POWERED CLEANING APPLIANCE
An autonomous cleaning appliance including a housing, a dirt container disposed in the housing, a brushroll disposed in the housing and configured to move dirt into the dirt container, a brush motor disposed in the housing for driving the brushroll, and a power drive assembly mounted in the housing for propelling the appliance. The power drive assembly including a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing (the second side being opposite the first side), and a second drive motor operatively connected to the second drive assembly. A floor sensor system is coupled to the housing for detecting a loss of floor condition and an off edge condition.
This application is a continuation application of U.S. application Ser. No. 12/856,238, filed on Aug. 13, 2010, which is a continuation application of U.S. application Ser. No. 12/174,283, filed on Jul. 16, 2008, which is a divisional application of U.S. application Ser. No. 10/967,551, filed Oct. 18, 2004, which claims the benefit of U.S. Provisional Patent Application No. 60/559,186, filed Apr. 2, 2004, the contents of which are incorporated herein by reference in their entirety.
BACKGROUNDCleaning appliances having a powered drive mechanism are known. For example, many vacuum cleaners include motors to propel the vacuum cleaner across a surface to be cleaned. Some of these vacuum cleaners include a handle to allow a user to maneuver the vacuum cleaner. Other vacuum cleaners are autonomously propelled. Autonomous vacuum cleaners receive directions via a remote signal or they can be programmed to move across a floor.
In addition to automatically propelled vacuum cleaners, sweepers having a powered brushroll are also known. Typically, a motor drives the brushroll. The brushroll rotates and contacts dirt and other debris to propel it into a dust cup located adjacent the brushroll.
SUMMARYIn one embodiment, the invention provides an autonomous cleaning appliance having a housing, a dirt container disposed in the housing, a brushroll disposed in the housing and configured to move dirt into the dirt container, a brush motor disposed in the housing for driving the brushroll, and a power drive assembly mounted in the housing for propelling the appliance. The power drive assembly includes a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing (the second side being opposite the first side), and a second drive motor operatively connected to the second drive assembly. A floor sensor system is coupled to the housing for detecting a loss of floor condition and an off edge condition.
In another embodiment, the invention provides an autonomous cleaning appliance having a housing, a dirt container disposed in the housing, and a power drive assembly mounted in the housing for propelling the appliance. The power drive assembly includes a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing (the second side being opposite the first side), and a second drive motor operatively connected to the second drive assembly. An infrared floor sensor system is coupled to the housing and includes an emitter and a corresponding detector.
In yet another embodiment, the invention provides an autonomous cleaning appliance having a housing, a dirt container disposed in the housing, a brushroll disposed in the housing and configured to move dirt into the dirt container, a brush motor disposed in the housing for driving the brushroll, and a power drive assembly mounted in the housing for propelling the appliance. The power drive assembly includes a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing (the second side being opposite the first side), and a second drive motor operatively connected to the second drive assembly. An infrared floor sensor system assembly is coupled to the housing and includes a first sensor, a second sensor, a third sensor, and a fourth sensor. Each sensor includes an emitter and a corresponding detector. The first sensor, the second sensor, the third sensor, and the fourth sensor are positioned such that when one of the first sensor, the second sensor, the third sensor, or the fourth sensor detects a loss of floor condition or an off edge condition, the infrared floor sensor system delivers a signal to the power drive assembly to stop propulsion of the appliance.
A powered cleaning appliance can take form in certain components and structures, an embodiment of which will be illustrated in the accompanying drawings.
A powered appliance 10 includes a housing 12, a removable dirt cup 14 located in the housing, a brushroll assembly located in housing, a drive assembly located in the housing, and a bumper 16 mounted to the housing. The appliance 10 will be described as an autonomous sweeper since in the depicted embodiment it does not include a suction source like that of a conventional vacuum cleaner. Alternative embodiments could include a suction source, such as a motor driven fan, that would direct airflow into the dirt cup 14. Furthermore, the appliance 10 will be described as having no upright handle to allow a user of the appliance to direct the movement of the appliance, similar to a conventional upright vacuum cleaner. Nevertheless, if desired, a handle can easily be attached to the appliance for directing its movement.
In the depicted embodiment, the housing 12 of the appliance 10 can be a generally circular plastic casing that encloses internal components of the appliance. With reference the
The base 22 of the housing 12 can also be generally circular and include a central cavity 38 that is dimensioned to receive the dirt cup 14. With reference to
As indicated above, in the embodiment disclosed, the dirt cup 14 is received through the central opening 24 of the cover 18 and in the central cavity 38 of the base 22. With reference to
In the embodiment illustrated in
As most clearly seen in
As mentioned, the dirt cup 14 can take alternative configurations. For example, in lieu of the door 76, the dirt cup can include a removable dirt cup tray that can slide into the bottom of the dirt cup housing. The dirt cup tray can be removed when the user desires to empty the dirt cup. Other possible configurations include a hinged lid that can open so that the contents of the dirt cup can be dumped out from the top of the dirt cup.
With reference back to the embodiments depicted in the figures, two brushroll assembles are provided to propel dust and dirt into the dirt cup 14. With reference to
A second brushroll assembly made up of a second brushroll motor 122, a pinion 124 and a belt 126 is disposed on opposite side of the housing 12 and the dirt cup 14 as the similar components of the first brushroll assembly. The second brushroll motor 122 also rests in a compartment formed in the housing 12. The belt 126 drives a second brushroll dowel 128 that is disposed on an opposite side of the dirt cup 14 from the first brushroll dowel 108. The second brushroll dowel 128 is disposed in the second brushroll chamber 44 (
Turning now to the manner in which the appliance moves across the floor, a drive assembly propels the appliance 10. In the embodiment disclosed, a first drive motor 132 drives a drive sprocket 134 through a gear reduction transmission assembly 136 encased in a gear housing 138 and a gear housing cover 142. In this embodiment, the first drive motor 132 is a reversible electric motor. The drive sprocket 134 engages and drives a toothed drive belt 144, which drives a toothed first track pulley wheel 146. In turn, the first track pulley wheel 146 drives a first belt tread 148 that surrounds the first track pulley wheel 146 and a second track pulley wheel 152 spaced from the first track pulley wheel. The first and second track pulley wheels 146 and 152 receive first and second drive pins 154 and 156, respectively, that attach to the housing 12 so that the pulley wheels are attached to the housing.
A second drive motor 162 drives a second belt tread 164 through components similar to the drive assembly described above. The second belt tread 164 surrounds a first track pulley wheel 166 and a second track pulley wheel 168, both mounted to the housing 12. The second belt tread 164 is disposed on an opposite side of the appliance 10 from the first drive tread 148 and can be driven independently thereof. Such a configuration allows for the appliance 10 to rotate about its central axis easily by driving one motor at one speed while driving the other motor at another speed or, perhaps, in the opposite direction. Because the appliance includes two separate drive assemblies, it can easily turn without the requirement of complicated differential gears and the like. In an alternative embodiment, the appliance 10 need not include the belt treads; instead the appliance could simply include one or more driven wheels that are driven through one or more suitable known transmissions.
Both the drive assemblies and the brushroll assemblies are driven by a power source. A rechargeable battery type power source is disclosed in this embodiment; however, the power source can be any conventional power source including an AC power source from a wall outlet, a solar power source, or a disposable battery power source. As most clearly seen in
In the depicted embodiment, the battery pack assembly is centrally located in the base 22 of the housing. If batteries are the desired power source, as mentioned, they can be located elsewhere in the housing, especially if an increase in the size of the dirt cup 14 is desired. As just one example, a set of batteries can be located toward each belt tread 148 and 164 or toward each brushroll chamber 42 and 44. The batteries could also be located elsewhere in the appliance, so long as they electrically connect to the brushroll assemblies and the drive assemblies.
The bumper 16 is movably mounted to the housing 12. In the depicted embodiment, the bumper 16 is a substantially circular shell that at least substantially surrounds the housing 12. The bumper 16 includes a central opening 184 that allows the dirt cup 14 to be lifted away from the housing 12 without having to remove the bumper. Two bottom brackets 186 and 188 are provided to attach the bumper 16 to the housing 12. Each bracket 186, 188 can be a generally rectangular plate having openings that receive fasteners to attach each bracket to the bumper. Fasteners 192 attach the first bottom bracket 186 to the bumper 16 and fasteners 194 attach the second bottom bracket 188 to the housing 16. As more clearly seen in
With reference to
Movement of the bumper 16 in relation to the housing 12 is limited. With reference to
Movement of appliance 10 can be controlled by sensing the movement of the bumper 16 in relation to the housing 12. In one embodiment, a joystick sensor assembly is disclosed as the sensing device; however, other known motion sensors can be used. With reference to
The bumper 16 includes a downwardly depending hollow cylindrical boss 224 that is dimensioned to receive the lever 214. Movement of the bumper 16 results in movement of the boss 224 which results in movement of the lever 214. An appropriate signal can be sent to the drive motors in response to movement of the lever. Examples of the types of signals that can be delivered by the sensor are further described in co-pending patent application entitled “Robotic Appliance with On-Board Joystick Sensor and Associated Methods of Operation” filed Sep. 21, 2004, which is incorporated herein by reference in its entirety.
In alternative embodiments, the location of the sensor assembly can be moved. For example, the joystick and lever shown in
Movement of the appliance 10 can also be controlled by floor sensor assemblies 226 that can deliver a signal to the drive motors 132 and 162 via the main PCB 218. As seen in
A plurality of switches can be provided to control power to the motors as well as the mode in which the appliance will work. With reference back to
While the appliance has been described above with reference to certain embodiments, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art upon reading and understanding the preceding description. The above embodiments are intended to be illustrative, rather than limiting, of the spirit and scope of the invention. It is intended that the invention embrace all alternatives, modifications, and alteration that fall within the spirit and scope of the appended claims and the equivalents thereof.
Claims
1. An autonomous cleaning appliance comprising:
- a housing;
- a dirt container disposed in the housing;
- a brushroll disposed in the housing and configured to move dirt into the dirt container;
- a brush motor disposed in the housing for driving the brushroll;
- a power drive assembly mounted in the housing for propelling the appliance, the power drive assembly including, a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing, the second side being opposite the first side, and a second drive motor operatively connected to the second drive assembly; and
- a floor sensor system coupled to the housing for detecting a loss of floor condition and an off edge condition.
2. The autonomous cleaning appliance of claim 1, wherein the dirt container does not communicate with a suction source.
3. The autonomous cleaning appliance of claim 1, wherein the floor sensor system delivers a signal to the power drive assembly to affect the propulsion of the appliance.
4. The autonomous cleaning appliance of claim 1, wherein the floor sensor system includes a first sensor, a second sensor, a third sensor, and a fourth sensor.
5. The autonomous cleaning appliance of claim 4, wherein the first sensor is positioned forward of the first drive assembly, wherein the second sensor is positioned forward of the second drive assembly, wherein the third sensor is positioned rearward of the first drive assembly, and wherein the fourth sensor is positioned rearward of the second drive assembly.
6. The autonomous cleaning appliance of claim 1, wherein the floor sensor system includes an infrared sensor.
7. The autonomous cleaning appliance of claim 6, wherein the infrared sensor includes an emitter and a corresponding detector.
8. The autonomous cleaning appliance of claim 7, wherein the emitter has a field of emission directed downward.
9. The autonomous cleaning appliance of claim 8, wherein the detector has a field of view that intersects the field of emission of the emitter such that the loss of floor condition and the off edge condition are detected.
10. The autonomous cleaning appliance of claim 1, wherein when the floor sensor system detects the loss of floor condition or the off edge condition, the floor sensor system delivers a signal to the power drive assembly to stop propulsion of the appliance.
11. An autonomous cleaning appliance comprising:
- a housing;
- a dirt container disposed in the housing;
- a power drive assembly mounted in the housing for propelling the appliance, the power drive assembly including, a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing, the second side being opposite the first side, and a second drive motor operatively connected to the second drive assembly; and
- an infrared floor sensor system coupled to the housing and includes an emitter and a corresponding detector.
12. The autonomous cleaning appliance of claim 11, wherein the emitter has a field of emission directed downward.
13. The autonomous cleaning appliance of claim 12, wherein the detector has a field of view that intersects the field of emission of the emitter such that a loss of floor condition and an off edge condition are detected.
14. The autonomous cleaning appliance of claim 11, wherein when the infrared floor sensor system detects a loss of floor condition or an off edge condition, the infrared floor sensor system delivers a signal to the power drive assembly to stop propulsion of the appliance.
15. The autonomous cleaning appliance of claim 11, wherein the infrared floor sensor system includes a first sensor, a second sensor, a third sensor, and a fourth sensor, each of the sensors including an emitter and a detector.
16. The autonomous cleaning appliance of claim 15, wherein the first sensor, the second sensor, the third sensor, and the fourth sensor are positioned such that when one of the first sensor, the second sensor, the third sensor, or the fourth sensor detects a loss of floor condition or an off edge condition, the infrared floor sensor system delivers a signal to the power drive assembly to stop propulsion of the appliance.
17. The autonomous cleaning appliance of claim 11, wherein the infrared floor sensor system includes:
- a first sensor positioned forward of the first drive assembly,
- a second sensor positioned forward of the second drive assembly,
- a third sensor positioned rearward of the first drive assembly, and
- a fourth sensor positioned rearward of the second drive assembly.
18. The autonomous cleaning appliance of claim 11, wherein the infrared floor sensor system communicates with the first drive motor and the second drive motor via a printed circuit board.
19. The autonomous cleaning appliance of claim 11, wherein the infrared floor sensor system is positioned on a bottom side of the housing.
20. An autonomous cleaning appliance comprising:
- a housing;
- a dirt container disposed in the housing;
- a brushroll disposed in the housing and configured to move dirt into the dirt container;
- a brush motor disposed in the housing for driving the brushroll;
- a power drive assembly mounted in the housing for propelling the appliance, the power drive assembly including, a first drive assembly disposed on a first side of the housing, a first drive motor operatively connected to the first drive assembly, a second drive assembly disposed on a second side of the housing, the second side being opposite the first side, and a second drive motor operatively connected to the second drive assembly; and
- an infrared floor sensor system coupled to the housing and including a first sensor, a second sensor, a third sensor, and a fourth sensor, each including an emitter and a corresponding detector,
- wherein the first sensor, the second sensor, the third sensor, and the fourth sensor are positioned such that when one of the first sensor, the second sensor, the third sensor, or the fourth sensor detects a loss of floor condition or an off edge condition, the infrared floor sensor system delivers a signal to the power drive assembly to stop propulsion of the appliance.
Type: Application
Filed: Mar 8, 2011
Publication Date: Jun 30, 2011
Inventor: Mark E. Reindle (Sagamore Hills, OH)
Application Number: 13/042,712