AUTOMATED APPARATUS AND EQUIPPED TRASHCAN

Abstract

An automated cleaning device for cleaning a floor surface and steps including a housing having a power source and a cleaning mechanism coupled thereto. A drive mechanism is coupled to the power source and can drive the cleaning mechanism. A sensor is provided that couples to the housing for detecting objects that lie along a path of movement being traveled by the apparatus. The apparatus further includes a leg movably coupled to the housing, such that the leg can move from a retracted position in which the leg is disposed in the housing to an extended position. As the leg moves to the extended position, the leg can engage a surface in which the device is positioned on and lift the housing away from the surface.

Description

BACKGROUND

The present invention generally relates to the field of automated cleaning devices and, more particularly, to a system including an automated vacuum apparatus and equipped trashcan for cleaning a plurality of surfaces.

Automated cleaning devices are well-known and have been used extensively in many different technical fields including industries such as automotive, clothing, financial, and governmental. These devices have been used to replace human labor in many instances for reducing costs and improving efficiency. More recently, these automated devices have been incorporated into the household services industry for performing tasks such as doing laundry, cleaning appliances and dishware, mopping, sweeping, and waxing various surfaces, and other traditional household chores.

One such automated device that has found its way into the marketplace is a robotic cleaning apparatus that moves about and cleans a defined space without human intervention. A basic navigation system and sensors incorporated within the robotic cleaning apparatus allow the apparatus to clean an entire floor space without missing areas within the space. The general use of such a robotic cleaning apparatus is for cleaning a substantially planar and horizontal surface.

SUMMARY OF THE INVENTION

An embodiment of the present invention provides an automated apparatus for cleaning a floor surface and steps. The apparatus can include a housing having a power source, plurality of cleaning mechanisms, and a drive mechanism coupled to the power source. The drive mechanism can drive the plurality of cleaning mechanisms and a sensor can be coupled to the housing for detecting objects that lie along a path of movement being traveled by the apparatus. A controller can be disposed in the housing for controlling the plurality of cleaning mechanisms. The controller can be configured to communicate with a remote communication system. The apparatus further includes a leg movably coupled to the housing, such that the leg can move from a retracted position in which the leg is disposed in the housing to an extended position. As the leg moves to the extended position, the leg can engage a surface adjacent to the apparatus and lift the housing away from the surface.

In a different embodiment, an automated system for cleaning steps is provided that includes an automated robot for cleaning and a collection device. The robot can be provided with a housing having a power source and a plurality of cleaning mechanisms coupled thereto, a drive mechanism coupled to the power source, the drive mechanism driving the plurality of cleaning mechanisms and a sensor coupled to the housing for detecting an elevation change and objects that lie along a path of movement being traveled by the apparatus. The robot can further have a controller disposed in the housing for controlling the plurality of cleaning mechanisms. Additionally, the robot can include a leg movably coupled to the housing such that the leg can move from a retracted position in which the leg is disposed in the housing to an extended position. As the leg moves to the extended position, the leg can engage a surface in which the apparatus is positioned on and lift the housing away from the surface.

In one embodiment, the collection device can include a communication center for communicating with the robot, a housing adapted to receive collected contents from the robot, and a vacuum coupled to the housing. The vacuum can assist with transferring collected contents from the robot into the housing. Further, the collection device can include a docking station to which the robot couples thereto.

In another embodiment, a method for using an automated cleaning apparatus from one step to another or up or down a step and cleaning the step is provided with the apparatus having a housing and a plurality of cleaning mechanisms coupled thereto, a drive mechanism coupled to the plurality of cleaning mechanisms, a sensor coupled to the housing, a controller, and a leg movably coupled to the housing. The method can include detecting a step with the sensor and transmitting a signal to the controller that the apparatus is near or at the step. Further, the method includes determining whether to move up or down the step. To do so, the leg moves to a position in which the leg contacts a surface and then lifts the housing away from the surface. The leg can then tilt at an angle and thereby move at least a portion of the housing to a position substantially above the step. The leg can be moved into the housing before the apparatus cleans the step.

The present invention is explained in more detail hereinafter on the basis of advantageous embodiments shown in the figures. The special features shown therein may be used individually or in combination to provide embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned aspects of the present invention and the manner of obtaining them will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention, taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective top view of a robotic cleaning device;

FIG. 2 is a perspective bottom view of the robotic cleaning device of FIG. 1;

FIG. 3 is a perspective view of internal components of the robotic cleaning device of FIG. 1;

FIG. 4 is a perspective view of additional or different internal components of the robotic cleaning device of FIG. 1;

FIG. 5 is a schematic of a robotic cleaning device detecting objects via a plurality of sensors;

FIG. 6 is a side view of the robotic cleaning device of FIG. 1 is a raised position for moving about a step;

FIG. 7 is a side view of the robotic cleaning device of FIG. 6 including a leg tilting and moving the device into contact with the step;

FIG. 8 is a perspective view of a leg of a robotic cleaning device;

FIG. 9 is a perspective view of a case of a robotic cleaning device for the leg of FIG. 8;

FIG. 10 is a perspective view of a holder of a robotic cleaning device;

FIG. 11 is a perspective view of the leg of FIG. 8 in a retracted position in the case of FIG. 9;

FIG. 12 is a perspective view of the leg of FIG. 8 in an extended position;

FIG. 13A is a perspective bottom view of another embodiment of the robotic cleaning device of FIG. 1;

FIG. 13B is a cross-sectional view of a cap mechanism for removing collected particles from the robotic cleaning device of FIG. 1;

FIG. 13C is a cross-sectional view of collected particles being transferred from the robotic cleaning apparatus of FIG. 1 to a collection device;

FIG. 14 is a partial perspective top view of a mechanism for coupling with a robotic cleaning device for transferring collected particles;

FIG. 15 is a partial perspective bottom view of a docking station of a collection receptacle;

FIG. 16 is a schematic of an exemplary brush being cleaned by a rotary mechanism;

FIG. 17 is a perspective view of an exemplary rotary mechanism for cleaning the brush of FIG. 16;

FIG. 18 is a partial perspective view of an exemplary side brush of a robotic cleaning device;

FIG. 19 is a schematic of a robotic cleaning device moving about an area;

FIG. 20 is a flow diagram of communication between a communication controller and a robotic cleaning device; and

FIG. 21 is a diagram of the connectivity between features of the robot and collection device.

Corresponding reference numerals are used to indicate corresponding parts throughout the several views.

DETAILED DESCRIPTION

The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.

An exemplary robotic cleaning device (“robot”) is shown in FIG. 1. The robot 2 includes a housing 4 supported by a plurality of wheels. In the embodiment of FIG. 1, the robot has a pair of rear wheels 6 near the rear of the robot 2 which drives the robot in forward, reverse, and lateral directions. The robot 2 may also have one or more wheels 8 positioned forward of the rear wheels 6 to provide stability and balance the weight of the robot. The forward wheel 8 may comprise a plurality of forward wheels 8. In one embodiment, the forward wheel 8 is free-spinning and the robot 2 is driven by the rear wheels 6. In another embodiment, the forward wheel 8 and rear wheels 6 drive the robot 2.

The robot 2 may include a plurality of sensors for detecting objects and obstacles in all directions that surround the robot. In the embodiment of FIG. 1, for example, the robot 2 has a sensor 12 disposed at the front end of the housing 4 for detecting objects. The sensor 12 can be any type of sensor, including infrared, radio-frequency (RF), photoelectric, magnetic, proximity, ultrasonic, or any other sensor known to the skilled artisan. Additionally, a sensor 10 is provided near the front end of the robot 2 to detect obstacles along a path of movement of the robot 2. This particular sensor 10 detects objects upon contact with the object and transmits a signal to a controller within the robot 2. In FIG. 2, a plurality of sensors 34, 36 are positioned on the bottom of the robot 2 to detect changes in the surface the robot 2 is moving about. For example, if the robot 2 is moving in a forward direction and it comes upon a sudden downward slope or step, sensors 56 near the front of the robot 2 can detect the surface change and communicate the change to the controller. Similarly, if the robot 2 is moving in a reverse direction and it comes upon a surface change (e.g., a downward step), sensors (not shown) which are disposed near the rear of the robot 2 can detect the sudden surface change and communicate the change to the controller. The location of the sensors 34, 36 can vary in different embodiments and those shown in the figures should not be limiting. One skilled in the art can appreciate other advantages by positioning the sensors along other edges and in various quantities.

In the embodiment of FIG. 1, the robot 2 can include an accessory compartment 14 in which different components, particularly audio and/or video equipment can be disposed therein. Such components may include a webcam, video camera, digital camera, and any other similar component known to one skilled in the art. Also, the compartment can store air freshner, deodorizer, or other scent-pleasing formula for enhancing the smell of the surrounding environment. To help cool the robot 2 and the internal components within the housing 4, an air vent 24 can be provided on the outside of the housing 4.

The robot 2 also can include a plurality of cleaning devices for sweeping, dusting, mopping, polishing, vacuuming, wiping, or other cleaning functions. In FIGS. 1 and 2, side cleaning brushes 16 are shown near the front end of the robot 2. The side brushes 16 can be driven electrically, hydraulically, mechanically, or by any other means. In one embodiment, for example, the side brushes 16 are driven by an electric motor 52 (see FIG. 4). Each side brush 16 can generally include several arms 18 coupled at one end to the center of the brush 16. At the other end of each arm 18 are bristles 20 which extend outward and perform most of the cleaning function. The robot 2 can also include a center brush 28 for performing a cleaning function. The center brush 28 can be driven by an electric motor 48, as illustrated in FIG. 4, but it can also be driven by other means known to a skilled artisan. The center brush 28 can be positioned anywhere on the robot, but in the embodiment of FIG. 2, the center brush is disposed between the side brushes 16 and wheel 8. The center brush 28 can rotate in clockwise and counterclockwise directions, and in some embodiments, as the brush rotates counterclockwise, dust and other particles are vacuumed and collected by secondary cleaning assembly 30. The secondary cleaning assembly 30 can include one or more apertures, such as slots, a vacuum device for collecting particles, or it may be any form of a brush or mop. Although the embodiments illustrated in FIGS. 1-4 only show the side brushes 16, center brush 28, and secondary cleaning assembly 30, it is possible for the robot 2 to include other components for performing cleaning functions such as a nozzle for dispensing liquid soap, shampoo, conditioner, carpet cleaner, polish, or water on a floor surface. The secondary cleaning assembly 30 may further include a dryer for blowing air onto a surface through the apertures, for example, after the robot 2 has mopped the floor surface. In this particular embodiment, the accessory compartment 14 can hold the liquid soap or shampoo and a nozzle or release apparatus (not shown) can dispense the material from the compartment 14.

The robot 2 can further include legs 22 which are coupled to the housing 4. As will be described in detail below, the legs 22 can move from a retracted position, as shown in FIGS. 1 and 2, in which the legs are substantially disposed in the housing to an extended position in which the legs are substantially disposed outside the housing. In the extended position, the legs 22 can lift the robot 2 from the surface it is positioned on and move the robot to another surface.

In the embodiment of FIG. 2, the robot 2 is shown with a dome-shaped cover 26. The housing 4 and cover 26 can be made from various materials including any plastic, metal or rubber material. The housing and cover should be durable to withstand contact from other objects, such as when the robot is moving in a direction and runs into an object. It is also desirable to use materials that enable the robot to be manufactured and sold cheaply to most consumers. The cover 26 can be coupled to the housing via hinges, snap-fit connectors, screws, adjustable fasteners, slip-fit, or any other means known to the skilled artisan. The cover 26 can also include a plurality of sensors or communication transmitters (not shown) for transmitting signals from any of the sensors of the robot 2 to a remote location. In one embodiment, as the robot 2 travels about a room, the sensors may detect the layout of the room and the detected signals are transmitted from a communication transmitter within the cover to a remote computer for storing the layout of the room being traveled. It is also possible that the cover 26 includes grooves or ribs that allow the robot 2 to be guided by a collection device 84. In other embodiments, wires or electrical conductors (not shown) can be positioned at or near the cover 26 for charging batteries or other power supply of the robot 2.

In one embodiment, the robot 2 can include a cap assembly 32. The cap assembly 32 can include a removable cap that allows collected dust and other particles to be emptied from inside the robot 2. The cap assembly 32 can include a rib or protrusion for assisting in manual removal of the cap. In another embodiment, the opening in which the cap covers can be automatically opened by moving the cap. Other embodiments will be described below with reference to FIGS. 13-15. The robot 2 can also include power supply recharger ports 36. These ports 36 define openings that can receive electrical connectors for recharging the robot's power supply.

In the embodiments of FIGS. 3 and 4, internal components of a robot 2 are shown (in phantom) and can include a plurality of side brushes 16 and center brush 28. As described above, the side brushes 16 and center brush 28 can be driven by motors 46 and 48, respectively. The robot 2 can include an air system 38 that incorporates the functionality of both a vacuum and air pump into a single unit. In a different embodiment, however, the air system 38 can be a vacuum only that collects dust and other particles passing through the apertures as part of the robot's cleaning operation. In an alternative embodiment, the air system 38 can be an air pump that distributes air and functions as a blower. In these latter two embodiments, the air system 38 serves only a single function (e.g., vacuum or blower), but in other embodiments the air system 38 performs multiple functions. For example, in the embodiment of FIG. 2, the air system 38 can operate as either a blower or vacuum, and the direction of the air flow can be distributed through or via the secondary cleaning assembly 30.

The robot 2 can also include a collection compartment 40 disposed in the housing 4 and positioned above or near an opening (not shown) on the bottom of the robot 2. The collection compartment 40 can be a container that receives and stores dust, dirt, hair, and other particles that are collected by the robot's plurality of cleaning devices. In one embodiment, the air system 38 may perform a vacuuming function and particles can be sucked up by the air system 38 and distributed to the collection compartment 40. The collection compartment 40 can include a removable filter (not shown) and the compartment can be made of a light-weight aluminum or plastic that is durable to withstand continued use. The collection compartment 40 can also be made of an environmentally-friendly material to allow the compartment to be recycled after use.

In FIG. 3, the robot 2 can also include a multi-function assembly 42, which is enclosed within the housing 4 to prevent the assembly 42 from being contaminated with moisture, dirt, and other contaminants. In an exemplary embodiment, the multi-function assembly 42 can include a controller 200, drive mechanism 204, and power source 202 (see FIG. 21). The controller 200 can include a microprocessor programmed to control the functions and components of the robot 2 including, but not limited to, the drive mechanism 204, one or more cleaning mechanisms 206, and the legs 210. The controller 200 can include a transmitter/receiver 212 to transmit signals, such as infrared, RF, ultrasonic, wireless (e.g., Bluetooth, WIFI), and others, to a remote controller 214 or computer system. In this embodiment, the controller 200 can include a robot communication system having a receiver 212 that receives detected signals from the plurality of sensors 208 of the robot 2, interprets the signals, and transmits corresponding signals to other components of the robot 2 or to the remote controller 214 or computer system.

In an embodiment in which the multi-function assembly 42 includes a drive mechanism 204, the drive mechanism 204 can provide power to the plurality of motors or other drivers (44, 46, 48, 50, 52) which operate or power other components of the robot 2. Although not shown in detail, in one exemplary embodiment, the multi-function assembly 42 can include a rechargeable battery supply 202 that provides electric power to the drive mechanism. In turn, the drive mechanism 204 provides power to the other motors or drivers of the robot, which operate the cleaning mechanisms 206, sensors 208, and legs 210. The drive mechanism can drive the robot 2 about a space and therefore is coupled to the rear wheels 6 and optionally the forward wheel 8.

FIG. 5 illustrates the robot 2 having a plurality of sensors for detecting objects and obstacles. In particular, as the robot 2 moves in a forward direction and approaches a step 126, the robot 2 can detect the step 126 with sensors 128 and 130. If the step 126 went downwards rather than upwards in FIG. 5, sensor 132 could detect a downward step. Likewise, if the robot 2 was traveling in a reverse direction, sensor 136 could detect a step or object (e.g., a downward step). In this embodiment, sensor 134 can be positioned at or near the rear of the robot 2 to more effectively detect the surface drop. As noted above, each of the previously mentioned sensors can be positioned differently than as depicted in the figures, and additional or fewer sensors can be incorporated into the design of the robot 2.

In the embodiment of FIG. 6, a robot 2 is shown moving from a first surface 60 to a second surface 62. The first surface 60 and second surface 62 are non-planar and separated by height H1. In this embodiment, the robot 2 originally contacted surface 60 before being lifted in direction 58 to a height H2. Height H2 is shown as being greater than Height H1, which would allow the robot to move to second surface 62. The robot 2 (not shown to scale) can be lifted from first surface 60 by moving legs 52 from a retracted position to an extended position. Once the legs 52 have moved to an extended position, the legs can tilt by moving the longitudinal axis of the legs off of vertical as shown in FIG. 7. As the legs 52 tilt, the rear wheels 6 engage second surface 62 and drive the robot 2 onto the surface. A plurality of forward wheels 8, one of which is shown in FIG. 1, can assist in moving the robot onto surface 62. In the embodiment of FIGS. 6 and 7, the majority of the weight of the robot is towards the rear of the robot and therefore as the rear wheels 6 move the robot onto the second surface 62, the front portion of the robot is able to hang over the edge. This becomes important to allow the legs 52 to retract back into the housing of the robot 2. In alternative embodiments, however, the weight of the robot is positioned substantially near the center, or between the center and rear of the robot. In this case, one or more of the plurality of forward wheels 8 can be positioned substantially between the center and rear of the robot for assisting in moving the robot onto second surface 62.

In a different embodiment, the robot 2 includes a leg 150, a hollow body 160, and a holder 180. In FIG. 8, the leg 150 is shown as being substantially rectangular in shape, but it can be any shape. The leg 150 can have a body 152 with one edge defined with teeth 156 and a protrusion 154 extending from the body in the same direction as the teeth. In FIG. 8, the widths of the protrusion 154 and teeth 156 are about the same as the width or thickness of the leg 150. However, in other embodiments, the widths of the protrusion 154 and teeth are less than the overall width of the leg 150. In this embodiment, the protrusion 154 and teeth 156 can be positioned such that in FIG. 11, for example, portions of the width of the leg 150 engage the inner wall of the hollow body 160 and thereby prevent the leg 150 from moving out of the hollow body 160. Although in this embodiment the hollow body 160 is shown, it is also within the scope of this invention that a hollow body 160 is not necessary. In such a case, a holder 180 may or may not be required either.

In FIG. 9, the edges of the hollow body 160 can be defined by a side slot 162, a bottom slot 164, an angled slot 168, a solid side surface 170, a solid top surface 172, and a solid angled surface 174. The hollow body 160 can also include a curved portion 166 between the side slot 162 and bottom slot 164. As shown in FIG. 10, the holder 180 can include a surface partially defined with teeth 182. The shape of the holder 180 is such that it fits along the edges of the hollow body 160. For example, a first surface 186 of the holder can fit along the solid angled surface 174 of the hollow body 160. A second surface 188 can fit along the angled slot 168 and a third surface 190 can fit along the solid side surface 170.

In the exemplary embodiment of FIG. 11, the interaction of the leg 150 and hollow body 160 is shown. In particular, the hollow body 160 is coupled to the housing 4 of the robot 2 and the leg 150 can move relative to the hollow body 160. In the embodiment of FIG. 11, the leg 150 is in the retracted position and substantially surrounded by the hollow body 160. In this position, the edge of the leg 150 that includes the protrusion 154 and teeth 156 extends out of the hollow body 160 through side slot 162. The leg 150 can be slightly smaller than the hollow body 160 so that in the retracted position the leg 150 is substantially surrounded, but in other embodiments the shapes and sizes may differ.

In order to move the leg 150 from the retracted position of FIG. 11 to the extended position, a motor or power drive 50 is coupled to the leg 150 and moves the leg 150 between positions. In one embodiment, the motor or power drive 50 includes a gear assembly that meshes with the teeth 156 of the leg 150. As the leg 150 is moved towards the extended position, the protrusion 154 acts as a stopper for stopping the leg movement in the extended position.

Once the leg 150 is in the extended position, to move the robot 2 to a higher step (as in FIGS. 6-7) the leg 150 can tilt at an angle with respect to the surface the leg is contacting (see FIG. 12). To achieve this movement, motor or power drive 52 can be coupled to the holder 180 via teeth 182 and move the holder 180 away from angled slot 168. As the holder 180 moves away from angled slot 168, clearance or space can be defined between the holder 180 and angled slot 168 to allow a portion of the leg 150 to extend through the angled slot 168 as it tilts. This can be important because substantial force from the weight of the robot 2 is on the leg 150, and by moving the holder 180, flexibility for tilting and/or retracting the leg 150 can be established. Motor or power drive 50 can initiate the tilting movement of the leg 150 and the curvature 166 allows for improved coupling between the motor or power drive 50 and teeth 156. As the rear wheels 6 of the robot 2 in FIG. 7 contact the second surface 62 and drive the robot 2 onto the surface, the motor or power drive 50 can retract the leg 150 back to the retracted position. Once the leg 150 returns to the retracted position, the robot 2 can then move along the second surface 62.

The process of extending and retracting the leg 150 as the robot moves up a step, for example, is similar to the process for moving the robot 2 down a step. To move down a step, e.g., from second surface 62 to first surface 60 in FIG. 6, the front end of the robot 2 is moved to a position such that it hangs over the edge of the second surface 62. In this position, motor or power drive 50 can move leg 150 out of the housing 4. The driving force of the motor or power drive 50 causes the leg 150 to begin pivoting in a counter-clockwise direction. Initially, the leg 150 is prevented from pivoting by the solid side surface 170 of the hollow body 160, and instead moves out of the housing 4 to a partially extended position. As the leg 150 continues to move out of the housing 4, however, the edge of the body 152 opposite the teeth 156 moves out of contact with the solid side surface 170. As such, the leg 150 can now pivot in a counter-clockwise motion until the leg 150 engages the second surface 188 of the holder 180.

The motor or power drive 50 can continue to move the leg 150 out of the housing such that the edge of the leg 150 slides along the second surface 188 of the holder until the leg contacts the lower surface. The interaction between the leg 150, solid side surface 170 of the hollow body 160, and second surface 188 of the holder 180 is substantially similar for when the robot 2 moves down a step as well. Once the leg 150 contacts the lower surface, e.g., first surface 60, the rear wheels 6 drive the robot 2 forward and thereby rotates the leg 150 to the substantially vertical position of FIG. 6. The leg 150 can be retracted into the housing 4 to complete the downward movement of the robot 2.

Other embodiments can include different means for raising and lowering the robot 2 from non-planar surfaces. For example, the leg 150 can be telescopically coupled to the hollow body and through other electrical or mechanical means the leg can be extended and retracted.

In another embodiment, a robot 2 shown in FIG. 13A can have an exit port 68 positioned on the bottom of the robot 2. The exit port 68 can be directly or indirectly coupled to the collection compartment 40 such that dust and other particles held within the collection compartment 40 can be removed from the robot through the exit port 68. In FIG. 13B, for example, the exit port 68 is positioned on the bottom surface 82 of the robot 2. The exit port 68 can be closed by a flexible or pliable cap 72 and a sliding member 76. The sliding member 76 can have a rib or protrusion 78 at one end to assist in moving the sliding member 76 and the cap 72 can be held to the bottom surface 82 of the robot 2 via a bolt, screw, or other fastener 74. In operation, the bottom surface 82 of the robot 2 can be positioned over an inlet of a collection device 84, for example as in FIG. 13C, such that the exit port 68 is aligned directly above the inlet. The sliding member 76 can be moved or slid to one side and the dust and other particles can be released into the collection device 84. In different embodiments, the sliding member 76, bumpers 88, and air intake 90 are missing and the inlet of collection device 84 can be made of a rubber or teflon® material that seals against the bottom surface 82.

In one embodiment, air from an air supply 38 can be pumped into the collection compartment 40 to assist in moving the dust and other particles in direction 80 into the container 84. The cap 72 can be made from an elastic material such that as the dust and other particles are released from the robot 2 into the collection device 84, the cap 72 can elastically bend without deforming. As the air flow from the air supply 38 is shutdown, the cap 72 can return to its original position and seal off the exit port 68. Further, the sliding member 76 can be moved back to its closed position in FIG. 13B. In other embodiments, the exit port 68 can be closed with different types of seals and o-rings and can even include different caps. The exit port 68 needs to be substantially sealed in the closed position to prevent dust and other particles being held in the collection compartment 40 from leaking or exiting the exit port 68.

In FIG. 14, a docking station 86 is provided and it includes a collection device 84, a plurality of bumpers 88, and a plurality of air intake slots 90. In one embodiment, the docking station 86 mates with the robot 2 of FIG. 13A to assist in transferring dust and other particles from the collection compartment 40 to the collection device 84. The transferring of dust and other particles from the collection compartment 40 of the robot 2 to the collection device 84 can take place due to a pressure differential, e.g., a vacuum is created between components, or a blower can blow the dust and other particles into the collection device 84. Alternatively, the dust and other particles can be transferred via gravity into the collection device 84.

As the robot 2 moves onto or into contact with the docking station 86, the plurality of bumpers 88 can engage the rib or protrusion 78 on the sliding member 76 and move the sliding member 76 to an open position (e.g., FIG. 13C). The robot 2 can be guided onto or into contact with the docking station 86 by guide members 92 (see FIG. 15). Alternatively, the cover 26 can have grooves or ribs that engage with the collection device 84 and serve as guides. The robot 2 can be correctly aligned with the docking station 86 once the rear wheels 6 of the robot 2 fit into wheel alignment slots 96 of the docking station 86. Likewise, the forward wheel 8 can fit into wheel holder 94 of the docking station 86. Sensors 98 on the docking station 86 can also detect the robot 2 and transmit signals to the controller of the robot 2 to assist with alignment. In a different embodiment, the docking station 86 can include battery connectors 98 that couple with charger ports 36 of the robot 2 for recharging the robot's power supply.

The docking station 86 can also perform additional functions including deionizing and cleaning the robot. For example, the plurality of air intake slots 90 can be coupled to a vacuum for removing dust and other particles that collect on the bottom surface 82 of the robot 2. The docking station 86 can also include a cleaning mechanism 100 and vacuum slots 102 that are positioned to remove dust, dirt, hair, and other particles that collect and entangle with the center brush 28. In one embodiment, the cleaning mechanism is a blade that can comb through the center brush 28, thereby releasing particles to be collected by the vacuum slots 102. In this embodiment, the cleaning mechanism 100 can spin or rotate at various speeds to achieve this cleaning function. For example, the cleaning mechanism can rotate between 10-1000 rpm. In an alternative embodiment shown in FIGS. 16 and 17, the cleaning mechanism 100 has a plurality of fingers 116, one of which has gear-like teeth 114. The fingers 116 can be made from a plastic, rubber or metal material. In this embodiment, the cleaning mechanism 100 can rotate causing the teeth 114 to comb through the center brush 28 and a blade or razor (not shown) can move in a scissor-like manner to dislodge dust, dirt, hair, and other particles caught in the center brush 28. The vacuum slots 102, which are coupled to vacuum intake 112, can then collect the loose particles from the center brush 28. In another embodiment, the cleaning mechanism 100 can be a brush with metal bristles that interacts with the center brush 28 and releases dust, dirt, hair, and other particles caught in the brush 28. In other embodiments, the cleaning mechanism 100 can be other types of cleaning devices for interacting with the center brush 28.

The docking station 86 can also include a brush cleaning apparatus 104 for every side brush 16 of the robot 2. As shown in FIG. 15, the brush cleaning apparatus 104 can include a rotatable brush 108 that has bristles 110 extending radially outward from the brush 108. As the robot 2 is aligned with the docking station 86, the brush cleaning apparatus 104 is positioned to clean the side brush 16 of the robot 2. The brush cleaning apparatus 104 can spin, rotate, move toward and away from the side brush 16 to remove dust, dirt, hair, and other particles that collect within the side brush 16. As the dust, dirt, hair, and other particles are removed from the side brush, a plurality of slots 106 positioned near the brush 108 can function as a vacuum source to collect the removed particles. A vacuum (not shown), for example, can create a pressure differential to suck loose dust, dirt, hair, and other particles from the side brush 16 through the slots 106 and into the collection device 84.

One way to align the side brush 16 with the brush cleaning apparatus 104 is through an alignment tool 118 disposed on the side brush 16. In FIG. 18, the side brush 16 can include a body 122, a plurality of arms 18 and bristles 20, and a shaft 120 for coupling the side brush 16 to a motor or power drive 46. In this embodiment, the alignment tool 118 is positioned at or near the bottom of the side brush 16 that faces the docking station 86. When the rear wheels 6 and forward wheel 8 of the robot 2 engage with wheel alignment slots 96 and 98, respectively, the robot 2 sinks downward toward the docking station 86. Alignment tool 118 can then engage or interact with corresponding alignment slots (not shown) on the docking station 86 or brush cleaning apparatus 104 to properly align the side brush 16 with the apparatus 104. For example, the plurality of slots 106 can have integrated sensors (now shown) that can properly align the side brush 16 with the brush cleaning apparatus 104. The alignment tool 118 can have various shapes and sizes and can connect in multiple ways with the brush cleaning apparatus 104. Also as shown in FIG. 18 is an outer shell 124 for coupling the motor or power drive 46 to the robot's bottom surface 82. The outer shell 124 can absorb and/or release heat from the motor or power drive 46.

In the exemplary embodiment of FIG. 19, a room or space 138 is shown with a robot 2 moving about an open area 148 of the room or space 138. The room or space 138 is provided with a closet area 146 defined by a plurality of walls 144. The moving path 140 of the robot 2 is shown as the robot moves along the room or space 138. It should be understood that the room layout is not limited to that shown in FIG. 19 and can include any room or space design.

Also disposed at a remote location from the robot 2 is a communication center 142. As described above, sensors from the robot 2 can detect objects and obstacles as the robot 2 moves about a space and relays signals to the communication center 142 about such objects and obstacles. In particular, the communication center 142 comprises a processor, memory, communication modules, and other electronic equipment that permits the communication center 142 to communicate with the robot 2. The communication center 142 can communicate wirelessly, e.g., via Bluetooth, WIFI, or through other communication means.

In one embodiment, the robot 2 can move about a room or space 138 and a robot controller 200 having a receiver and/or transmitter 212 transmits signals to a corresponding receiver/transmitter 218 of a collection device controller 214 (see FIG. 21). The collection device controller 214 receives the signals and can create a layout of the space 138 such that the collection device controller 214 can locate and instruct the robot 2 about various objects and obstacles. GPS locating software is stored in a memory module of the collection device controller 214 and can load stored GPS data and/or maps prior to a cleaning operation. The collection device transmitter 218 can then transmit signals to the robot controller receiver 212 about potential obstacles or objects throughout a given room or space 138 and further instruct the robot 2 where to clean and not clean (for example, if the room or space 138 has carpeted areas and non-carpeted areas).

In another embodiment, the communication center 142 of the collection device 84 can be user-friendly and user-interactive. For example, the collection device controller 214 can be coupled to user interface 222 that includes a keyboard, mouse, joystick, controller, and other user interface equipment known to the skilled artisan. It may also be possible for a user to create software or edit software stored in the memory module of the collection device controller 214 such that a user can track how long it takes a robot 2 to clean a space. A user may also be able to set time of day or length of time for each cleaning operation. The user may be able to track whether the collection compartment 40 of the robot 2 is empty or full and the amount of energy remaining in a robot power source 202 (when the robot operates from battery power, for example). The user may also create software or download software that controls when the robot 2 returns to a docking station 216 to recharge or empty the collection compartment 40.

Many other user options are available with the communication center 142 for controlling the operation of a robot 2, including the type of cleaning function a robot is to perform, when that particular cleaning function is to be performed, and other functions known to the skilled artisan. In an embodiment in which a joystick or hand-operated controller are included, the user can move the robot 2 in various directions, e.g., if the robot needs to complete another sweeping operation over a small area the user can manually control the robot. In this case, through user interaction, the collection device controller 214 can instruct the collection device transmitter 218 to send a signal to the robot receiver 212 and controller 200. The robot controller 200 can then control the drive mechanism 204, cleaning mechanism 206 and leg(s) 210 to perform said operation. Additionally, the user can also control the cleaning functionality of the collection device 84, including a vacuum 220 and other features built into the collection device 84.

A different embodiment of the communication center 142 can include the collection device 84 and the docking station 86. In this particular embodiment, the communication center 142 can be referred to as a “disposal facility” or collection receptacle that not only communicates with the robot 2, but also provides docking functionality and collects dust, dirt, hair, and other particles collected by the robot 2. The disposal facility 142 can be positioned in a space layout 138 as shown in FIG. 19 or at another location remote from the robot 2. For instance, the robot 2 and disposal facility 142 are not required to be positioned within the same room or a set distance apart, but rather wireless communication between the two devices can be accomplished. The robot 2 can therefore operate in an upstairs area and the disposal facility 142 can be disposed in a downstairs area. Much of this communication can be via Bluetooth, WIFI, and other known wireless communication means.

The disposal facility 142 can include an outer housing or body that encloses the communication center, collection device 84, docking station 86, user interface 222, and vacuums 220 for assisting with the transfer of dust, dirt, hair, and other particles from the robot 2 to the collection device 84. The disposal facility 142 can be plugged into an electric outlet to provide power to the various components or it can operate from a battery. Other forms of power can be used to operate the disposal facility. In one embodiment, the collection device 84 can include a removable bag and/or filter for collecting particles from the robot 2. The collection device 84 can slide out of the disposal facility 142 along tracks or rails, or it can have a door that opens for removing the bag and/or filter (neither of which are shown).

FIG. 20 illustrates a flow diagram including a list of commands in one embodiment of software stored within a memory module of the communication center. For example, before a robot 2 begins performing a function, the communication center 142 can load a map of a room or space in which the robot 2 is going to perform the function. If the layout of the room has not been determined, an initial run by the robot 2 can assist in generating the map. The sensors from the robot 2 can detect walls, openings to closets, objects, obstacles, and any other additional information that defines a given space (e.g., pillars, steps, etc.). As the robot 2 moves about a given space, the sensors can detect the robot movement as well as the objects encountered during the movement and transmit signals to the communication center. The communication center can process and record these signals and begin organizing and creating a map of the space. In those embodiments in which the robot 2 has a webcam housed in the accessory compartment 14, live video can be transmitted to the communication center and stored therein. As the robot 2 continues to move about an area, the robot 2 and/or communication center can calculate runtime and adjust any movements being made by the robot 2. For example, if the robot encounters an object such as a pillar or step, the object can be placed within the layout being generated by the communication center, and during subsequent cleaning operations the robot's path 140 can be adjusted for such an object.

At various times, the volume of the collection compartment 40 can be analyzed to determine whether the robot 2 needs to dock and release its collected contents. Additionally, the battery power of the robot 2, in such an embodiment in which the robot 2 has a battery, can be checked randomly, continuously, or periodically. As the robot 2 continues to move about a room or space 148, the robot sensors continue transmitting signals to the communication center 142 to allow the communication center 142 to record and update the map of the room or space 148. Generally, the robot 2 will begin its path along an edge or wall 144 of the room 148. Once the perimeter of the room or space 148 is established, the communication center can begin to locate the robot 2. In one embodiment, the communication center 142 can have a display screen that permits a user to follow the robot as it moves about a room or space 148. Further, in those embodiments in which the communication center 142 has a user interface, the user can instruct the robot 2 which areas of the room or space 148 to move about. Therefore, user control over a given room or space 148 is possible.

As the robot 2 completes a cleaning operation or cycle within a room or space 138, and the communication center 142 has created a map or room layout 138, the robot 2 can return to a docking station. It is not always necessary for the robot 2 to return to the docking station, as there may be other rooms or spaces in which the robot 2 can move to and clean. However, in the case in which the robot 2 returns to the docking station, it can recharge its battery (if applicable) and/or empty its collection compartment 40 into the collection device 84. Once the robot 2 has docked, emptied its collection compartment, and recharged its battery, the communication center 142 can check for any user instructions and instruct the robot 2 to perform any user-desired functions. If none exist, the robot can remain docked with the docking station until further commanded.

Additional functionality is possible with the communication center 142. For example, the user can control and wirelessly communicate with the communication center 142 and/or robot 2 through a laptop or desktop computer, PDA, cell phone, or other electronic device. Communication can be via Bluetooth, WIFI, or other wireless communication.

While exemplary embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims

1. An automated cleaning device for cleaning a floor surface and steps, comprising:

a housing and a power source disposed therein;

one or more cleaning mechanisms coupled to the housing;

a drive mechanism coupled to the power source, the drive mechanism driving the one or more cleaning mechanisms;

a sensor coupled to the housing for detecting objects that lie along a path of movement being traveled by the device;

a controller disposed in the housing and controlling the one or more cleaning mechanisms, the controller configured to communicate with a remote communication system; and

a leg movably coupled to the housing, the leg including a retracted position in which the leg is substantially disposed in the housing and an extended position in which at least a portion of the leg is disposed outside the housing, whereby the leg engages a surface adjacent to the device and lifts the housing away from the surface.

2. The automated cleaning device of claim 1, further comprising a hollow body coupled to the housing and at least partially enclosing the leg.

3. The automated cleaning device of claim 2, wherein the hollow body comprises an opening through which the leg extends in the extended position.

4. The automated cleaning device of claim 1, wherein the leg comprises a surface that defines teeth configured for engaging a gear to move the leg between the extended position and retracted position.

5. The automated cleaning device of claim 1, wherein the leg comprises a plurality of legs.

6. The automated cleaning device of claim 1, wherein the plurality of cleaning mechanisms comprises a brush, mop, rag, towel, broom, sponge, or cloth.

7. The automated cleaning device of claim 1, wherein the sensor comprises a bumper sensor configured for contacting an object.

8. The automated cleaning device of claim 1, wherein the sensor detects an object and communicates the detection to the controller.

9. The automated cleaning device of claim 1, further comprising a collection compartment disposed in the housing, the collection compartment adapted to receive contents from the floor surface or steps.

10. The automated cleaning device of claim 9, further comprising a vacuum disposed in the housing and coupled to the collection compartment, wherein the vacuum transports contents into the collection compartment.

11. The automated cleaning device of claim 9, wherein a bottom surface of the housing defines an opening through which contents are transported from the cleaning mechanisms to the collection compartment.

12. The automated cleaning device of claim 1, wherein the leg further includes a tilted position.

13. The automated cleaning device of claim 1, wherein the controller is configured to communicate wirelessly.

14. The automated cleaning device of claim 13, wherein the controller is configured to communicate via Bluetooth.

15. An automated cleaning device for cleaning steps, comprising:

an automated robot for cleaning, comprising: a housing and a power source disposed therein; one or more cleaning mechanisms coupled to the housing; a drive mechanism coupled to the power source, the drive mechanism driving the one or more cleaning mechanisms; a sensor coupled to the housing configured for detecting an elevation change and objects that lie along a path of movement being traveled by the robot; and a controller disposed in the housing and controlling the one or more cleaning mechanisms; and

a collection device, comprising: a housing configured for receiving contents from the robot; a communication center and vacuum disposed within the housing, wherein the vacuum is adapted to transfer contents from the robot into the housing; and a docking station to which the robot couples to the collection device.

16. The automated cleaning device of claim 15, wherein the robot comprises a leg movably coupled to the housing, the leg including a retracted position in which the leg is substantially disposed in the housing and an extended position in which at least a portion of the leg is disposed outside the housing, whereby the leg engages a surface adjacent the device and lifts the housing away from the surface

17. The automated cleaning device of claim 15, wherein the communication center comprises a user-interface.

18. A method for using an automated cleaning device to move up or down a step and clean the step, the device having a housing and a cleaning mechanism coupled thereto, a drive mechanism coupled to the cleaning mechanism, a sensor coupled to the housing, a controller, and a leg movably coupled to the housing, the method comprising:

detecting a step with the sensor;

transmitting a signal to the controller with the sensor;

determining with the controller whether to move up or down the step;

moving the leg into contact with a surface;

lifting the housing away from the surface;

tilting the leg at an angle and thereby moving at least a portion of the housing above the step;

moving the portion of the housing into contact with the step;

moving the leg into the housing; and

cleaning the step.

19. The method of claim 18, further comprising sensing objects that lay along a path of movement being traveled by the device.

20. The method of claim 18, wherein the cleaning step further comprises driving the cleaning mechanism.