JP2004195215A - Autonomous floor cleaning robot - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To optimize a cleaning ability, and also to minimize a request for electric power. <P>SOLUTION: An autonomous floor-cleaning robot comprises: a housing infrastructure; a power subsystem; a motive subsystem; a command and control subsystem; and a self-adjusting cleaning head subsystem. The self-adjusting cleaning head subsystem 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 the particulates during the cleaning operations, and a deck adjusting subassembly which is mounted in combination with the motive subsystem, the brush assembly, and the chassis and is automatically operative in response to an increase in brush torque in the brush assembly to pivot the deck with respect to the chassis. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

  The present invention relates to cleaning devices, and more particularly, to optimize the cleaning capability and efficiency of the self-adjustable cleaning head subsystem while concomitantly minimizing the power requirements of the self-adjustable cleaning head subsystem. Thus, an autonomous floor cleaning robot with a self-adjustable cleaning head subsystem that includes a two-stage brush assembly having asymmetric brushes rotating counter to each other and a nearby but independent vacuum assembly. The autonomous floor cleaning robot further includes a side brush assembly that directs dust outside of the robot's envelope into the self-adjustable cleaning head subsystem.

  Autonomous robot cleaning devices are known in the art. For example, U.S. Patent Nos. 5,940,927 and 5,781,960 disclose "Autonomous Surface Cleaning Apparatus and a Nozzle Arrangement for a Self-Guiding Vacuum Cleaner". I have. One of the main requirements for an autonomous cleaning device is a self-contained power supply, and if such an autonomous cleaning device utilizes a power cord to an outlet to an external power source, it must be removed immediately without autonomous cleaning. The usefulness of the device is considerably reduced.

  Also, while the driving capability of self-contained power supplies, such as batteries, has been clearly improved, today's self-contained power supplies still have time limitations on power delivery. Cleaning mechanisms for cleaning devices, such as brush assemblies and vacuum assemblies, typically require large power loads to provide efficient cleaning capabilities. This is especially true when the brush assembly and the vacuum assembly are configured as a combination, since the brush and / or vacuum assembly of such a combination is typically designed for co-operation. Or it is not configured.

  Thus, an autonomous design and configuration that optimizes the cleaning capability and efficiency of the cleaning mechanism of the autonomous cleaning device for co-operation while concomitantly minimizing or reducing the power requirements for such a cleaning mechanism. There is a need to provide a strategic cleaning device.

  One object of the present invention is to provide a cleaning device operable to clean a designated area without human intervention.

  It is another object of the present invention to design and be configured to optimize the cleaning capability and efficiency of the cleaning mechanism of the autonomous cleaning device for co-operation, while concomitantly minimizing the power requirements for such mechanism. To provide an autonomous cleaning device.

  These and other objects of the present invention are directed to a housing substructure including a chassis, a power subsystem for providing energy to power the autonomous floor cleaning robot, and the autonomous floor cleaning for cleaning operations. A drive subsystem operative to propel the robot; a control module operative to control the autonomous floor cleaning robot to perform a cleaning operation; and a self-adjusting cleaning head subsystem; A head assembly pivotally mounted to the chassis; a brush assembly mounted in combination with the deck and powered by the drive subsystem to sweep dust during a cleaning operation; The cleaning unit is provided in combination with the deck and is powered by the driving subsystem. A vacuum assembly that draws dust between the drive assembly, the brush assembly, and the chassis, in combination with the chassis, and pivoting the deck relative to the chassis in response to a change in torque in the brush assembly. An autonomous floor cleaning robot according to one embodiment of the present invention includes a deck height adjustment sub-assembly that automatically acts to adjust the height of the brush from the floor. The autonomous floor cleaning robot is also mounted in combination with the chassis to capture dust outside the outer perimeter of the housing substructure and direct such dust to the self-adjusting cleaning head subsystem. Also includes a side brush assembly powered by the drive subsystem.

  The present invention and its attendant features and advantages will be more fully understood with reference to the detailed description of the invention when taken in conjunction with the accompanying drawings.

  Referring to the drawings, in which like reference numerals represent corresponding or similar elements throughout the several views, FIG. 1 is a schematic diagram of an autonomous floor cleaning robot 10 according to the present invention. Robot 10 includes a housing substructure 20, a power subsystem 30, a drive subsystem 40, a sensor subsystem 50, a control module 60, a side brush assembly 70, and a self-adjusting cleaning head subsystem 80. As described in more detail in the following paragraphs, the power subsystem 30, drive subsystem 40, sensor subsystem 50, control module 60, side brush assembly 70, and self-adjusting cleaning head subsystem 80 are combined. Then, it is integrated with the housing basic structure 20 of the robot 10.

  In the following description of the autonomous floor cleaning robot 10, the term "forward / fore" refers to the main direction of operation of the autonomous floor cleaning robot 10, and includes a fore-aft axis ( The term “FA” in FIGS. 4 and 5) defines the forward direction of the movement that corresponds to the front-rear diameter of the robot 10.

  Referring to FIGS. 2, 3, and 4 to 6, the housing substructure 20 of the robot 10 includes a chassis 21, a cover 22, a displaceable bumper 23, a tip wheel subassembly 24, and a transfer handle 25. The chassis 21 preferably mounts or otherwise incorporates components of the power subsystem 30, drive subsystem 40, sensor subsystem 50, side brush assembly 70 and self-adjusting cleaning head subsystem 80 to combine with the chassis 21. It is molded from a material such as plastic as a single element, including a plurality of preformed recesses, recesses and structural members for integration. The cover 22 preferably protects the components / components attached to the chassis 21 and / or the components / components that make up the self-adjusting cleaning head subsystem 80 which are unitary components complementary to the chassis 21 in configuration. It is molded from a material such as plastic as a single element providing access thereto. The chassis 21 and the cover 22 cooperate to be detachably integrated by any appropriate means, for example, screws, and the chassis 21 and the cover 22 cooperate to be generally symmetrical along the front-rear axis FA. Forming a minimum height structural envelope having a generally cylindrical configuration.

  A displaceable bumper 23 having a generally arcuate configuration extends outwardly therefrom, ie to a normal operating position, by being mounted in a movable connection at the front of the chassis 21. The mounting configuration of the displaceable bumper is such that whenever the bumper 23 encounters a stationary object or obstacle having a predetermined mass, the bumper 23 is displaced toward the chassis 21 (from the normal operation position), that is, the displacement position, and , (In response to any such displacement of the bumper 23, implement a "reaction" mode in which the robot 10 avoids the stationary object or obstacle, and restarts the forward movement in different directions by random or weighted random. Bumper 23 returns to the normal operating position when contact with stationary object or obstacle is terminated (by operation of control module 60 to continue a cleaning routine, such as starting a turn). The mounting configuration of the displaceable bumper 23 includes a pair of rotatable support members 23RSM that operate to facilitate movement of the bumper 23 with respect to the chassis 21.

  The pair of rotatable support members 23RSM are mounted symmetrically around the longitudinal axis FA of the autonomous floor cleaning robot 10 near the center of the displaceable bumper 23. One end of each support member 23RSM is rotatably attached to the chassis 21 by customary means such as pin / matching pin and sleeve arrangement, and the other end of each support member 23RSM is also rotated by a displaceable bumper 23 by similar customary means. Mounted as possible. A biasing spring (not shown) is provided in combination with each of the support members 23RSM, and the spring is always turned on (when the rotation of each of the support members 23RSM is completed) when the contact with the stationary object or the obstacle is terminated. ) Acts to provide the necessary biasing force to return the displaceable bumper 23 to the normal operating position.

  The embodiment described herein involves a pair of bumper arms symmetrically mounted parallel to and about the longitudinal axis FA of the autonomous floor cleaning robot 10 distal of the center of the displaceable bumper 23. Including 23BA. These bumper arms 23BA do not themselves provide structural support for the displaceable bumper 23, but rather serve to determine the location of stationary objects or obstacles encountered via the displaceable bumper 23. Part of 50. With one or both bumper arms 23BA being linearly displaceable with respect to the chassis 21 during encounters with stationary objects or obstacles, the control module 60 provides a corresponding signal for performing the "reaction" mode. One end of each bumper arm 23BA is fixedly secured to the displaceable bumper 23 and the other end of each bumper arm 23BA is provided to activate the associated sensor provided, for example, an IR blocking beam sensor, a mechanical switch, a capacitance sensor, or the like. The ends are mounted in combination with the chassis 21 in a manner such as a slot arrangement. Further details regarding the operation of this aspect of the sensor subsystem 50 as well as alternative embodiments of sensors useful for detecting contact or proximity with stationary objects or obstacles may be found in the present Applicant's own See U.S. Patent Application No. 10 / 056,804, filed January 24, 2002, entitled "Methods and Systems for Multimodal Application to Autonomous Robots".

  The tip wheel subassembly 24 includes wheels 24W rotatably mounted in combination with a clevis member 24CM including a mounting shaft. The U-link mounting shaft 24CM is disposed in a recess of the chassis 21 at the front end of the chassis 21 on the front and rear diameter of the autonomous floor cleaning robot 10. In combination with the U-link mounting shaft 24CM, a biasing spring 24BS (hidden behind the legs of the U-link member 24CM in FIG. 6) is disposed, the spring having a surface to which the tip wheel subassembly 24 is to be cleaned. Whenever contact is lost, it acts to bias tip wheel subassembly 24 to the 'extended' position. During the cleaning operation, the weight of the autonomous floor cleaning robot 10 is partially retracted by the wheels freely rotating on the surface to be cleaned by overcoming the force exerted by the biasing spring 24BS. Sufficient to bias tip wheel subassembly 24 into position. From each end of the U-link member, a triangular or conical wing portion 24TW extends outward, and the side of the wheel is an obstacle in which the side of the wheel is lower during the turning movement of the autonomous floor cleaning robot 10. To prevent engagement. The wing portion 24TW acts as an inclined portion when the robot slides over a raised portion when the robot turns.

  Each end 25E of the transport handle 25 is fixed in combination so as to pivot with respect to the cover 22 at the front end of the cover 22 which is centered with respect to the longitudinal axis FA of the autonomous floor cleaning robot 10. When the autonomous floor cleaning robot 10 sits on or moves over the surface to be cleaned, the transport handle 25 is positioned substantially flush with the surface of the cover 22 (in a handle / cover pivot configuration). The weight of the transport handle 25 associated with the arrangement is sufficient to automatically return the transport handle 25 to this flush position by gravity.) When the autonomous floor cleaning robot 10 is lifted by the transfer handle 25, the rear end of the autonomous floor cleaning robot 10 is located below the front end of the autonomous floor cleaning robot 10, so that the self-adjusting cleaning head is used. -No granular debris will fall out of subsystem 80.

  The power subsystem 30 of the described embodiment includes individual components / components of the drive subsystem 40, the sensor subsystem 50, the side brush assembly 70, and the self-adjusting cleaning head subsystem 80 during a cleaning operation. , And provide energy to power the circuits and components of control module 60 via associated circuits 32-4, 32-5, 32-7, 32-8, and 32-6, respectively (FIG. 1). reference). The power subsystem 30 for the described embodiment of the autonomous floor cleaning robot 10 comprises a rechargeable battery pack 34, such as a NiMH battery pack. The rechargeable battery pack 34 is mounted in a recess formed in the chassis 21 (and specifically sized for mounting / holding the battery pack 34) and includes any customary, such as, for example, a spring latch (not shown). It is held there by means. The battery recess is covered by a cover 34L fixed to the chassis 21 by a learning means such as a screw. A friction pad 36 for facilitating the stop of the autonomous floor cleaning robot 10 during the automatic shutdown is fixed to the lid 34L. The friction pads 36 assist the robot in stopping when the robot attempts to climb over a cliff. The rechargeable battery pack 34 includes components / components comprising a drive subsystem 40, a sensor subsystem 50, a side brush assembly 70, a self-adjusting cleaning head subsystem 80, and the circuitry and components of the control module 60. , While providing sufficient power to operate the autonomous floor cleaning robot 10 for 60-90 minutes at maximum charge.

The drive subsystem 40 (1) propels the autonomous floor cleaning robot 10 for cleaning operations, (2) activates the side brush assembly 70, and (3) self-cleans during such cleaning operations. Independent means for operating the conditioning cleaning head subsystem 80 is provided. Such independent means include left and right main wheel sub-assemblies 42A, 42B, each having their own independently operating motors 42A _M , 42B _M , and independent electric motors 44 for the side brush assembly 70, while 46 comprises the vacuum assembly And the other 48 includes two independent electric motors 46,48 for the two-stage brush assembly.

  The left and right main wheel subassemblies 42A, 42B are independently mounted within recesses in the chassis 21 formed at each end of the chassis 21 in the transverse diameter (the transverse diameter is the longitudinal axis of the robot 10). Orthogonal to FA). Mounting at this point provides the autonomous floor cleaning robot 10 with enhanced turning capability, since the motors of the main wheel subassemblies 42A, 42B may be, for example, sharp turning, gradual turning, home position. This is because they can be operated independently to perform a wide range of turning operations such as turning.

The main wheel sub-assemblies 42A, 42B include wheels 42A _W , 42B _W rotatably mounted in combination with the U-link members 42A _CM , 42B _CM , respectively. Each U-link member 42A _CM , 42B _CM is pivotally mounted to the chassis 21 behind the wheel rotation axis (see FIG. 6 showing the wheel rotation axis 42A _AR ; for a wheel subassembly 42B not shown). The wheel rotation axes are the same), that is, they are independently suspended. According to the rear pivot axes 42A _PA , 42B _{PA of the} main wheel subassemblies 42A, 42B (see FIG. 4), the mobility of the autonomous floor cleaning robot 10, ie, the pivotal movement of the subassemblies 42A, 42B over a predetermined arc. Is promoted. Motors 42A _M and 42B _M associated with the main wheel subassemblies 42A and 42B, respectively, are mounted at the rear ends of the U-link members 42A _CM and 42B _CM . One end of the tension spring 42B _TS is attached to the rear part of the U-link member 42B _CM , and the other end of the tension spring 42B _TS is attached to the chassis 21 in front of the respective wheels 42A _W and 42B _W (right wheel sub The tension spring for assembly 42A is not shown, but is the same as tension spring 42BTS for left wheel subassembly 42A).

Each tension spring causes the respective main wheel sub-assembly 42A, 42B to pivotally move over a predetermined arc of the corresponding U-link member 42A _CM , 42B _CM when the autonomous floor cleaning robot 10 is removed from the floor. Actuate to rotatably bias into the 'extended' position (in which the wheel rotation axis is below the bottom plane of the chassis 21). When the autonomous floor cleaning robot 10 sits on or moves over the surface to be cleaned, the weight of the autonomous floor cleaning robot 10 causes each main wheel subassembly 42A, 42B to move to a retracted or activated position. Although gravityly biased, the axis of rotation of each wheel is then substantially coplanar with the bottom plane of the chassis 21. The motors 42A _M and 42B _M of the main wheel subassemblies 42A and 42B are (1) at the same speed in the same rotation direction and at the same speed to propel the autonomous floor cleaning robot 10 linearly forward or backward, At different speeds to provide a turning pattern for the autonomous floor cleaning robot 10 (including the situation where none of the wheels are operated at zero speed), or (3) the robot 10 makes an in-situ turn or "turn in a tight space" It operates to drive each main wheel at the same speed in the reverse rotation direction.

The wheels 42A _W , 42B _W of the main wheel subassemblies 42A, 42B preferably have a “rough” tread configuration 42A _KT , 42B _KT . This uneven tread configuration 42A _KT , 42B _KT is particularly useful when traversing smooth surfaces and when traversing between successive surfaces of different tissues, for example from a bare floor to a carpet or vice versa. It provides a large traction force to the floor cleaning robot 10. This textured tread configuration 42A _KT , 42B _KT also allows the tuft of carpet / rug to be captured by wheels 42A _W , 42B _W between each wheel and chassis 21 during the movement of autonomous floor cleaning robot 10. Also prevent getting caught. However, one of ordinary skill in the art will recognize that other tread patterns / configurations are within the scope of the present invention.

  The sensor subsystem 50 comprises a variety of different sensing units that can be broadly characterized as (1) control sensing unit 52 or (2) emergency sensing unit 54. As the name implies, the control detection unit 52 operates to regulate the normal operation of the autonomous floor cleaning robot 10, and the emergency detection unit 54 can adversely affect the operation of the autonomous floor cleaning robot 10 (e.g., The autonomous floor-cleaning robot 10 operates to detect the stairs descending from the surface being cleaned and to provide a signal responsive to such detection so that the control module 60 can perform the appropriate response. The control detection unit 52 and the emergency detection unit 54 of the autonomous floor cleaning robot 10 will be described in summary in the following paragraphs, but a more complete description will be made in co-pending patents owned by the applicant as in the present application. US Patent Application Serial No. 09 / 768,773, filed January 24, 2001 entitled "Robot Obstacle Detection System", entitled "Method and System for Robot Positioning and Localization", June 2002 U.S. patent application Ser. No. 10 / 167,851, filed on Jan. 12, and U.S. patent application Ser. See 056,804.

  The control detection unit 52 includes an obstacle detection sensor 52OD mounted in association with the linearly displaceable bumper arm 23BA of the displaceable bumper 23, and a wall detection assembly 52WS mounted on the right hand portion of the displaceable bumper 23, A virtual wall detection assembly 52VWS mounted on the top of the bumper 23 displaceable along the front-rear diameter of the autonomous floor cleaning robot 10, and an IR sensor / encoder combination 52WE mounted in combination with each wheel subassembly 42A, 42B. including.

  Since each obstacle detection sensor 52OD includes an emitter / detector combination positioned in association with one of the linearly displaceable bumper arms 23BA, the sensor 52OD generates a detection signal in response to the displacement of the bumper arm 23BA. Operates to transmit to control module 60. The wall sensing assembly 52WS includes an emitter / detector combination that operates to detect the approach of a wall or other similar structure and send a detection signal to the control module 60. Each IR sensor / encoder combination 52WE serves to measure the rotation of the associated wheel subassembly 42A, 42B and send a corresponding signal to the control module 60.

  The virtual wall detection assembly 52VWS operates to detect a force field and a parallel beam emitted by a stand-alone emitter (virtual wall unit not shown) and transmit respective signals to the control module 60. . Since the autonomous floor cleaning robot 10 is programmed so as not to pass through the parallel beam, the virtual wall unit allows the robot 10 to enter a prohibited area such as an ascending staircase or access to a room not to be cleaned. Can be used to prevent The robot 10 is further programmed to avoid the force field generated by the virtual wall unit, thereby preventing the robot 10 from overrunning the virtual wall unit during a floor cleaning operation.

The emergency detection unit 54 includes an 'upright detector' assembly 54CD mounted within the displaceable bumper 23 and a wheel lowering assembly mounted in connection with the left and right main wheel subassemblies 42A, 42B and tip wheel assembly 24. 54WD and the respective current stop detection units 54CS and motors 44, 48 for the motors 42A _M , 42B _M of each main wheel subassembly 42A, 42B (these two motors are powered via a common circuit in the described embodiment). ) And one current stop detection unit 54CS. For the described embodiment of the autonomous floor cleaning robot 10, four upright detector assemblies 54CD are mounted within the displaceable bumper 23. Each upright detector assembly 54CD includes an emitter / detector combination operable to detect a predetermined descent in the path of the robot 10, eg, down stairs, and send a signal to the control module 60. Wheel lowering assembly 54WD detects when the corresponding left and right main wheel subassemblies 32A, 32B and / or tip wheel assembly 24 enters an extended position, such as a contact switch, and sends a corresponding signal to control module 60. It works to. The current stop detection unit 54CS operates to detect a change in the current of each motor indicating the stop state of the motor corresponding to each component and transmit a corresponding signal to the control module 60.

  The control module 60 includes a control circuit (eg, FIG. 1) for controlling the movement of the autonomous floor cleaning robot 10 in response to signals generated by the sensor subsystem 50 during the floor cleaning operation. Control lines 60-4, 60-5, 60-7 and 60-8) and a microcontroller. The control module 60 of the autonomous floor cleaning robot 10 according to the present invention can be classified into (1) “spot coverage” mode, (2) “wall / obstacle following” mode, and (3) “reaction” mode. It is pre-programmed (with hard wiring, software, firmware or a combination thereof) to implement three basic modes of operation or movement patterns. In addition, the control module 60 is pre-programmed to initiate actions based on signals received from the sensor subsystem 50, but such actions are not limiting and include movement patterns (2) and ( Implementation of 3), emergency stop of the robot 10, or generation of an audible alarm. Further details regarding the operation of the robot 10 by the control module 60 can be found in the same U.S. patent application, filed Jan. 24, 2001, entitled the co-pending "Robot Obstacle Detection System" owned by the same applicant. Patent Application No. 09 / 768,773, U.S. Patent Application No. 10 / 167,851, filed June 12, 2002, entitled "Methods and Systems for Robot Positioning and Localization" and "Multimode for Autonomous Robots" No. 10 / 056,804, filed Jan. 24, 2002, entitled "Methods and Systems for Application."

  The side brush assembly 70 captures large and small particles outside the outer perimeter of the housing substructure 20 of the autonomous floor cleaning robot 10 and transfers such particles to a self-regulating cleaning head subsystem 80. Operate to steer. This provides the robot 10 with the ability to clean surfaces near the baseboard (during the wall following mode).

  The side brush assembly 70 is mounted in a recess formed in the lower surface of the right front quadrant of the chassis 21 (in front of the right main wheel subassembly 42A, just behind the right end of the displaceable bumper 23). The side brush assembly 70 includes a shaft 72 having one end rotatably connected to the electric motor 44 for torque transfer, a hub 74 connected to the other end of the shaft 72, and a cover enclosing the hub 74. It comprises a plate 75, brush means 76 secured to a hub 74, and a group of bristle 78.

  The cover plate 75 is configured and secured to the chassis 21 to surround the hub 74 to prevent the brush means 76 from jamming under the chassis 21 during a floor cleaning operation.

  For the embodiment of FIGS. 4-6, the brush means 76 comprises opposed brush arms extending outwardly from the hub 74. These brush arms 76 are formed of a fixed width "L" / hockey stick shaped elastic plastic or rubber material. The cooperation of the shape and structure of the brush arm 76 allows the brush arm 76 to be elastically deformed when an obstacle or obstacle is temporarily encountered during a cleaning operation. Additionally, the use of a constant width opposed brush arm 76 may reduce the operation of the nearby upright detector assembly 54CD (the leftmost upright detector assembly 54CD in FIG. 5) at the displaceable bumper 23. An alternative (as opposed to using a full or partially circular brush configuration) to ensure that the action of the brush means 76 of the side brush assembly 70 is not adversely affected (ie, due to blockage). The brush arm 76 has a length sufficient to extend beyond the outer perimeter of the autonomous floor cleaning robot 10, especially its displaceable bumper 23. With such a length, the autonomous floor-cleaning robot 10 can use the chassis 21 and / or the displaceable bumper 23 of the robot 10 without scraping the wall / baseboard (during wall-following mode). May be cleaned.

  A group of bristles 78 is provided at the outermost free end of each brush arm 76 (similar to a toothbrush shape) to provide the sweeping capability of the side brush assembly 70. The bristles 78 are long enough to engage the surface being cleaned when the main wheel subassemblies 42A, 42B and the tip wheel subassembly 24 are in the operative position.

  Self-adjusting cleaning head subsystem 80 provides a cleaning mechanism for autonomous floor cleaning robot 10 according to the present invention. The cleaning mechanism for the preferred embodiment of the self-adjusting cleaning head subsystem 80 includes a brush assembly 90 and a vacuum assembly 100.

  4-6, the brush assembly 90 is a two-stage brush mechanism, and the two-stage brush assembly 90 and the vacuum assembly 100 provide the robot 10 with simultaneous efficient cleaning capabilities. A structurally and functionally independent cleaning mechanism adapted and designed for use with the robot 10 to minimize the overall power requirements of the robot. In addition to the cleaning mechanism described in the preceding paragraph, the self-adjusting cleaning head subsystem 80 includes a deck structure 82 pivotally connected to the chassis 21, an automatic deck adjustment subassembly 84, a removable dust cartridge 86, And one or more bail 88 that shields the step brush assembly 90.

  The deck 82 is preferably made as a unitary structure from a material such as plastic and includes a pair of spaced side walls 82SW formed at the rear end of the deck 82 (one of each side wall 82SW is a motor 46 U-shaped structure for accommodating therein, a brush assembly recess 82W, and a lateral hand formed in the middle of the lower deck surface to define an opening between the two-stage brush assembly 90 and the removable dust cartridge 86. Aperture 82LA and a mounting bracket 82MB formed in a forward portion of the upper deck surface relative to the motor 48).

Each side wall 82SW is positioned and configured to pivotally attach the deck 82 to the chassis 21 by conventional means such as, for example, a rotary joint (see reference numeral 82RJ in FIG. 4). The pivot axis of the deck 82 / chassis 21 combination is orthogonal to the front-rear axis FA of the autonomous floor cleaning robot 10 at the rear end of the robot 10 (see FIG. 4 for specifying the pivot axis). Reference number 82 _PA ).

  The mounting bracket 82MB is positioned and configured to mount the constant torque motor 48 to the front lip of the deck 82. The rotation axis of the attached motor 48 is orthogonal to the front-rear diameter of the autonomous floor cleaning robot 10 (see reference numeral 48RA specifying the rotation axis of the motor 48 in FIG. 4). A shaft 48S that transmits a constant torque extends from the attached motor 48 to the input side of the fixed-use conventional two-stage output transmission 48B (the housing of the two-stage output transmission 48B is a part of the deck 82. Produced).

The deck adjustment sub-assembly 84, shown in more detail in FIGS. 7-9, is mounted in combination with the motor 48, deck 82 and chassis 21 and in combination with the electric motor 48 provides a two-stage brush assembly 90. Provides a physical mechanism and motive force to pivot the deck 82 relative to the chassis 21 about the pivot axis 82 _PA whenever a situation is encountered that results in a predetermined decrease in the rotational speed of the two-stage brush assembly 90. Act to do. This situation that most commonly occurs when the autonomous floor cleaning robot 10 transitions between a smooth surface, such as a floor, and a carpet surface is characterized as an 'adjustment mode' in the remainder of this description.

  The deck adjustment subassembly 84 for the described embodiment of FIG. 4 includes a motor cage 84MC, a pulley 84P, a pulley cord 84C, an anchor member 84AM, and a complementary cage stop 84CS. Motor 48 is non-rotatably secured within motor cage 84MC, and motor cage 84MC is mounted in a rotatable combination between mounting brackets 82MB. The pulley 84P is fixedly fixed to the motor cage 84MC on the opposite side of the inner mounting bracket 82MB in such a manner that the shaft 48S of the motor 48 passes freely through the center of the pulley 84P. The anchor member 84AM is fixedly fixed to the top surface of the chassis 21 in alignment with the pulley 84P.

  One end of the pulley cord 84C is fixed to the anchor member 84AM, and the other end of the pulley cord 84C is stretched such that the pulley cord 84C is stretched when the deck 82 is in the 'down' or non-pivoting position. Fixed to 84P. One of each cage stop 84CS is secured to the motor cage 84MC, and the complementary cage stop 84CS is secured to the deck 82. Each complementary cage stop 84CS abuts when the deck 82 is in the 'down' position due to the weight of the self-adjusting cleaning head subsystem 80 during a normal cleaning operation.

  During a normal cleaning operation, the torque generated by the motor 48 is transmitted to the two-stage brush assembly 90 by the shaft 48S via the two-stage output transmission 48B. The motor cage assembly is prevented from rotating by the reaction torque generated by the pulley cord 84C on the pulley 84P. As the resistance encountered by the rotating brush changes, the deck height is adjusted to compensate for this. For example, if the brush torque increases as the device rolls from the smooth floor onto the carpet, the torque output of motor 48 will increase. Accordingly, the output torque of motor 48 increases. The increased torque overcomes the reaction torque exerted by pulley cord 84C on pulley 84P. This causes the pulley 84P to rotate itself to effectively pull the pulley cord 84C. This causes the deck to pivot about the pivot axis, raises the brush, reduces friction between the brush and the floor, and is required by the two-stage brush assembly 90 The torque is reduced. This continues until the reaction torque generated on the pulley 84P by the motor 48 and the pulley cord 84C is again balanced and a new deck height is established.

  In other words, the torque transmission mechanism is shut off during the adjustment mode because the shaft 48S is essentially stationary. Under these conditions, the motor 48 effectively rotates around the shaft 48S. Since the motor 48 is non-rotatably fixed to the motor cage 84MC, the motor cage 84MC and, concomitantly, the pulley 84P rotate with respect to the mounting bracket 82MB. By the rotation operation given to the pulley 84P, the pulley 84P 'winds up' around the pulley cord 84PC toward the anchor member 84AM. This movement of the pulley 84P causes the deck 82 to pivot about its pivot axis 82PA to an "up" position since the motor cage 84MC is effectively attached to the front lip of the deck 82 by the mounting bracket 82MB. Move. This pivotal movement causes the front of the deck 82 to move away from the surface on which the autonomous floor cleaning robot is stepping.

  Such pivoting also effectively moves the two-stage brush assembly 90 away from the surface with which the two-stage brush assembly 90 was in contact, so that the two-stage brush assembly 90 increases in speed (transmitted from the motor 48). The steady state rotational speed (corresponding to the constant torque performed) can be resumed. At this time (when the two-stage brush assembly 90 has reached its steady state rotational speed), the weight of the leading edge of the deck 82 (primarily the motor 48) causes the deck 82 to be 'down' or in the normal state, i.e., the bottom of the chassis 21. It is gravitationally biased to pivot back to planar, where each complementary cage stop 84CS abuts.

  Although the deck adjustment subassembly 84 described in the preceding paragraph is a preferred pivot mechanism for the autonomous floor cleaning robot 10 according to the present invention, those skilled in the art will appreciate that the pivot movement of the deck 82 in the adjustment mode described above. It will be appreciated that other mechanisms may be employed to utilize the torque developed by the deck adjustment subassembly 84 to induce. For example, the deck adjustment subassembly may be a spring-loaded clutch mechanism, such as shown in FIG. 9 (identified by SLCM) or a centrifugal clutch, for pivoting the deck 82 to the "up" position during the adjustment mode. Mechanism or a torque limiting clutch mechanism. In another embodiment, the motor torque uses either the spring or the weight of the cleaning head to create the reaction torque by replacing the pulley with a cam and constant force spring or replacing the pulley with a rack and pinion. Thus, it can be used to adjust the height of the cleaning head.

  The removable dust cartridge 86 provides temporary storage of large and small dust swept by the action of the two-stage brush assembly 90, and small dust aspirated by the action of the vacuum assembly 100. The removable dust cartridge 86 includes a first storage chamber 86SC1 for large and small dust swept by the two-stage brush assembly 90, and a second storage chamber 86SC2 for small dust sucked by the action of the vacuum assembly 100. As a dual chamber structure. Since the removable dust cartridge 86 is further configured to be inserted in combination with the deck 82, the segments of the deck adjustment subassembly 84 define a portion of the rear exterior sidewall structure of the autonomous floor cleaning robot 10.

  As shown in FIGS. 10 and 11, the detachable dust cartridge 86 includes a bottom plate member 86FM and a top plate member 86CM which are joined to each other by opposing side wall members 86SW. The bottom plate member 86FM and the top plate member 86CM extend beyond the side wall member 86SW to define an open end 86OE, and the free end of the bottom plate member 86FM is slightly angled to form a plurality of baffle protrusions 86AJ. The inclusion removes debris trapped in the brush mechanism of the two-stage brush assembly 90, and inserts and sweeps the removable dust cartridge 86 in combination with the deck 82 into the removable dust cartridge 86. Promotes retention and retention of dust. A rear wall member 86BW that is in abutting engagement with the side wall member 86SW is mounted between the bottom plate member 86FM and the top plate member 86CM at the distal end of the open end 86OE. The rear wall member 86BW has a baffle configuration for the purpose of deflecting the dust angularly in order to prevent the dust swept by the two-stage brush assembly 90 from jumping back into the brush assembly 90. The bottom plate member 86FM, the top plate member 86CM, the side wall member 86SW, and the rear wall member 86BW are combined to define the first storage chamber 86SC1.

  The removable dust cartridge 86 further includes a curved arc member 86CAM that defines a rear outer sidewall structure of the autonomous floor cleaning robot 10. The curved arc member 86CAM is engaged with the top plate member 86CM, the bottom plate member 86F, and the side wall member 86SW. A gap is formed between the curved arc member 86CAM and the one side wall member 86SW to define a vacuum inlet 86VI for the detachable dust cartridge 86. A replaceable filter 86RF is configured to be elastically fitted and inserted in combination with the bottom plate member 86FM. The replaceable filter 86RF, the curved arc member 86CAM and the rear wall member 86BW combine to define a second storage chamber 86SC1.

  Since the removable dust cartridge 86 is configured to be inserted between the opposing and separated side walls 82SW of the deck 82, the open end of the removable dust cartridge 86 is aligned with the lateral opening 82LA formed in the deck 82. . A latch member 86LM is attached to the outer surface of the top plate member 86CM. The latch member engages with a complementary shoulder formed on the upper surface of the deck 82 to integrate the detachable dust cartridge 86 with the deck 82. It works so that it may be combined and locked.

  Divider 88 includes one or more narrow gauge wire structures that cover two-stage brush assembly 90. For the described embodiment, the divider frame 88 comprises a continuous narrow gauge wire structure formed in a castellated shape, ie, an alternating open sided rectangle. Alternatively, divider 88 may consist of a plurality of side opening single rectangles formed of narrow gauge wires. Divider frame 88 is designed and configured to be press-fit into complementary retaining grooves 88A, 88B, respectively, formed in deck 82 immediately adjacent to both sides of two-stage brush assembly 90. The divider frame 88 acts to shield the two-stage brush assembly 90 from large external objects such as carpet locks, tufts, rug edges, etc. during the cleaning operation, i. Deflection away from the step brush assembly 90 prevents the object from becoming entangled in the brush mechanism.

  The two-stage brush assembly 90 for the described embodiment of FIG. 4 includes a flapper brush 92 and a primary brush 94 shown schematically in FIG. Structurally, the flapper brush 92 and the primary brush 94 are asymmetrical with respect to each other, with the primary brush 94 having an OD greater than the OD (outer diameter) of the flapper brush 92. Flapper brushes 92 and primary brushes 94 are mounted in recesses in deck 82, as described in more detail below, to minimize the spacing between each sweep perimeter defined by their respective rotating elements. I do. Functionally, the flapper brush 92 and the primary brush 94 rotate counter to each other, the flapper brush 92 rotates in a first direction that directs large dust particles into a removable dust cartridge 86, and the primary brush 94 rotates large. The autonomous floor cleaning robot 10 rotates in a second direction opposite to the forward movement of the autonomous floor cleaning robot 10 in order to direct small and small dust particles into the removable dust cartridge 86. In addition, this rotational movement of the primary brush 94 is oversized and sized so that dust not swept by the two-stage brush assembly 90 can be subsequently sucked (sucked) by the vacuum assembly 100 by movement of the autonomous floor cleaning robot 10. It has the secondary effect of directing small dust toward the pickup area of the vacuum assembly 100.

Flapper brush 92 includes a central member 92CM having first and second ends. The first and second ends connect the flapper brush 92 to the deck 82 and the first output port of the two-stage transmission 48B such that rotation of the flapper brush 92 is provided by torque transmitted from the electric motor 48. 48B _O1 and are designed and configured to be mounted in rotatable combinations with each other. (Transmission 48B is configured such that the rotational speed of flapper brush 92 is related to the speed of autonomous floor cleaning robot 10, and description of robot 10 Examples have a maximum speed of about 0.9 feet / second). In other embodiments, the flapper brush 92 rotates substantially faster than the traverse speed, with or without the traverse speed. The forced separation of the hair and other similar objects from the flapper brush 92 prevents such objects from tangling at each end of the central member 92CM and stopping the two-stage brush assembly 90 from moving. Each axle guard 92AG having a slope configuration is integrally formed near the first and second ends.

  The brush element of the flapper brush 92 includes a plurality of cleaning segments formed from a resilient plastic material secured to and extending along the central member 92CM between the inner ends of each axle guard 92AG. A strip 92CS is provided (for the embodiment shown, the sleeve to be fitted and secured to the central member 92CM has an integral segment strip extending outwardly therefrom). When these cleaning segment strips 92CS are arranged in a herringbone pattern or a chevron pattern, an optimum cleaning effect (function) for the two-stage brush assembly 90 of the autonomous floor cleaning robot 10 according to the present invention is obtained. And noise levels). When the cleaning segment strip 92CS was arranged in a herringbone / chevron pattern, the large-sized dust captured by the strip 92CS was moved to the center of the flapper brush by the rotation of the flapper brush 92. Thus, it was confirmed that the cleaning strips arranged in a linear / linear pattern caused irritating flapping noise when the brush was rotated. Further, the cleaning strips arranged in a helical pattern have moved large particles towards each end of the brush, and the dust has resulted from the sweeping action provided by the rotating brush.

  For the described embodiment, six cleaning segment strips 92CS were equidistantly spaced in a herringbone / chevron pattern around the circumference of the central member 92CM. One skilled in the art will appreciate that more or less cleaning segment strips 92CS may be employed in the flapper brush 90 without departing from the scope of the present invention. Each cleaning strip 92S is segmented at a predetermined interval, and the segmenting interval depends on the configuration (interval) between the wires forming the partition frame 88. As a result of the embodiment of divider frame 88 described above, each cleaning strip 92CS in the described embodiment of flapper brush 92 has five segments.

  The primary brush 94 includes a central member 94CM having first and second straight ends (i.e., aligned along the spiral centerline) (for the described embodiment, the central member 94CM has a circular configuration having a spiral configuration). Shaped metal member). The segmented protective member 94PM is integrated with the central member 94CM. Each segment of the protection member 94PM includes oppositely spaced semi-circular end caps 94EC having integral ribs 94IR extending between the respective semi-circular end caps. For the described embodiment, each pair of semi-circular end caps EC has two integral ribs extending therebetween. The protective member 94PM is assembled by joining the complementary end caps 94EC by any conventional means, such as screws, such that the assembled complementary semicircular end caps 94EC have a circular shape.

Since the protection member 94PM is combined with and integrated with the center member 94CM, the center member 94CM is disposed along the center line of the protection member 94PM, and the first end of the center member 94CM ends with one circular cap 94EC; The second end of the central member 94CM extends through the other circular end cap 94EC. A second end of the central member 94CM is mounted in a rotatable combination with respect to the deck 82, and cooperates with a first end of the central member 94CM to form a circular end cap 94EC via an electric motor 48B. as the rotation of the main brush 94 is provided by the torque transmitted from 48, designed and configured to be attached rotatably combined to the second output port 48B _O2 transmission 48B.

  Each bristle 94B is set in combination with a central member 94CM to extend between each integral rib 94IR of the protective member 94PM and beyond the OD established by each circular end cap 94EC. Each integral rib 94IR is configured and operative to prevent the primary brush 94 from sucking in objects such as rug tresses and tufted cloth.

  The bristles 94B of the primary brush 94 can be made from any material conventionally used to form bristles for surface cleaning operations. The bristles 94B of the primary brush 94 are particularly configured to provide a "flicking" effect on dust encountered during cleaning operations performed by the autonomous floor cleaning robot 10 of the present invention, thereby providing a large sweep. Provide competence. For the described embodiment, each bristle 94B has a diameter of about 0.210 millimeters (0.010 inches), a length of about 22.86 millimeters (0.90 inches), and a rounded free end. This configuration has been found to provide optimal tapping action. While bristles having a diameter greater than about 0.314 millimeters (0.014 inches) have a longer wear life, such bristles may be too tough to provide adequate tapping action for the two-stage brush assembly 90 of the present invention. Absent. Also, bristle diameters less than 0.210 millimeters (0.010 inches) suffer from premature wear of the free ends of such bristles, reducing the sweeping capability of the primary brush. In a preferred embodiment, the primary brush is set slightly below the flapper brush to ensure that the flapper does not contact the hard surface floor.

  The vacuum assembly 100 is independently powered by an electric motor 46. The operation of the vacuum assembly 100 independently of the self-adjustable brush assembly 90 allows for a higher vacuum force using battery power than would otherwise be possible if the vacuum assembly had been operated, depending on the brush system. Can be generated and maintained. In another embodiment, the motor of the primary brush may drive a vacuum. Independent herein is used herein in that the inlet to vacuum assembly 100 is an independent structural unit having dimensions independent of the "sweep area" defined by two-stage brush assembly 90.

  The vacuum assembly 100, i.e., the rear end vacuum source, located immediately after the two-stage brush assembly 90, is oriented such that the vacuum inlet points forward near the main brush 94 of the two-stage brush assembly 90. Thus, the effectiveness of suction or evacuation of the vacuum assembly 100 is increased. Referring to FIGS. 13 and 14, the vacuum assembly 100 includes a vacuum inlet 102, a vacuum compartment 104, a compartment cover 106, a vacuum chamber 108, an impeller 110, and a vacuum channel 112. The vacuum inlet 102 comprises first and second blades 102A, 102B formed of a semi-rigid / elastic plastic or elastic material, the blades having a fixed size (width and gap-see below). By being constructed and arranged to provide the inlet 102, the vacuum assembly 100 ensures a constant air inflow velocity of about 4 m / sec for the described embodiment.

The first blade 102A has a generally rectangular shape with a predetermined width (lateral) dimension such that each end of the first blade 102A extends beyond the lateral dimension of the two-stage brush assembly 90. One lateral edge of the first blade 102A is immediately adjacent to the main brush 94 in a direction substantially symmetrical to the anterior-posterior diameter of the autonomous floor cleaning robot 10 but below the deck 82 apart from the brush. Attached to the side surfaces (lateral ridges formed in deck 82 provide separation between them in addition to embodying retaining grooves for divider frame 88 described above). This lateral edge also extends into the vacuum compartment 104 where it sealingly engages the leading edge of the vacuum compartment 104. The first blade 102A is angled forward with respect to the bottom surface of the deck 82 and has a length such that the free end 102A _FE of the first blade 102A just smears the surface to be cleaned.

The free end 102A _FE has a fortified shape that prevents the vacuum inlet 102 from pressing dust during the cleaning operation. Projections 102P having a predetermined height are aligned with the fortified segment 102CS of the free end 102A _FE , which is spaced along the width of the first blade 102A. For certain embodiments, the height of protrusion 102P is about 2 mm. The predetermined height of the projection 102P defines a "gap" between the first and second blades 102A, 102B.

  The second blade 102B has a flat, unitary configuration that is complementary in width and length to the first blade 102A. However, the second blade 102B does not have a fortified free end; instead, the free end of the second blade 102B has a straight edge. The second blade 102B is joined in a seal combination to the leading edge of the compartment cover 106 and is angled with respect to the compartment cover 106 to be substantially parallel to the first blade 102A. When the section cover 106 is fitted to a predetermined position of the vacuum section 104, the flat surface of the second blade 102B comes into contact with the plurality of projections 102P of the first blade 102A, so that the first and second blades 102A and 102B To form a "gap".

  Vacuum compartment 104 in fluid communication with vacuum inlet 102 includes a recess formed in the lower surface of deck 82. The recess includes a compartment bottom plate 104F and a continuous compartment wall 104CW that draws a periphery of the vacuum compartment 104. An opening 104A is formed through the bottom plate 104 and offset with respect to one side of the bottom plate 104F. Because of the location of this aperture 104A offset from the geometric center of the partition bottom plate 104F, it is prudent to form several guide ribs 104GR that project upward from the partition bottom plate 104F. These guide ribs 104GR serve to distribute the air flowing through the gap between the first and second blades 102A and 102B over the entire partition bottom plate 104, so that a constant air inflow is generated throughout the gap. And maintained, ie, the vacuum inlet 102 has a substantially constant 'negative' pressure (with respect to atmospheric pressure).

  The partition cover 106 has a configuration complementary to the shape of the peripheral edge of the vacuum partition 104. The cover 106 is further configured to be press fit in a sealing combination against the continuous partition wall 104CW, where the vacuum compartment 104 and the vacuum cover 106 combine to define a vacuum chamber 108 of the vacuum assembly 100. The compartment cover 106 can be removed to remove any debris from the vacuum channel 112. The compartment cover 106 is preferably made of a transparent or translucent plastic material so that the user can visually determine when the clogging has occurred.

  The impeller 110 is mounted in combination with the deck 82 in such a manner that the inlet of the impeller 110 is located in the opening 104A. Since the impeller 110 is operatively connected to the electric motor 46, the torque from the motor 46 is transmitted to the impeller 110, the impeller is rotated at a constant speed, and air is released from the vacuum chamber 108. It is sucked. The outlet of the impeller 110 is integrated with one end of the vacuum channel 112 by a seal combination.

  Vacuum channel 112 is a hollow structural member formed as a separate structure and attached to deck 82 or formed as an integral part of deck 82. The other end of the vacuum channel 110 is integrated with the vacuum inlet 86VI of the removable dust cartridge 86 by a seal combination. The outer surface of the vacuum channel 112 has a shape complementary to the outer shape of the curved arc member 86CAM of the removable dust cartridge 86.

  Various modifications and variations of the present invention are possible in light of the above teachings. For example, the preferred embodiment described above includes a self-adjusting cleaning head subsystem 80, i.e., the deck 82 automatically moves relative to the chassis 21 with a predetermined increase in brush torque of the two-stage brush assembly 90 during the adjustment mode. It was made pivotable. Another embodiment of an autonomous floor cleaning robot according to the present invention is as described above, except that the cleaning head subsystem is not adjustable, ie the deck is not pivotable with respect to the chassis. This embodiment does not include the deck adjustment subassembly described above, ie, the deck is rigidly fixed to the chassis. Alternatively, the deck may be made as an integral part of a chassis, in which case the deck is of a practical configuration, i.e., the identification of each component comprising the cleaning head subsystem and their combined integration into a robot This is a configuration for simplifying.

  It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

1 is a schematic view of an autonomous floor cleaning robot according to the present invention. 1 is a perspective view of an embodiment of an autonomous floor cleaning robot according to the present invention. FIG. 3 is a bottom plan view of the autonomous floor cleaning robot of FIG. 2. FIG. 10 is a plan view of a partially broken top portion of another embodiment of the autonomous floor cleaning robot according to the present invention with the cover removed. FIG. 5 is a partially broken bottom plan view of the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 5 is a partially broken side view of the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 5 is a plan view of a deck and a chassis of the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 8 is a sectional view of FIG. 7 along the line BB. FIG. 5 is a perspective view of a deck adjustment subassembly of the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 5 is a first exploded perspective view of a dust cartridge for the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 11 is a second exploded perspective view of the dust cartridge of FIG. 10. FIG. 5 is a perspective view of a two-stage brush assembly including a flapper brush and a primary brush for the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 5 is a perspective view illustrating a blade and a vacuum compartment for the embodiment of the autonomous floor cleaning robot of FIG. 4. FIG. 14 is a partially exploded perspective view of the embodiment of the autonomous floor cleaning robot of FIG. 13.

Explanation of reference numerals

10… Autonomous floor cleaning robot
20… Housing basic structure
21… Chassis
22 ... Cover
23… Bumper
23RSM ... rotatable support member
24 ... Tip wheel assembly
25 ... Transport handle
30 ... Power subsystem
34… Rechargeable battery pack
40 ... Drive subsystem
42A, 42B… Wheel subassembly
42AAR: Wheel rotation axis
42AM, 42BM… Motor
44… Electric motor
48… Motor
48B ... Transmission
48S ... Shaft
50 ... subsystem
52… Control detection unit
60 ... Control module
60 ... Control line
72 ... shaft
74 ... Hub
75… plate
76 ... Brush means
78 ... Bristle
82MB… Mounting bracket
82PA… Pivot axis
82SW ... each side wall
84 ... Automatic deck adjustment subassembly
84 AM…Anchor member
84CS… Complementary cage stop
84MC… Cage
86 ... Removable dust cartridge
86AJ… Baffle protrusion
86BW ... rear wall member
86CAM… Curved arc-shaped member
86CM ... Top plate member
86FM ... Bottom plate member
86LM… Latch member
86OE ... open end
86RF ... Exchangeable filter
86VI… Vacuum inlet
94 PM…Segmentation protection member
94 PM…Protective member
100… Vacuum assembly

Claims (77)

A housing base structure including a chassis;
A power subsystem that provides energy to power the autonomous floor cleaning robot;
A drive subsystem that acts to propel the autonomous floor cleaning robot for a cleaning operation;
A control module operative to control the autonomous floor cleaning robot to perform a cleaning operation;
A self-adjusting cleaning head subsystem;
The self-adjusting cleaning head subsystem includes:
A deck mounted on the above chassis in a pivotal combination,
A brush assembly mounted in combination with the deck and powered by the drive subsystem during the cleaning operation to sweep dust;
A deck adjustment subassembly mounted in combination with the drive subsystem, the brush assembly, and the chassis, and automatically acting to pivot the deck relative to the chassis in response to a change in torque in the brush assembly;
Means coupled to the brush assembly for collecting dust swept by the brush assembly;
including,
An autonomous floor cleaning robot.   The autonomous floor cleaning robot of claim 1, wherein the brush assembly is a two-stage brush assembly with first and second brushes rotating counter to each other.   3. The autonomous floor cleaning robot according to claim 2, wherein the first and second brushes are asymmetric, and the second brush has an outer diameter larger than an outer diameter of the first brush.   3. The brush of claim 2, wherein the first brush is a flapper brush including a plurality of cleaning strips rotatably mounted to the deck and to the drive subsystem for the two-stage brush assembly. Autonomous floor cleaning robot.   5. The autonomous floor cleaning robot of claim 4, wherein the plurality of cleaning strips are arranged in a chevron pattern.   The autonomous floor cleaning robot of claim 4, wherein each of the plurality of cleaning strips is segmented.   7. The autonomous floor cleaning robot of claim 6, wherein the plurality of cleaning segment strips comprises six cleaning segment strips.   The autonomous floor cleaning robot of claim 7, wherein the cleaning segment strip comprises five segments. The autonomous floor cleaning robot has a fortified shape with a portion of the divider frame press-fitted into the deck in such a manner that the divider frame forms a guard over the two-stage brush assembly. Further equipped with a partition frame,
7. The autonomous floor cleaning robot of claim 6, wherein the fort-like shape of the divider frame defines segmentation of the plurality of cleaning strips. The second brush is a main brush,
The main brush is
A central member,
A protective member mounted in combination with the central member, each end configured to rotatably mount the primary brush to the deck and to the drive subsystem for the two-stage brush assembly. Cap and
The autonomous floor cleaning robot according to claim 2, comprising:   11. The autonomous floor cleaning robot of claim 10, wherein the protection member includes an integral rib configured and operative to prevent suction of objects by the primary brush.   12. The autonomous bristles of claim 11, further comprising a plurality of bristles set in combination with the central member to extend beyond the integral rib and beyond an outer diameter defined by the end cap. Floor cleaning robot.   12. The autonomous floor cleaning robot of claim 11, wherein each bristle has a diameter of about 0.254 millimeters (0.01 inches), a length of about 22.86 millimeters (0.9 inches), and a rounded free end. The brush assembly is a two-stage brush assembly comprising a flapper brush and a primary brush;
The flapper brush is configured to be rotatably mounted to the deck and to the drive subsystem for the two-stage brush assembly, and includes a plurality of cleaning spaced segments arranged in a chevron pattern. Including a strip, and
The primary brush is a central member and a protective member mounted in combination with the central member, the primary brush being rotatable with respect to the deck and relative to the drive subsystem for the two-stage brush assembly. A protective member having respective end caps configured for attachment, and a plurality of bristles associated with the central member to extend beyond an outer diameter defined by the respective end caps.
The autonomous floor cleaning robot according to claim 1.   15. The autonomous floor cleaning robot of claim 14, wherein the protection member includes an integral rib configured and operative to prevent suction of objects by the primary brush. The flapper brush and the primary brush are asymmetric, the primary brush having an outer diameter greater than the outer diameter of the flapper brush, and
16. The autonomous floor cleaning robot of claim 15, wherein the flapper brush and the primary brush rotate counterclockwise with respect to each other. A housing base structure including a chassis;
A power subsystem that provides energy to power the autonomous floor cleaning robot;
A drive subsystem that acts to propel the autonomous floor cleaning robot for a cleaning operation;
A control module operative to control the autonomous floor cleaning robot to perform a cleaning operation;
A self-adjusting cleaning head subsystem;
The self-adjusting cleaning head subsystem includes:
A deck mounted on the above chassis in a pivotal combination,
A brush assembly mounted in combination with the deck and powered by the drive subsystem during the cleaning operation to sweep dust;
A vacuum assembly disposed in combination with the deck near the brush assembly and powered by the drive subsystem independent of the brush assembly to draw dust during a cleaning operation;
A deck adjustment subassembly mounted in combination with the drive subsystem, the brush assembly, and the chassis, and automatically acting to pivot the deck relative to the chassis in response to a change in torque in the brush assembly;
Means coupled to the brush assembly and the vacuum assembly for collecting dust swept by the brush assembly and sucked by the vacuum assembly;
including,
An autonomous floor cleaning robot. The vacuum assembly comprises:
A vacuum inlet having a predetermined width and gap, the vacuum inlet being separate from and independent of a brush sweep area defined by the brush assembly;
Formed on the deck, a partition bottom plate, a continuous partition wall portion, and a vacuum partition including an aperture formed through the partition bottom plate,
A detachable compartment cover configured to be pressure-fitted in a seal combination with the vacuum compartment and the vacuum inlet, wherein the compartment cover and the vacuum compartment define a vacuum chamber with the pressure-fit combination. Compartment cover,
An impeller mounted in combination with the deck such that an intake of the impeller is located within the aperture, operatively connected to the drive subsystem to receive torque from the drive subsystem. An impeller,
A vacuum channel integrated with the impeller in a seal combination to remove collected dust from the vacuum chamber;
The autonomous floor cleaning robot of claim 17, comprising: The vacuum inlet is
A first blade having a general rectangular shape and a lateral dimension defining the predetermined width of the vacuum inlet, one lateral edge of the first blade being attached to a lower surface of the deck. A first blade, wherein the first blade is angled forward with respect to the deck because the first blade is sealed and extended into the continuous compartment wall;
A second blade having a general rectangular shape that is complementary to the shape of the first blade, wherein one lateral edge of the second blade is disposed in sealing combination with the removable compartment cover. A second blade,
The first and second blades are combined to define the vacuum inlet having the predetermined width and gap;
An autonomous floor cleaning robot according to claim 18.   The lateral free edge of the first blade is fortified to relieve dust pressure by the vacuum inlet during a cleaning operation and includes a plurality of fortified segments along the lateral free edge. 20. The autonomous floor cleaning robot of claim 19, having a fort-like shape defining   The autonomous floor cleaning robot further comprises a plurality of protrusions having a predetermined height, the protrusions being aligned with and extending from the fortified segment, and being combined with the second blade. 21. The autonomous floor cleaning robot according to claim 20, wherein a flat surface of the robot contacts the protrusion of the first blade to form the predetermined gap of the vacuum inlet. The vacuum inlet is
A first blade having a general rectangular shape and a lateral dimension defining the predetermined width of the vacuum inlet, one lateral edge of the first blade being attached to a lower surface of the deck. The first blade is angled forward with respect to the deck as it extends into the continuous compartment wall and seals together, and the lateral free edge of the first blade is used for cleaning operations. A first blade having a fortified shape to mitigate the pressing of dust by the vacuum inlet therebetween and defining a plurality of fortified segments along the lateral free edge,
A second blade having a general rectangular shape that is complementary to the shape of the first blade, wherein one lateral edge of the second blade is disposed in sealing combination with the removable compartment cover. The second blade,
A plurality of protrusions having a predetermined height and aligned with and extending from the fortified segment, wherein the flat surface of the second blade abuts the protrusion of the first blade when combined. A plurality of projections, forming the predetermined gap of the vacuum inlet,
19. The autonomous floor cleaning robot of claim 18, comprising: The opening is formed through the partition bottom plate to be offset from the geometric center of the partition bottom plate, and
19. The partition bottom plate further comprising guide ribs projecting upwardly from the partition bottom plate to distribute airflow over the predetermined gap such that a substantially constant negative pressure is maintained over the predetermined gap. Autonomous floor cleaning robot. The deck adjustment subassembly includes:
A motor cage mounted in a rotatable combination on the deck, wherein the drive subsystem for the brush assembly is non-rotatably secured within the motor cage;
A pulley fixedly fixed to the motor cage,
An anchor member fixedly fixed to the chassis in alignment with the pulley;
A pulley cord secured between the anchor member and the pulley when the deck is in a non-pivoted position with respect to the chassis;
In response to a change in torque of the brush assembly, the motor cage automatically pivots in a manner such that the pulley wraps around the pulley cord and raises the deck relative to the chassis.
The autonomous floor cleaning robot according to claim 1.   The deck adjustment subassembly includes a complementary cage stop secured to the motor cage and the deck in such a manner that the complementary cage stop abuts the deck in a non-pivoting position with respect to the chassis. The autonomous floor cleaning robot according to claim 24, further comprising:   Attached in combination to the chassis and powered by the drive subsystem to capture dust outside the outer perimeter of the housing substructure and direct such dust to the self-adjusting cleaning head subsystem. 18. The autonomous floor cleaning robot of claim 1 or claim 17, further comprising a side brush assembly. The side brush assembly includes:
A shaft having one end rotatably connected to the drive subsystem for transmitting torque to the shaft;
A hub connected to the other end of the shaft,
Brush means connected to the hub for trapping dust outside the outer perimeter of the housing substructure and for directing such dust toward the self-regulating cleaning head subsystem;
27. The autonomous floor cleaning robot of claim 26, comprising: The brush means,
An opposing brush arm extending outwardly from the hub;
A group of bristles set at the free end of each of the brush arms;
28. The autonomous floor cleaning robot of claim 27, comprising:   29. The autonomous floor cleaning of claim 28, wherein each of the brush arms has an L-shape, a long side of the L-shape has a constant width, and the free end thereof is provided with the group of bristles. robot.   2. The autonomous floor cleaning robot of claim 1, wherein the dust collection means comprises a removable dust cartridge configured to be integrated in combination with the deck for connection to the brush assembly and the vacuum assembly. . The removable dust cartridge,
A bottom plate member,
A top plate member,
A side wall member for joining the bottom plate member and the top plate member to each other so that the bottom plate member and the top plate member extend beyond the side wall to define an open end;
A curved arc-shaped member disposed in combination with the bottom plate member, the top plate member and the side wall member, and defining a rear outer side wall structure of the autonomous floor cleaning robot;
The autonomous floor cleaning robot according to claim 1, comprising:   32. The autonomous floor of claim 31, wherein the free end of the bottom plate member is angled and includes a plurality of protrusions that interact with the brush assembly to remove trapped debris from the brush assembly. Cleaning robot. The autonomous floor cleaning robot further includes a rear wall member attached between the bottom plate member and the top plate member to abut and engage the side wall member,
The bottom plate member, the top plate member, the side wall and the rear wall member are combined to define a first storage chamber positioned to receive dust from the brush assembly;
The bottom plate member, the side wall member, the curved arc member and the rear wall member are combined to define a second storage chamber coupled to the vacuum assembly and receiving dust from the vacuum assembly;
The autonomous floor cleaning robot according to claim 31.   The autonomous floor cleaning robot of claim 33, wherein the rear wall member has a baffle configuration.   32. The autonomous floor cleaning robot of claim 31, further comprising a replaceable filter resiliently fitted in combination with the bottom plate member.   32. A latch member attached to the top plate member, the latch member further comprising a latch configured to be hooked on the deck to combine and attach the removable dust cartridge to the deck. Autonomous floor cleaning robot. The drive subsystem includes:
First and second wheel subassemblies independently mounted in combination with the chassis at each lateral diameter end of the chassis, wherein each wheel subassembly is configured to pivot with respect to the chassis. First and second wheel subassemblies,
Each of the wheel subassemblies includes a wheel and a motor coupled to the motor to transmit torque to the wheel to rotate the wheel.
The wheels of the first and second wheel subassemblies are different to perform a turning pattern for the autonomous floor cleaning robot at the same speed to propel the autonomous floor cleaning robot linearly forward or backward. Operable at the same speed and at the same speed in the opposite direction to rotate the autonomous floor cleaning robot in its original position;
The autonomous floor cleaning robot according to claim 1.   The autonomous floor cleaning robot of claim 1, further comprising a bumper centered about a longitudinal axis of the chassis and displaceably mounted to the chassis at a front end of the chassis. The autonomous floor cleaning robot further includes a cover having a shape complementary to the chassis and configured to be mounted in combination with the chassis,
The autonomous floor cleaning robot has a generally cylindrical configuration that is roughly symmetrical along the longitudinal axis.
The autonomous floor cleaning robot according to claim 1. A sensor subsystem arranged in combination with the autonomous floor cleaning robot,
(a) providing a signal to the command / control module to coordinate a normal cleaning operation of the autonomous floor cleaning robot; and
(b) detecting a situation that may adversely affect the normal cleaning operation of the autonomous floor cleaning robot and responding to the detection so that the autonomous floor cleaning robot can perform an appropriate response via the command / control unit; Act to provide a signal
The autonomous floor cleaning robot according to claim 1, further comprising a sensor subsystem. A housing base structure including a chassis, a part of which is configured as a deck,
A power subsystem that provides energy to power the autonomous floor cleaning robot;
A drive subsystem that acts to propel the autonomous floor cleaning robot for a cleaning operation;
A control module operative to control the autonomous floor cleaning robot to perform a cleaning operation;
A cleaning head subsystem;
The cleaning head subsystem includes:
An asymmetric first and second brush mounted in combination with the deck and powered by the drive subsystem during a cleaning operation to sweep dust, the second brush being larger than the first brush; A two-stage brush assembly with first and second brushes having outer diameters;
Means coupled to the brush assembly for collecting dust swept by the brush assembly;
including,
An autonomous floor cleaning robot.   42. The autonomous floor cleaning robot of claim 41, wherein the asymmetric first and second brushes are counter-rotating with respect to each other.   42. The first brush is a flapper brush including a plurality of cleaning strips rotatably mounted to the deck and to the drive subsystem for the two-stage brush assembly. Autonomous floor cleaning robot.   47. The autonomous floor cleaning robot of claim 46, wherein the plurality of cleaning strips are arranged in a chevron pattern.   44. The autonomous floor cleaning robot of claim 43, wherein said plurality of cleaning strips are segmented.   46. The autonomous floor cleaning robot of claim 45, wherein the plurality of cleaning segment strips comprises six cleaning segment strips.   47. The autonomous floor cleaning robot of claim 46, wherein the cleaning segment strip comprises five segments. The autonomous floor cleaning robot has a fortified shape with a portion of the divider frame press-fitted into the deck in such a manner that the divider frame forms a guard over the two-stage brush assembly. Further equipped with a partition frame,
46. The autonomous floor cleaning robot of claim 45, wherein the fort-like shape of the divider frame defines segmentation of the plurality of cleaning strips. The second brush is a main brush,
The main brush is
A central member,
A protective member mounted in combination with the central member, each end configured to rotatably mount the primary brush to the deck and to the drive subsystem for the two-stage brush assembly. Cap and
42. The autonomous floor cleaning robot of claim 41, comprising:   50. The autonomous floor cleaning robot of claim 49, wherein the protection member includes an integral rib configured and operative to prevent suction of objects by the primary brush.   51. The autonomous bristles of claim 50, further comprising a plurality of bristles set in combination with the central member to extend beyond the integral rib and beyond an outer diameter defined by the end cap. Floor cleaning robot.   52. The autonomous floor cleaning robot of claim 51, wherein each bristle has a diameter of about 0.254 millimeters (0.01 inches), a length of about 22.86 millimeters (0.9 inches), and a rounded free end. The two-stage brush assembly includes a flapper brush and a primary brush;
The flapper brush is configured to be rotatably mounted to the deck and to the drive subsystem for the two-stage brush assembly, and includes a plurality of cleaning spaced segments arranged in a chevron pattern. Including a strip, and
The primary brush is a central member and a protective member mounted in combination with the central member, the primary brush being rotatable with respect to the deck and relative to the drive subsystem for the two-stage brush assembly. A protective member having respective end caps configured for attachment, and a plurality of bristles associated with the central member to extend beyond an outer diameter defined by the respective end caps.
An autonomous floor cleaning robot according to claim 41.   54. The autonomous floor cleaning robot of claim 53, wherein the protection member includes an integral rib configured and operative to prevent suction of objects by the primary brush. The flapper brush and the primary brush are asymmetric, the primary brush having an outer diameter greater than the outer diameter of the flapper brush, and
55. The autonomous floor cleaning robot of claim 54, wherein the flapper brush and the primary brush rotate counter-rotating with respect to each other. A housing base structure including a chassis, a part of which is configured as a deck,
A power subsystem that provides energy to power the autonomous floor cleaning robot;
A drive subsystem that acts to propel the autonomous floor cleaning robot for a cleaning operation;
A control module operative to control the autonomous floor cleaning robot to perform a cleaning operation;
A cleaning head subsystem;
The cleaning head subsystem includes:
An asymmetric first and second brush mounted in combination with the deck and powered by the drive subsystem during a cleaning operation to sweep dust, the second brush being larger than the first brush; A two-stage brush assembly with first and second brushes having outer diameters;
A vacuum assembly disposed in combination with the deck behind and immediately adjacent the two-stage brush assembly and powered by the drive subsystem to draw dust during a cleaning operation;
Means coupled to the brush assembly and the vacuum assembly for collecting dust swept by the brush assembly and sucked by the vacuum assembly;
including,
An autonomous floor cleaning robot. The vacuum assembly comprises:
A vacuum inlet having a predetermined width and gap, the vacuum inlet being separate from and independent of the brush sweep area defined by the two-stage brush assembly;
Formed on the deck, a partition bottom plate, a continuous partition wall portion, and a vacuum partition including an aperture formed through the partition bottom plate,
A detachable compartment cover configured to be pressure-fitted in a seal combination with the vacuum compartment and the vacuum inlet, wherein the compartment cover and the vacuum compartment define a vacuum chamber with the pressure-fit combination. Compartment cover,
An impeller mounted in combination with the deck such that an intake of the impeller is located within the aperture, operatively connected to the drive subsystem to receive torque from the drive subsystem. An impeller,
A vacuum channel integrated with the impeller in a seal combination to remove collected dust from the vacuum chamber;
57. The autonomous floor cleaning robot of claim 56, comprising: The vacuum inlet is
A first blade having a general rectangular shape and a lateral dimension defining the predetermined width of the vacuum inlet, one lateral edge of the first blade being attached to a lower surface of the deck. A first blade, wherein the first blade is angled forward with respect to the deck because the first blade is sealed and extended into the continuous compartment wall;
A second blade having a general rectangular shape that is complementary to the shape of the first blade, wherein one lateral edge of the second blade is disposed in sealing combination with the removable compartment cover. A second blade,
The first and second blades are combined to define the vacuum inlet having the predetermined width and gap;
58. The autonomous floor cleaning robot of claim 57.   The lateral free edge of the first blade is fortified to relieve dust pressure by the vacuum inlet during a cleaning operation and includes a plurality of fortified segments along the lateral free edge. 59. The autonomous floor cleaning robot of claim 58, having a fort-like shape defining:   The autonomous floor cleaning robot further includes a plurality of protrusions having a predetermined height, the protrusions being aligned with the fortified segment and extending from the segment, and being combined with the second blade. 60. The autonomous floor cleaning robot of claim 59, wherein a flat surface of the abutment abuts the protrusion of the first blade to form the predetermined gap of the vacuum inlet. The vacuum inlet is
A first blade having a general rectangular shape and a lateral dimension defining the predetermined width of the vacuum inlet, one lateral edge of the first blade being attached to a lower surface of the deck. The first blade is angled forward with respect to the deck as it extends into the continuous compartment wall and seals together, and the lateral free edge of the first blade is used for cleaning operations. A first blade having a fortified shape to mitigate the pressing of dust by the vacuum inlet therebetween and defining a plurality of fortified segments along the lateral free edge,
A second blade having a general rectangular shape that is complementary to the shape of the first blade, wherein one lateral edge of the second blade is disposed in sealing combination with the removable compartment cover. The second blade,
A plurality of protrusions having a predetermined height and aligned with and extending from the fortified segment, wherein the flat surface of the second blade abuts the protrusion of the first blade when combined. A plurality of projections, forming the predetermined gap of the vacuum inlet,
58. The autonomous floor cleaning robot of claim 57, comprising: The opening is formed through the partition bottom plate to be offset from the geometric center of the partition bottom plate, and
58. The compartment bottom plate further comprising guide ribs projecting upwardly from the compartment bottom plate to distribute airflow over the predetermined gap such that a substantially constant negative pressure is maintained over the predetermined gap. Autonomous floor cleaning robot.   Attached in combination with the chassis and powered by the drive subsystem to capture dust outside the outer perimeter of the housing substructure and direct such dust to the self-adjusting cleaning head subsystem. 57. The autonomous floor cleaning robot of claim 41 or 56, further comprising a side brush assembly. The side brush assembly includes:
A shaft having one end rotatably connected to the drive subsystem for transmitting torque to the drive subsystem;
A hub connected to the other end of the shaft,
Brush means connected to the hub for trapping dust outside the outer perimeter of the housing substructure and for directing such dust toward the self-regulating cleaning head subsystem;
64. The autonomous floor cleaning robot of claim 63, comprising: The brush means,
An opposing brush arm extending outwardly from the hub;
A group of bristles set at the free end of each of the brush arms;
65. The autonomous floor cleaning robot of claim 64, comprising:   66. The autonomous floor cleaning of claim 65, wherein each of the brush arms has an L-shape, a long side of the L-shape has a constant width, and the free end thereof is provided with the group of bristles. robot.   42. The autonomous floor cleaning robot of claim 41, wherein the dust collecting means comprises a removable dust cartridge configured to be integrated in combination with the deck for connection to the brush assembly and the vacuum assembly. . The removable dust cartridge,
A bottom plate member,
A top plate member,
A side wall member for joining the bottom plate member and the top plate member to each other so that the bottom plate member and the top plate member extend beyond the side wall to define an open end;
A curved arc-shaped member disposed in combination with the bottom plate member, the top plate member and the side wall member, and defining a rear outer side wall structure of the autonomous floor cleaning robot;
68. The autonomous floor cleaning robot of claim 67, comprising:   69. The autonomous floor of claim 68, wherein the free end of the bottom plate member is angled and includes a plurality of protrusions that interact with the brush assembly to remove trapped debris from the brush assembly. Cleaning robot. The autonomous floor cleaning robot further includes a rear wall member attached between the bottom plate member and the top plate member to abut and engage the side wall member,
The bottom plate member, the top plate member, the side wall and the rear wall member are combined to define a first storage chamber positioned to receive dust from the brush assembly;
The bottom plate member, the side wall member, the curved arc member and the rear wall member are combined to define a second storage chamber coupled to the vacuum assembly and receiving dust from the vacuum assembly;
70. The autonomous floor cleaning robot of claim 69.   71. The autonomous floor cleaning robot of claim 70, wherein the rear wall member has a baffle configuration.   69. The autonomous floor cleaning robot of claim 68, further comprising a replaceable filter resiliently fitted in combination with the bottom plate member.   69. A latch member attached to the top plate member, the latch member further comprising a latch configured to be hooked on the deck to combine and attach the removable dust cartridge to the deck. Autonomous floor cleaning robot. The drive subsystem includes:
First and second wheel subassemblies independently mounted in combination with the chassis at each lateral diameter end of the chassis, wherein each wheel subassembly is configured to pivot with respect to the chassis. First and second wheel subassemblies,
Each of the wheel subassemblies includes a wheel and a motor coupled to the motor to transmit torque to the wheel to rotate the wheel.
The wheels of the first and second wheel subassemblies are different to perform a turning pattern for the autonomous floor cleaning robot at the same speed to propel the autonomous floor cleaning robot linearly forward or backward. Operable at the same speed and at the same speed in the opposite direction to rotate the autonomous floor cleaning robot in its original position;
An autonomous floor cleaning robot according to claim 41.   42. The autonomous floor cleaning robot of claim 41, further comprising a bumper centered about a longitudinal axis of the chassis and displaceably mounted to the chassis at a front end of the chassis. The autonomous floor cleaning robot further includes a cover having a shape complementary to the chassis and configured to be mounted in combination with the chassis,
The autonomous floor cleaning robot has a generally cylindrical configuration that is roughly symmetrical along the longitudinal axis.
An autonomous floor cleaning robot according to claim 41. A sensor subsystem arranged in combination with the autonomous floor cleaning robot,
(a) providing a signal to the command / control module to coordinate a normal cleaning operation of the autonomous floor cleaning robot; and
(b) detecting a situation that may adversely affect the normal cleaning operation of the autonomous floor cleaning robot and responding to the detection so that the autonomous floor cleaning robot can perform an appropriate response via the command / control unit; Act to provide a signal
42. The autonomous floor cleaning robot of claim 41, further comprising a sensor subsystem.

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