center of the chassis, so as to guide liquid away from the central area when the robot placed substantially flat on the floor.
In some embodiments, the primary drainage channel includes a circular race surrounding the cover.
In some embodiments, the primary drainage channel includes a recessed lower surface of the chassis ceiling traced by a raised outer rim of the body. In some examples, the cover is surrounded by the outer rim, and the primary drainage channel is configured to conduct the liquid towards a discharge gap formed in the outer rim.
In some embodiments, a lower surface of the primary drainage channel is downwardly sloped along a radial direction from the center of the chassis, so as to guide liquid to egress from the robot through an area along a side of the robot when the robot is placed substantially flat on the floor.
In some embodiments, the cover is removably coupled to the chassis ceiling.
In some embodiments, the cover includes a continuous sealing lip tracing an edge of the chassis ceiling when the cover is coupled to the chassis ceiling. In some examples, the cover further includes a plurality of locking tabs distributed intermittently along an inner face of the sealing lip to grip the edge of the chassis ceiling.
In some embodiments, the robot further includes a button plate coupled to an inner surface of the cover, the button plate including: a substantially flat base; a grommet situated within the base, the grommet including a flexible diaphragm; and a disk retained by an inner flange of the grommet, the disk positioned above an activatable mechanical button disposed beneath the chassis ceiling.
In some embodiments, an outer surface of the cover defines a domed contour sloping downwardly toward the primary drainage channel.
In yet another aspect of the present disclosure, an autonomous floor-traversing robot includes: a wheeled chassis including a chassis housing and at least one motorized wheel configured to propel the chassis across a floor, the chassis defining an interior compartment disposed beneath a chassis ceiling; a cover extending across at least a central area of the chassis ceiling; and a graspable handle connected to the chassis and located outside the cover so as to be accessible from above the robot, the handle arranged to enable lifting of the robot. The chassis ceiling has an upper surface defining one or more open drainage channels extending beneath the cover from a corner of a mounting bay retaining the handle and configured to conduct liquid toward an edge region of the robot.
In some embodiments, at least one of the drainage channels is defined by a plurality of struts extending integrally from a surface of the chassis ceiling to support the cover atop the chassis.
In some embodiments, at least one of the drainage channels defines an arcuate path leading across the chassis without traversing the central area. In some examples, the arcuate path leads to a downwardly sloped egress region near a back end of the chassis. In some implementations, the egress region leads to an opening to the interior of a cleaning bin of the robot.
In some embodiments, at least one of the drainage channels is located radially inwards of a primary drainage channel outside the cover configured to catch liquid from an outer surface of the cover and conduct the liquid away from the central area.
In some embodiments, at least one of the drainage channels is downwardly sloped along a radial direction from the center of the chassis, so as to guide liquid away from the central area when the robot placed substantially flat on the floor.
In yet another aspect of the present disclosure, an autonomous floor-traversing robot includes: a wheeled chassis including a chassis housing and at least one motorized wheel configured to propel the chassis across a floor, the chassis defining an interior compartment disposed beneath a chassis ceiling; a cover extending across at least a central area of the chassis ceiling; and a button plate coupled to an inner surface of the cover. The button plate includes: a substantially flat base; a grommet situated within the base, the grommet including a flexible diaphragm; and a disk retained by an inner flange of the grommet, the disk positioned above an activatable mechanical button disposed beneath the chassis ceiling.
In some embodiments, the disk is formed from a material that is substantially more rigid than a material of the flexible diaphragm.
In some embodiments, the base and the grommet include a unitary structure manufactured from an elastomeric polymer material.
In some embodiments, the button plate is aligned with an opening of the chassis ceiling exposing a mechanical button, with the flexible diaphragm of the grommet and the disk being configured to be received within the opening so as to reach the mechanical button when the disk is pressed downward by a user.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
During use, autonomous robots can encounter unexpected hazards including liquid (water, coffee, or juice, for example) being spilled or otherwise deposited on the robot. For example, if a vase or glass of water is placed near the edge of a table and the robot bumps into the table, the water could potentially spill onto the top surface of the robot. Such hazards resulting in a liquid being spilled on the robot may be particularly problematic if the liquid comes into contact with the electronics autonomously controlling the robot. For instance, liquids can short or otherwise cause a controller circuit board included in the robot to fail or operate improperly. Systems, components, and methods described herein can help to lessen the likelihood that liquid deposited (e.g., spilled) on the top surface of the robot will migrate to the circuit boards or other components that could potentially fail or malfunction due to contact with the liquid.
In some examples, to lessen the likelihood that liquid spilled on the top surface of the robot will migrate to the internal components, the robot includes a contoured protective cover and one or more drainage channels that cooperate to cause liquid to safely egress from the robot (e.g., flow off the sides of the robot and onto the floor). For example, the cover may direct the liquid into a primary drainage channel that surrounds the cover like a moat, and the primary drainage channel may guide the liquid to egress from the robot chassis without contacting any liquid-sensitive components. In some situations, rogue liquid may migrate past a sealing lip of the protective cover. Accordingly, a top surface of the robot chassis (e.g., a chassis ceiling) to which the cover is attached includes one or more secondary drainage channels extending beneath the cover. The secondary drainage channels are designed to guide or “channel” the liquid across the chassis ceiling to a safe egress point while preventing the liquid from entering an internal compartment of the robot chassis where the electronics are housed. In some examples, the raised edges which define the secondary drainage channels are provided by one or more struts that support the protective cover atop the chassis ceiling. In some examples, the secondary drainage channels can lead from locations where the liquid is most likely to migrate past the robot's protective cover to a sloped egress region where the liquid is unlikely to cause significant damage. For instance, a secondary drainage channel could lead from the edge of a mounting bay supporting the robot's handle at the front of the robot to an egress region at the back of the robot, such that the liquid is safely deposited into the robot's cleaning bin. The cleaning bin may become fouled in this case, but the more critical electronic components are preserved. Further, in some examples, a secondary drainage channel can direct the liquid radially outward towards the edge of the cover and away from a central region of the chassis where there are openings in the robot chassis exposing the internal electronics (e.g., openings exposing mechanical buttons or sensors).
In some examples, the protective cover can include one or more specially designed pressable buttons that prevent liquid from seeping past the protective cover in areas surrounding the buttons. For example, the protective cover can be fitted with a liquid-tight button plate that aligns with openings in the robot chassis that expose mechanical buttons. The button plate can include one or more grommets and one or more disks retained by the respective grommets. In some examples, the grommets may include flexible diaphragms that allow the disks to be pushed down into contact with the mechanical buttons by a user. When a disk is depressed down in\to contact with a mechanical button, the diaphragm flexes, but no fluid can seep or penetrate through the flexible seal.
The robot 100 may move in both forward and reverse drive directions; accordingly, the chassis 102 has corresponding forward and back ends 102a, 102b. The bumper 106 is mounted at the forward end 102a and faces the forward drive direction. Upon identification of furniture and other obstacles, the robot 100 can slow its approach and lightly and gently touch the obstacle with its bumper and then change direction to avoid further contact with the obstacle. In some embodiments, the robot 100 may navigate in the reverse direction with the back end 102b oriented in the direction of movement, for example during escape, bounce, and obstacle avoidance behaviors in which the robot 100 drives in reverse.
A cleaning head assembly 108 is located in a roller housing 109 coupled to a middle portion of the chassis 102. The cleaning head assembly 108 is mounted in a cleaning head frame (not shown) attachable to the chassis 102. The cleaning head frame supports the roller housing 109. The cleaning head assembly 108 includes a front roller 110 and a rear roller 112 rotatably mounted parallel to the floor surface and spaced apart from one another by a small elongated gap. The front 110 and rear 112 rollers are designed to contact and agitate the floor surface during use. In this example, each of the rollers 110, 112 features a pattern of chevron-shaped vanes distributed along its cylindrical exterior. Other suitable configurations, however, are also contemplated. For example, in some embodiments, at least one of the front and rear rollers may include bristles and/or elongated pliable flaps for agitating the floor surface.
Each of the front 110 and rear 112 rollers is rotatably driven by a brush motor (not shown) to dynamically lift (or “extract”) agitated debris from the floor surface. A robot vacuum (not shown) disposed in a cleaning bin 116 towards the back end 102b of the chassis 102 includes a motor driven fan (not shown) that pulls air up through the gap between the rollers 110, 112 to provide a suction force that assists the rollers in extracting debris from the floor surface. Air and debris that passes through the roller gap is routed through a plenum that leads to the cleaning bin 116. Air exhausted from the robot vacuum is directed through an exhaust port 118. In some examples, the exhaust port 118 includes a series of parallel slats angled upward, so as to direct airflow away from the floor surface. This design prevents exhaust air from blowing dust and other debris along the floor surface as the robot 100 executes a cleaning routine. The cleaning bin 116 is removable from the chassis 102 by a spring-loaded release mechanism 120.
Installed along the sidewall of the chassis 102, proximate the forward end 102a and ahead of the rollers 110, 112 in a forward drive direction, is a side brush 122 rotatable about an axis perpendicular to the floor surface. The side brush 122 allows the robot 100 to produce a wider coverage area for cleaning along the floor surface. In particular, the side brush 122 may flick debris from outside the area footprint of the robot 100 into the path of the centrally located cleaning head assembly.
Installed along either side of the chassis 102, bracketing a longitudinal axis of the roller housing 109, are independent drive wheels 124a, 124b that mobilize the robot 100 and provide two points of contact with the floor surface. The forward end 102a of the chassis 102 includes a non-driven, multi-directional caster wheel 126 which provides additional support for the robot 100 as a third point of contact with the floor surface.
A robot controller circuit 128 (depicted schematically) is carried by the chassis 102. In some examples, the controller circuit 128 is mounted on a printed circuit board (PCB), which carries a number of computing components (e.g., computer memory and computer processing chips, input/output components, etc.), and is attached to the chassis 102 in the interior compartment below the chassis ceiling 154. The robot controller circuit 128 is configured (e.g., appropriately designed and programmed) to govern over various other components of the robot 100 (e.g., the rollers 110, 112, the side brush 122, and/or the drive wheels 124a, 124b). As one example, the robot controller circuit 128 may provide commands to operate the drive wheels 124a, 124b in unison to maneuver the robot 100 forward or backward. As another example, the robot controller circuit 128 may issue a command to operate drive wheel 124a in a forward direction and drive wheel 124b in a rearward direction to execute a clock-wise turn. Similarly, the robot controller circuit 128 may provide commands to initiate or cease operation of the rotating rollers 110, 112 or the side brush 122. For example, the robot controller circuit 128 may issue a command to deactivate or reverse bias the rollers 110, 112 if they become tangled. In some embodiments, the robot controller circuit 128 is designed to implement a suitable behavior-based-robotics scheme to issue commands that cause the robot 100 to navigate and clean a floor surface in an autonomous fashion. The robot controller circuit 128, as well as other components of the robot 100, may be powered by a battery 130 disposed on the chassis 102 forward of the cleaning head assembly 108.
The robot controller circuit 128 implements the behavior-based-robotics scheme in response to feedback received from a plurality of sensors distributed about the robot 100 and communicatively coupled to the robot controller circuit 128. For instance, in this example, an array of proximity sensors (not shown) are installed along the periphery of the robot 100, including the front end bumper 106. The proximity sensors are responsive to the presence of potential obstacles that may appear in front of or beside the robot 100 as the robot moves in the forward drive direction. The robot 100 further includes an array of cliff sensors 132 installed along bottom of the chassis 102. The cliff sensors 132 are designed to detect a potential cliff, or flooring drop, forward of the robot 100 as the robot 100 moves in the forward drive direction. More specifically, the cliff sensors 132 are responsive to sudden changes in floor characteristics indicative of an edge or cliff of the floor surface (e.g., an edge of a stair).
The robot still further includes a visual sensor 134 aligned with a substantially transparent viewport 135 of the otherwise opaque protective cover 104. In some examples, the visual sensor 134 is provided in the form of a digital camera having a field of view optical axis oriented in the forward drive direction of the robot, for detecting features and landmarks in the operating environment and building a map, for example, using VSLAM technology. In the current example, the viewport 135 has a rounded rectangular shape with a viewing area of about 1,500 mm2 to about 2,000 mm2 (e.g., about 1,600 mm2 to about 1,800 mm2). In some examples, a ratio of the area of the viewport 135 to the area of the entire protective cover is from about 1:32 to about 1:31. In some examples, the viewport 135 is provided having a convex contour which may be incorporated in the overall domed shape of the cover 104, may facilitate the shedding of spilled liquid away from the viewport to keep the field of view of the visual sensor 134 unobstructed.
Various other types of sensors, though not shown or described in connection with the illustrated examples, may also be incorporated in the robot 100 without departing from the scope of the present disclosure. For example, a tactile sensor responsive to a collision of the bumper 106 and/or a brush-motor sensor responsive to motor current of the brush motor may be incorporated in the robot 100.
A communications module 136 mounted at the forward end 102a of the chassis 102 and communicatively coupled to the robot controller circuit 128. In some embodiments, the communications module is operable to send and receive signals to and from a remote device. For example, the communications module 136 may detect a navigation signal projected from an emitter of a navigation or virtual wall beacon or a homing signal projected from the emitter of a docking station. Docking, confinement, home base, and homing technologies discussed in U.S. Pat. Nos. 7,196,487; 7,188,000, U.S. Patent Application Publication No. 20050156562, and U.S. Patent Application Publication No. 20140100693 (the entireties of which are hereby incorporated by reference) describe suitable homing-navigation and docking technologies.
As shown in
Returning to
As shown, the shape of the forward edge 146 of the handle 138 matches the curved contour of the bumper 106 and includes a small concave notch 150 to accommodate the communications module 136, which provides sufficient clearance for the pivoting movement of the handle (see
Referring now to
In this example, the ceiling 154 includes a raised upper surface 156 and a recessed lower surface 160 that forms a flange-like ring surrounding the upper surface. The lower surface 160 of the ceiling 154 provides the base of a primary drainage channel 162 formed between a plateaued edge 161 of the chassis ceiling separating the upper surface from the lower surface and the robot's outer rim 105. As described below, the protective cover 104 is removably attached to the upper surface 156 of the ceiling 154, leaving the lower surface 160 (the base of the primary drainage channel) exposed outside the cover 104. Thus, in the illustrated example, the primary drainage channel 162 forms a circular race around the outside of the protective cover 104 like a moat to catch liquid shed from the top surface of the cover. In some examples, the depth of the primary drainage channel 162 is between about 0.3 cm and 0.6 cm (e.g., between about 0.4 cm and 0.5 cm, or about 4.5 cm). In some examples, the primary drainage channel 162 has a width of between about 5 mm and about 10 mm as measured between the edge of the channel and the robot's outer rim 105. The channel 162 has a width between about 20 mm and 25 mm to the edge of the surface of the ceiling.
In some examples, the base of the primary drainage channel (the lower surface 160) is substantially flat. However, in some other examples, the base is sloped, so as to cause liquid contained therein to flow off of the robot and down the sides of the robot body. In some examples, the slope of the primary drainage channel 162 as measured along a radial axis from the center of the robot is between about 5 degrees and about 10 degrees. Accordingly, when the robot 100 is in use or positioned substantially flat on the floor, liquid that reaches the primary drainage channel 162 in the front of the robot where the bumper 106 is located will flow off of the primary drainage channel 162 in an area between the robot chassis 102 and the bumper 106. For example, liquid that reaches the robot chassis near the robot's sidebrush 122 can flow off of the robot chassis along the side of the robot (e.g., past the cliff sensors 132). Thus, the liquid is directed away from the electronics that are inside the robot's chassis. In contrast, when the robot is lifted from the floor, the liquid can flow around the robot in the primary drainage channel and exit the robot near the dust bin as shown in
A central area 163 of the upper surface 156 of the chassis ceiling 154 includes a plurality of circular openings 164 exposing mechanical buttons 166 engageable by a user for operating the robot 100, and a plurality of rectangular openings 168 exposing indicator lights 170 selectively illuminated by the controller circuit 128 to communicate a status of the robot to the user. The drainage channels of the chassis ceiling are configured to direct liquid away from the openings in the central area to prevent liquid from coming into contact with the circuit boards and other electronic components inside the robot chassis. The central area 163 further includes an enlarged opening 172 receiving a mounting boot 174 supporting the visual sensor 134 (e.g., a camera). In this example, the mounting boot 174 includes a sealing rim 176 that engages the inner surface of the cover 104 to inhibit or prevent ingress of dust and other foreign matter. The mounting boot 174 is formed of a unitary piece of flexible, resilient material (e.g., molded rubber) and includes an aperture for receiving the visual sensor 134. The visual sensor 134 is protected from particulate egress by the sealing rim 176 of the mounting boot 174 which extends upwardly by between 0-3 mm from the surface of the chassis ceiling 154 and from the surface of the mounting boot 174 to form a seal with the inner surface of the cover 104.
Outside the central area 163, a patterned framework of struts (e.g., struts 177a′, 177a″, 177b′ and 177b″) rises integrally from the upper surface 156 of the chassis ceiling 154. In this example, the struts 177a, 177b serve two purposes; first, to support the cover 104 under vertical loading, and second, to define a secondary drainage channel 178—located radially inward of the primary drainage channel 162—for guiding liquid that may migrate beneath the cover 104 away from the central area 163 of the chassis ceiling 154. In some examples, the struts have a height of between about 1-3 mm (e.g., between 1-2 mm), which defines the depth of the secondary drainage channel 178. Thus, the secondary drainage channel 178 has sufficient depth to channel the liquid without adding significantly to the overall height of the robot 100.
In the example shown in
In the illustrated example, the secondary drainage channel 178 is primarily used to conduct fluid away from the central area 163 of the upper surface 156 during drainage when the robot 100 is lifted by the handle 138. However, similar to the primary drainage channel 162, the secondary drainage channel 178 may be sloped to guide liquid towards its outer edge formed by the crescent-shaped struts 177a″ and therefore away from the central area 163 when the robot is placed on a generally flat surface, such as when the robot 100 is in use. In some examples, the slope of the secondary drainage channel 178 as measured along a radial axis from the center of the robot is between about 5 degrees and about 10 degrees. In some other examples, the secondary drainage channel 178 is substantially flat.
As shown in
Any remaining fluid 12c that may flow under the handle 138 and into the mounting bay 142 is drained from the robot 100 via two drainage gutters 182 provided at the floor 144 of the mounting bay (see
As noted above, the protective cover 104 is detachably coupled to the ceiling 154 of the chassis 102. Referring to
As shown in
In some embodiments, the button plate 190 is provided in the form of a unitary structure manufactured from an elastomeric polymer material (e.g., silicone, a thermoplastic elastomer, or other appropriate thermoset). In some examples, the button-plate material has a Shore A hardness of about 10-40 (e.g., about 20). In the illustrated examples, the disks and grommets each have a circular shape and vary in size based on the corresponding openings of the chassis ceiling. In some examples, the inner flanges and the flexible diagrams are appropriately shaped and dimensioned to be received by the openings, so that the substantially rigid disks can reach the mechanical buttons beneath the ceiling. However, these components may be provided having any suitable shape or size without departing from the scope of the present disclosure.
While a number of examples have been described for illustration purposes, the foregoing description is not intended to limit the scope of the invention, which is defined by the scope of the appended claims. There are and will be other examples and modifications within the scope of the following claims.
This application is a continuation application of and claims priority to U.S. application Ser. No. 14/621,052, filed on Feb. 12, 2015, the entire contents of which are hereby incorporated by reference.
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