Automatic charging system and method of robot cleaner

An automatic charging system of a robot cleaner includes: a rotating plate installed at a robot cleaner; an infrared ray receiving unit mounted at the rotating plate and receiving an infrared signal generated from a power supply unit while being rotated; a microcomputer for moving the robot cleaner to the power supply unit on the basis of the received infrared signal; and an ultrasonic generator for generating a stop signal when the robot cleaner nears to the power supply unit. A robot cleaner can be accurately and quickly moved to a power supply unit for a rapid charging operation, and a cost for implementing the robot cleaner can be reduced.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a robot cleaner and, more particularly, to an automatic charging system and method of a robot cleaner.

2. Description of the Background Art

FIG. 1is a schematic block diagram showing a construction of a charging system of a robot cleaner in accordance with a conventional art.

As shown inFIG. 1, a charging system of a robot cleaner (not shown) consists of a power receiving unit100of a robot cleaner and a power supply unit200for charging a battery101of the robot cleaner.

The power supply unit200includes an infrared ray sensor201for communicating with the robot cleaner and a charging unit202for charging the battery101of the robot cleaner. The infrared ray sensor201is installed at the charging unit202and generates an infrared signal in a predetermined direction.

The power receiving unit100of the robot cleaner includes: a battery101; a remaining battery capacity detector102for detecting a remaining capacity of the battery101installed in the robot cleaner; a infrared ray sensor103fixedly installed in the robot cleaner and communicating with the power supply unit200; and a microcomputer104for moving the robot cleaner along a pre-set path through a mapping algorithm in order to receive an infrared signal outputted from the infrared ray sensor201of the power supply unit200if the detected remaining battery capacity is below a reference value, and moving the robot cleaner to the charging unit202on the basis of an infrared ray signal upon receipt of it.

The infrared ray sensor103is fixedly installed at the robot cleaner in order to detect the infrared signal of the infrared ray sensor201of the charging unit202.

The infrared ray sensor103of the robot cleaner outputs to the power supply unit200a start signal for transmitting a data informing that a communication protocol starts for charging to the charging unit200, a coupler signal for informing that a charge switching unit (not shown) of the robot cleaner is turned on; a complete signal informing that the communication protocol for charging is terminated, and an end signal for informing that charging is ended when an error is generated in the robot cleaner, according to a control signal of the microcomputer104.

The infrared ray sensor201of the power supply unit200outputs to the power receiving unit100a connection request signal for informing that the charging unit202is available for charging, a charge signal for indicating that charging is started, and a fault signal for informing the robot cleaner that there is an error in the charging unit202, according to a control signal of the charging unit202.

The operation of the charging system of the robot cleaner will now be described with reference to FIG.1.

First, when the robot cleaner is in a charging mode, the microcomputer104of the robot cleaner moves the robot cleaner along a pre-set path through a mapping algorithm in order to receive an infrared signal.

When the infrared ray sensor103of the robot cleaner receives an infrared signal generated from the infrared ray sensor201of the power supply unit200while the robot cleaner is moved along the pre-set path, the infrared ray sensor103outputs the received infrared signal to the microcomputer104.

Then, the microcomputer104moves the robot cleaner to a position of the charging unit202on the basis of the infrared signal, generates a start signal through the infrared ray sensor103, and transmits the generated start signal to the infrared ray sensor201. Then, the infrared ray sensor201of the power supply unit200detects the start signal and transmits the connection request signal to the infrared ray sensor103of the robot cleaner.

Thereafter, when the microcomputer104detects the connection request signal through the infrared ray sensor103of the robot cleaner, a power terminal (not shown) of the robot cleaner is electrically connected to a charge terminal (that is, charge plate, not shown) installed at the charging unit202according to a control signal of the microcomputer104.

When the power terminal and the charge terminal are connected to each other (available for charging), the microcomputer104transmits the coupler signal to the infrared ray sensor201of the charging unit200through the infrared ray sensor103of the robot cleaner. Then, the charging unit202receives the coupler signal through the infrared ray sensor201, generates the charge signal, and charges the battery101.

Thereafter, when the battery is completely charged, the microcomputer104transmits the complete signal to the infrared ray sensor201of the charging unit202, and upon receipt of the complete signal, the charging unit202cuts off the charge signal. As the charge signal is cut off, the coupler signal of the robot cleaner is not generated any longer.

Meanwhile, if the end signal is generated from the robot cleaner or if the fault signal is generated from the charging unit202while the battery101is being charged, the connection request signal is cut off and the battery charging operation is ended after a certain time lapse.

However, the charging system of the robot cleaner in accordance with the conventional art has the following problems.

That is, in order to receive the infrared signal generated from the infrared ray sensor installed at the charging unit202, the robot cleaner itself is moved along the pre-set path, so that the robot cleaner fails to quickly move to the charging unit (that is, the charge terminal of the charging unit). In other words, because the robot cleaner is moved along the pre-set path to detect the infrared signal, it can not detect the infrared signal quickly.

In addition, in order to detect the infrared signal quickly, a plurality of infrared ray sensors are fixedly installed at the robot cleaner. Thus, fixedly installation of the plural infrared ray sensors at the robot cleaner to receive the infrared signal outputted from the charging unit within a short time causes an increase in a cost for implementing the charging system of the robot cleaner.

SUMMARY OF THE INVENTION

Therefore, an object of the present invention is to provide an automatic charging system and method of a robot cleaner in which a few infrared ray sensors are installed at the robot cleaner and rotated to sense an infrared signal to thereby accurately and quickly move a robot cleaner to a charging unit.

Another object of the present invention is to provide an automatic charging system and method of a robot cleaner in which a few infrared ray sensors are installed at a robot cleaner and rotated to sense an infrared signal to thereby accurately and quickly connect a robot cleaner to a charge terminal.

Still another object of the present invention is to provide an automatic charging system and method of a robot cleaner in which a few infrared ray sensors are installed at a robot cleaner and rotated to sense an infrared signal to thereby reduce a cost for implementing a robot cleaner.

To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided an automatic charging system of a robot cleaner including: a rotating plate installed at a robot cleaner; an infrared ray receiving unit mounted at the rotating plate and receiving an infrared signal generated from a power supply unit while being rotated; a microcomputer for moving the robot cleaner to the power supply unit on the basis of the received infrared signal; and an ultrasonic generator for generating a stop signal when the robot cleaner nears to the power supply unit.

The microcomputer stops movement of the robot cleaner on the basis of the stop signal, and the robot cleaner receives power from the power supply unit according to a control signal from the microcomputer.

To achieve the above objects, there is also provided an automatic charging system of a robot cleaner including: a power supply unit having a charging unit for supplying power and an infrared ray generator for positioned at the charging unit and generating an infrared signal; and a power receiving unit having a rotating plate installed at the robot cleaner, an infrared ray receiving unit mounted at the rotating plate and receiving the infrared signal while being rotated, a microcomputer for moving a robot cleaner to the charging unit on the basis of the received infrared signal, and an ultrasonic generator for generating a stop signal when the robot cleaner nears to the charging unit.

The microcomputer stops movement of the robot cleaner on the basis of the stop signal, and the robot cleaner receives power from the charging unit according to a control signal from the microcomputer.

To achieve the above objects, there is also provided an automatic charging system of a robot cleaner including: a power supply unit having a charging unit fixedly installed to charge a battery and an infrared ray generator positioned at the charging unit and generating an infrared signal; and a power receiving unit having a battery installed at the robot cleaner and charged by the charging unit, a remaining battery capacity detecting unit for detecting a remaining battery capacity; a rotating plate mounted at a main body of the robot cleaner, an infrared ray receiving unit mounted at the rotating plate and rotating to receive the infrared signal if the detected remaining battery capacity is below a reference value, a microcomputer for moving the robot cleaner to the charging unit along the direction that the infrared signal is generated, and an ultrasonic generator for generating a stop signal when the robot cleaner nears to the charging unit.

The microcomputer stops movement of the robot cleaner on the basis of the stop signal and charges the battery.

To achieve the above objects, there is also provided an automatic charging method of a robot cleaner including: rotating an infrared ray receiving unit of a rotating plate mounted at a main body of a robot cleaner when the robot cleaner is in a charge mode; receiving an infrared signal generated from a power supply unit and detecting a direction of the power supply unit on the basis of the infrared signal received through an infrared ray receiving unit; moving the robot cleaner along the detected direction; generating a stop signal when the robot cleaner nears to the power supply unit; stopping movement of the robot cleaner on the basis of the stop signal; and docking a power terminal of the robot cleaner and a charge terminal of the power supply unit when the robot cleaner is stopped.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An automatic charging system and method of a robot cleaner of the present invention is featured in that a few infrared ray sensors are installed at a robot cleaner and rotated to accurately and quickly detect an infrared signal received from a fixedly installed charging unit, so that the robot cleaner can be accurately and quickly moved to the charging unit, a power terminal of the robot cleaner can be accurately and quickly connected to a charge terminal of the charging unit, and a cost for implementing the robot cleaner can be reduced.

The automatic charging system and method of a robot cleaner of the present invention may be installed at a toy or any device which is movable by using a battery.

FIG. 2is a schematic block diagram showing the construction of an automatic charging system of a robot cleaner in accordance with the present invention.

As shown inFIG. 2, the automatic charging system of a robot cleaner in accordance with the present invention includes: a power receiving unit300installed at a robot cleaner and a power supply unit400for inducing the robot cleaner and charging a battery mounted in the robot cleaner.

The power supply unit400includes a charging unit403for charging the battery301of the robot cleaner; and first and second infrared ray generators401and402positioned at left and right sides of a charge terminal of the charging unit403and outputting first and second infrared signals at a certain angle (e.g., 120°) to guide the robot cleaner (reference numeral500ofFIG. 3) to the charging unit403.

The power receiving unit300of the robot cleaner includes: a battery301; a remaining battery capacity detecting unit302for detecting a remaining capacity of the battery301installed at the robot cleaner; a rotating plate306mounted at a main body (308ofFIG. 3) of the robot cleaner; first and second infrared ray sensors304and305mounted at the rotating plate306and receiving the first and second infrared signals outputted from the first and second infrared ray sensors401and402; a microcomputer303for moving the robot cleaner along a direction that the first and second infrared signals are generated; and an ultrasonic generator308for generating a stop signal when the robot cleaner nears to the charging unit403.

The microcomputer303stops the robot cleaner on the basis of the stop signal, and the robot cleaner stopped in front of the charging unit403is connected to a charge terminal of the charging unit403and performs a battery charging operation according to a control signal of the microcomputer303.

FIG. 3is a detailed view showing infrared sensors of the automatic charging system of a robot cleaner of FIG.2.

As shown inFIG. 3, of the power supply unit400, the first infrared ray generator401is installed at the left side of the charge terminal (not shown) of the charging unit403, while the second infrared ray generator402is installed at the right side of the charge terminal of the charging unit403.

Of the power receiving unit300of the robot cleaner, the first infrared ray receiving unit304is installed at the rotating plate306mounted at the main body308of the robot cleaner while the second infrared ray receiving unit305is installed at the opposite direction of the first infrared ray receiving unit304. Reference numeral500denotes the robot cleaner, and308denotes a main body of the robot cleaner.

The operation of the automatic charging system of the robot cleaner in accordance with the present invention will now be described in detail with reference toFIGS. 2to4.

FIG. 4is a flow chart of an automatic charging method of a robot cleaner in accordance with the present invention.

As shown inFIG. 4, the automatic charging method of a robot cleaner in accordance with the present invention includes: performing a cleaning operation by the robot cleaner as selected by a user in a specific region while moving the robot cleaner (step S1) and detecting a remaining battery capacity of the robot cleaner (step S2); judging whether the robot cleaner is in a charge mode if the detected remaining battery capacity is below a reference value or if the cleaning operation is terminated by the user (step S3); rotating the first and second infrared ray receiving units304and305mounted at the rotating plate306of the robot cleaner and receiving first and second infrared signals generated at a predetermined angle from the first and second infrared ray generators401and402of the power supply unit400, if the cleaning operation is terminated or if the robot cleaner is in the charge mode for charging the battery301(step S4); detecting a direction of the charging unit403on the basis of the received first and second infrared signals (step S5); stopping movement of the robot cleaner if a stop signal is inputted from the ultrasonic generator308(step S7) while the robot cleaner is being moved to the charging unit503on the basis of the detected direction (step S6); and switching the mode of the robot cleaner to a docking mode (step S8) when the robot cleaner is stopped, and docking the power terminal of the robot cleaner to the charge terminal of the charging unit403to charge the battery101(step S9).

First, the robot cleaner500performs a cleaning operation according to a user's command in a specific region (step S1). The cleaning operation is based on a general technique, descriptions of which are thus omitted.

The remaining battery capacity detecting unit302of the robot cleaner checks a remaining capacity of the battery301installed in the robot cleaner, and outputs a value corresponding to the checked remaining battery capacity to the microcomputer303(step S2).

If the checked remaining battery capacity is below a reference value, the microcomputer303switches the mode of the robot cleaner to a charge mode in order to charge the battery301. The charge mode in this connection is a mode in which the robot cleaner returns to the charging unit403to charge the battery301if the checked remaining battery capacity is below the reference value.

When the cleaning operation is terminated according to a user's command, the microcomputer303switches the mode of the robot cleaner to the charge mode (step S3).

When the robot cleaner is in the charge mode, the microcomputer303of the power receiving unit300generates a drive signal and outputs it to the driving unit307. Then, the driving unit307rotates the rotating plate306on the basis of the drive signal. As the rotating plate306is rotated, the first and second infrared ray receiving units304and305mounted at the rotating plate306are rotated accordingly.

While being rotated by the rotating plate306, the first and second infrared ray receiving units304and305of the robot cleaner receive first and second infrared signals respectively outputted from the first and second infrared ray generators401and402.

At this time, if one infrared ray receiving unit (infrared ray sensor) of the power receiving unit300of the robot cleaner is mounted at the rotating plate306, the infrared ray sensor receives the first and second infrared signals outputted from the first and second infrared ray generators401and402while being rotated by 360°.

If two infrared ray sensors are installed at the rotating plate306, they receive first and second infrared signals outputted from the first and second infrared ray generators401and402while being rotated by 180°, respectively.

If three infrared ray sensors are mounted at the rotating plate306, they receive the first and second infrared signals outputted from the first and second infrared ray generators401and402while being rotated by 120°, respectively.

If four infrared ray sensors are mounted at the rotating plate306, they receive the first and second infrared signals outputted from the first and second infrared ray generators401and402while being rotated by 90°, respectively.

Thereafter, the microcomputer303of the robot cleaner detects a direction of the charging unit403on the basis of the first and second infrared signals received from the first and second infrared ray generators401and402, and moves the robot cleaner in the detected direction. That is, the robot cleaner is moved in the direction that the first and second infrared ray signals are generated.

In detail, the first infrared ray receiving unit304of the power receiving unit300detects the first infrared ray signal while being rotated, and the second infrared ray receiving unit305of the power receiving unit300detects the second infrared ray signal while being rotated.

At this time, the microcomputer303moves the robot cleaner500along the center between the detected direction in which the first infrared signal is generated and the detected direction in which the second infrared signal is generated.

As the robot cleaner500keeps moving to the direction that the first and second infrared signals are generated, it eventually reaches the charging unit403. Then, the power receiving unit300of the robot cleaner500and the charging unit403face each other, and at this time, the robot cleaner500is close to the charging unit403.

As the robot cleaner approaches the charging unit403, the ultrasonic generator308generates a stop signal and outputs it to the microcomputer303. The ultrasonic generator308usually measures a distance, so that when the robot cleaner comes close to the charging unit403, it outputs the stop signal to the microcomputer303.

While the microcomputer303moves the robot cleaner to the charging unit403along the received direction of the infrared signal, when it receives the stop signal from the ultrasonic generator308, the microcomputer303stops movement of the robot cleaner.

In addition, when the robot cleaner is stopped, the microcomputer303switches the mode of the robot cleaner to a docking mode. The docking mode in this connection is a mode for connecting the power terminal of the robot cleaner and the charge terminal of the charging unit402in order to charge the battery301of the robot cleaner.

In the docking mode, the robot cleaner cokes the power terminal of the robot cleaner to the charge terminal of the charging unit403. That is, moved at the charging unit403, the robot cleaner is connected to the charge terminal of the charging unit403and performs a battery charging operation according to a control signal from the microcomputer303.

When power is supplied from the charging unit403to the battery301as the power terminal of the robot cleaner and the charge terminal of the charging unit403are connected to each other, the remaining battery capacity detecting unit302outputs a docking complete signal to the microcomputer303.

If, however, the power terminal of the robot cleaner and the charge terminal of the charging unit403are not connected to each other and thus no power is supplied from the charging unit403to the battery301, the remaining battery capacity detector302outputs a docking error signal to the microcomputer303.

Then, the microcomputer303controls the robot cleaner so that the power terminal of the robot cleaner can be docked again to the charge terminal of the charging unit403on the basis of the docking error signal.

In the meantime, the robot cleaner can be also moved to the charging unit403by installing one infrared ray generator at the charging unit403and one infrared ray receiving unit at the rotating plate306.

In this case, for example, one infrared ray receiving unit installed at the rotating plate306receives an infrared signal generated from one infrared ray generator installed at the charging unit403while being rotated, and outputs the received infrared signal to the microcomputer303. then, the microcomputer303moves the robot cleaner500along the direction in which the infrared signal si generated.

Accordingly, in the present invention, by mounting one or more infrared receiving units at the rotating plate306mounted at the main body of the robot cleaner and rotated, the infrared signal generated from one or more infrared ray generators positioned at a certain angle at the charging unit403can be accurately and quickly received.

In addition, in the present invention, by accurately and quickly detecting the direction of the charging unit403, the power terminal of the robot cleaner can be accurately and quickly connected (docked) to the charge terminal of the charging unit403.

As so far described, the automatic charging system and method of a robot cleaner of the present invention have many advantages.

That is, for example, because a few infrared ray receiving units (infrared ray sensor) are installed at the robot cleaner and rotated to quickly and accurately receive the infrared signal generated from the power supply unit, so that the robot cleaner can be accurately and quickly moved to the charging unit.

For example, in the present invention, the infrared ray sensor for generating an infrared signal is installed at the charge terminal of the charging unit, the rotating plate is installed at the main body of the robot cleaner, and the infrared ray sensor is installed at the rotating plate and rotated to quickly and accurately detect infrared signals generated from the infrared sensors of the power supply unit, so that the robot cleaner can be accurately and quickly moved to the charging unit.

Second, a few infrared ray receiving units are installed at the robot cleaner and then the infrared ray receiving unit is rotated to quickly and accurately receive the infrared signal generated from the power supply unit, so that the robot cleaner can be accurately and quickly connected to the charge terminal.

Third, by installing a few infrared ray receiving units at the robot cleaner, a cost for implementing the robot cleaner can be reduced. For example, the charging system of a robot cleaner of the present invention uses one or two or more infrared ray sensors, rather than using a plurality of infrared ray sensors. Accordingly, a cost for implementing the robot cleaner can be reduced.