Patent Abstract:
The present invention is a mobile robot with an attached cleaning element and capable of autonomously seeking areas with low overhead clearance. In the preferred embodiment is a mobile robot using an array of upward facing distance sensors in communication with a controller to detect the presence of obstructions or surfaces above the apparatus. The controller directs the movements of the mobile robot through the use of a drive system, using pattern recognition to avoid becoming stuck and using random movements to increase floor coverage.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 62/110,482, filed Jan. 31, 2015, which is hereby incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to cleaning devices, and more particularly to robotic cleaning devices. 
       BACKGROUND OF THE INVENTION 
       [0003]    Over the years, various robotic devices have been devised to clean or vacuum floors and other surfaces. The use of a mobile robot with a cleaning head is known in the art as a solution to the need for autonomous and automatic floor cleaning devices. The robotic cleaners in the prior art can use a vacuum cleaner head or a sweeping attachment to clean floors as they move. 
         [0004]    While robotic cleaners have gotten smaller over time, even the current robotic cleaners are too large to fit under low horizontal obstructions, such as the area under an entertainment console or sideboard. Open areas in a room can be cleaned using conventional techniques or a robotic cleaner, but neither is capable of easily cleaning under low furniture. Because these areas with low overhead clearance can only be cleaned by moving the obstructing furniture, they often go without cleaning for prolonged periods of time. Therefore, there is a need for a device that is able to automatically identify areas in a room with low overhead clearance and that has the capability to clean those areas. 
         [0005]    While the robotic cleaners in the prior art are capable of vacuuming or sweeping a room with stationary objects, they are unable to adjust to changes in the environment (e.g. a chair moving). Existing robotic cleaners often use an array of sensors coupled with a preset expanding pattern or a creeping line pattern to cover an entire room. These navigation systems are only effective in simple and static environments and are prone to problems in dynamic environments where a previously identified object moves. Other robotic cleaners in the prior art use a random pattern consisting of operating in a straight line until an obstruction is detected. This programming can cause the robot to be stuck in a corner or within a small area with multiple obstructions, such as under a table and chairs. Therefore, there is a need for a robotic cleaner with a navigation system capable of adapting to a dynamic environment. 
         [0006]    The robotic cleaners in the prior art are also prone to getting stuck in corners or falling off raised areas, such as off a stair. A solution in the prior art includes the use of complex electronic boundaries set into the navigation programming, but this only provides parameters for operation without providing an algorithm for determining when the robot is in danger of becoming stuck. Other solutions in the prior art use reactive systems to detect when the robot is stuck to merely turn the device off. The cleaning robots in the prior art are unable to determine when they are in danger of becoming stuck and initiating an action to avoid the situation. When stuck, the cleaning robots in the prior art are also inefficient at freeing themselves due to their large size and weight. Therefore, there is a need for a robotic cleaner that is capable of detecting when it is at risk of becoming stuck so that it can initiate a movement to avoid the condition. There is also a need for a robotic cleaner capable of efficiently freeing itself in the event it does become stuck on an obstruction. 
         [0007]    Existing robotic floor sweepers use a rectangular cleaning pad located in front of the robot. The rectangular pusher pads are unable to clean in corners or small gaps and tend to push dirt into the corners of a room rather than collecting it. The pusher style of cleaning pad is prone to becoming stuck on small irregularities in the floor surface and requires a relatively heavy robot to provide adequate traction to push the cleaning pad. Therefore, there is a need for a robotic cleaner with a cleaning pad that is capable of cleaning corners and capable of moving over small irregularities on the surface of a floor. 
         [0008]    Accordingly, it is an object of the present invention to provide a robotic cleaner capable of fitting under areas with low overhead clearance and targeting those areas for cleaning. It is also an object of the present invention to provide a robotic cleaner that is capable of adapting to a dynamic environment and detecting when it is in danger of becoming stuck to avoid the condition. It is also an object of the present invention to provide a lightweight mobile robot and cleaning pad attachment capable of cleaning in corners and under low furniture. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    The present invention is a robotic floor cleaning apparatus comprising a mobile robot with a detachable cleaning element extending from the bottom of the mobile robot. The mobile robot comprises a case containing a micro-controller, a power supply, two or more wheels and associated drive motors, upward facing ultrasonic sensors, collision detection sensors and downward facing infrared transmitters and receivers. The present invention can use multiple types of detachable cleaning elements, including disposable and reusable versions. 
         [0010]    The present invention uses a navigation system that in one mode, uses the data collected from the upward facing ultrasonic sensors to target areas in a room with a low overhead clearance for cleaning. The navigation system is also capable of detecting patterns in the mobile robot&#39;s movements that are precursors or indicative of the mobile robot being stuck and uses a variety of preprogrammed motions to avoid the situation. The navigation system specifically uses an algorithm that randomizes the movements of the apparatus and reacts to the environment to provide more thorough floor coverage than possible using the navigation systems in the prior art. 
         [0011]    While the invention described has been described as being particularly applicable to robotic cleaners, it is appreciated that the present invention could be used in other applications within the scope of the inventive concept. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0012]      FIG. 1  is a perspective view of the robotic floor cleaning apparatus with a first embodiment of a disposable cleaning element attached. 
           [0013]      FIG. 2  is a perspective view of the robotic floor cleaning apparatus with the top cover removed and with a first embodiment of a disposable cleaning element attached. 
           [0014]      FIG. 3  is a top view of the robotic floor cleaning apparatus with the top cover removed and with a first embodiment of a disposable cleaning element attached. 
           [0015]      FIG. 4  is a bottom view of the robotic floor cleaning apparatus with the bottom cover removed. 
           [0016]      FIG. 5  is a front view of the robotic floor cleaning apparatus with a first embodiment of a disposable cleaning element attached. 
           [0017]      FIG. 6  is a side view of the robotic floor cleaning apparatus with the top cover removed and with a first embodiment of a disposable cleaning element attached. 
           [0018]      FIG. 7  is a bottom view of the robotic floor cleaning apparatus without a cleaning element attached. 
           [0019]      FIG. 8  is a bottom view of the robotic floor cleaning apparatus with a first embodiment of a disposable cleaning element attached. 
           [0020]      FIG. 9  is a perspective view of a first embodiment of a disposable cleaning element. 
           [0021]      FIG. 10  is a perspective view of a first embodiment of a reusable cleaning element. 
           [0022]      FIG. 11  is a perspective view of a second embodiment of a disposable cleaning element. 
           [0023]      FIG. 12  is a perspective view of a second embodiment of a reusable cleaning element. 
           [0024]      FIG. 13  is a block diagram of the apparatus. 
           [0025]      FIG. 14  is a flow chart showing the operations carried out by the apparatus. 
           [0026]      FIG. 15  is a flow chart showing the operations carried out by the apparatus when in the clean step. 
           [0027]      FIG. 16  is a flow chart showing the operations carried out by the apparatus when in the backup and spin step. 
           [0028]      FIG. 17  is a flow chart showing the operations carried out by the apparatus when in the move forward step. 
           [0029]      FIG. 18  is a flow chart showing the operations carried out by the apparatus when in the forward under step. 
           [0030]      FIG. 19  is a flow chart showing the operations carried out by the apparatus when in the spiral outward step. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]      FIG. 1  shows the apparatus of the present invention  10  in an exemplary configuration as a robotic floor sweeper. The apparatus  10  comprises a mobile robot  11  with a first embodiment of a detachable disposable cleaning element  12  attached to the underside of the mobile robot and in contact with the surface to be cleaned. The mobile robot  11  includes an upper case  13  and a lower case  14  that provide the main body of the mobile robot and support for the internal components. Providing propulsion are a left wheel  15  and a right wheel  16  driven by electric motors not seen in this view. 
         [0032]    The mobile robot  11  includes a variety of sensors connected to an internally mounted micro-controller  33  (visible in  FIG. 2 ). Visible through openings  20  and  21  in the upper case  13  are upward facing ultrasonic sensors  22 . The ultrasonic sensors  22  are used to detect the height of surfaces above the mobile robot  11 . At the front of the mobile robot  11  is a bumper  24  capable of displacing switches on internally mounted collision sensors (not shown in this view). 
         [0033]    Also visible through openings in the upper case  13  are a power switch  23 , a trouble light  26  and a status light  27 . The trouble light  26  illuminates when certain problems are detected by the mobile robot  11 . The status light  27  is green in normal operation and changes in its lighting configuration can be used to indicate different modes of the apparatus  10 . In the preferred embodiment, the trouble light  26  and status light  27  are LED lights, but it is appreciated that multiple types of lights are available in the art and capable of being used in this application. 
         [0034]      FIG. 2  contains a perspective view of the apparatus  10  with a first embodiment of a disposable cleaning element  12  attached and the top cover  13  removed (not shown in this view). The top cover  13  and the bottom cover  14  contain multiple internally molded partitions and extrusions to sandwich and securely hold the internal components when the top cover  13  and bottom cover  14  are fastened together. The top cover  13  and bottom cover  14  can be fastened using mechanical fasteners or an adhesive. In  FIG. 2 , the top cover  13  has been removed, leaving the internal components sitting on the bottom cover  14 . 
         [0035]    The power supply  30  comprises a battery or other electrical storage device. The preferred embodiment uses a NiMH (Nickel metal hydride) battery, but it is appreciated that multiple types of electrical storage devices would be appropriate for this application. Electrically connected to the battery  30  is a connector  31 , also connected to the power printed circuit board (“PCB”)  32 . 
         [0036]    The power PCB  32  contains a micro-controller  33 , a power board  34 , a motor driver  35  and a charging port  36 . The power button  23 , trouble light  26  and status light  27  are also mounted to the power PCB  32 . The specific functions and the interrelationship of these components is discussed in further detail in the block diagram of  FIG. 13  and its associated description in the specification. 
         [0037]    Mounted towards the front of the apparatus  10  are the ultrasonic sensors  22  and collision sensors  38 . The ultrasonic sensors  22  are electrically connected to and mounted above a sensor PCB  37  which is not visible in this view (the sensor PCB  37  is visible in  FIG. 3 ). The collision sensors  38  are fixed to the sensor PCB  37  and detect when the bumper  24  is displaced towards the collision sensors  38 . 
         [0038]    The left electric drive motor  40  and right electric drive motor  41  are mounted on movable arms  42  and coupled to their respective drive wheels  15  and  16  through a reduction gear assembly. The movable arms  42  are mounted to suspension cage  43  at pivots  44 , allowing the movable arms to rotate in a limited range about an axis substantially parallel to the longitudinal axis of the mobile robot  11 . Between the movable arms  42  and the suspension cage  43  are springs  45  which push the movable arms  42  downward. When at rest, the movable arms  42  are at their lower rotational limit and deflect upwards when in motion, in reaction to surface irregularities. 
         [0039]      FIG. 3  contains a top view of the apparatus  10  with a first embodiment of a disposable cleaning element  12  attached and the top cover  13  removed (not shown in this view). Similar to  FIG. 2 , the internal components are resting on the bottom cover  14  in this view. Visible in this view is the selector switch  50  mounted to the underside of the power PCB  32 . The selector switch extends through opening  51  between the upper case  13  (not shown in this view) and lower case  14 . In the preferred embodiment, the selector switch  50  is used to cycle the apparatus  10  between various cleaning modes. 
         [0040]    Also visible in  FIG. 3  is the sensor PCB  37 , which is electrically connected to the power PCB  32 . In the preferred embodiment, the sensor PCB  37  is connected to the power PCB  32  using a six cable connector. Below the sensor PCB  37  are the infrared transmitters  52 , used as fall detectors. The infrared transmitters  52  are downward facing and detect the presence of the ground beneath the apparatus  10 . When the infrared transmitters stop detecting the ground under the apparatus  10 , the micro-controller interprets this change as a fall or impending fall depending on the duration of the signal. The infrared transmitters  52  are mounted to the bottom case  14  using brackets  55 . 
         [0041]      FIG. 4  contains a bottom view of the apparatus  10  with the bottom cover  14  removed (not shown in this view). In this view the internal components are resting on the top cover  13  as they would be if the apparatus  10  was inverted. In this bottom view, the underside of the power PCB  32  and the sensor PCB  37  are visible. On the underside of the power PCB  32  is selector switch  50 . On the underside of the sensor PCB  37  is a path illuminating light  56 . The path illuminating light  56  is used to illuminate the front of the apparatus  10  and make it more visible to people in the area. There is an opening between the upper case  13  and lower case  14  containing a clear plastic lens  57  to allow the light from the path illuminating light  56  to travel through the case. 
         [0042]    Also visible in  FIG. 4  are the infrared transmitters  52  and their associated brackets  55 . The brackets  55  are normally fixed to the bottom case  14 , however, as this is a bottom view, the infrared transmitters  52  and brackets  55  are merely placed in the upper case  13  to show their arrangement. Also in this view are the clear lenses  53  mounted to the bottom case  14  using a skirt  54  that snaps into an opening on the bottom case  14  to hold the assembly. 
         [0043]    In  FIGS. 5 and 6  are views of the apparatus  10  with a first embodiment of a detachable disposable cleaning element  12  attached to the underside of the mobile robot  11 . In  FIG. 5  is a front view of the apparatus  10  and in  FIG. 6  is a side view of the apparatus  10  with the top cover  13  (not shown in this view) removed. The bumper  24  contains a logo  25  cut through the bumper material to allow the light from the path illuminating light  56  to travel through the bumper. In the preferred embodiment, the bumper  24  comprises a rigid plastic base with a rubber or rubberized coating to reduce the amount of sound created when the bumper impacts an obstruction during use. The bumper  24  can alternatively be made entirely of a semi-rigid material to reduce noise or a transparent or semi-transparent material to allow light to pass through without the use of a logo  25  cut through the bumper. 
         [0044]    In  FIG. 7  is a bottom view of the apparatus  10  without a cleaning pad installed. On the underside of the mobile robot  11  are openings  25  that allow the internally mounted infrared sensors to view the ground ahead of the wheels  15  and  16 . Visible in this view are the four screws  71  that secure the lower case  14  to the upper case  13  (not shown in this view). While the preferred embodiment uses screws, other types of mechanical fasteners or an adhesive could be substituted. On the surface of lower case  14  are three recesses  72 , each containing a hook and loop fastener  73 . The recesses  72  are recessed into the surface of lower case  14  to the depth necessary to make the surface of hook and loop fasteners  73  flush with the surface of the lower case  14 . The hook and loop fasteners  73  can be either of the hook or loop variety as long as the type used on a corresponding attachment is of the opposite type. The hook and loop fasteners  73  are secured to the lower case  14  with an adhesive in the preferred embodiment, but it is appreciated that there are other methods in the art to achieve this end. 
         [0045]      FIG. 8  is a bottom view of the apparatus  10  with a first embodiment of a disposable cleaning element  12  attached to the underside of the mobile robot  11 . In the preferred embodiment, the disposable cleaning element  12  is made largely of an electrostatic cleaning cloth  64 , however it is appreciated that there are other materials known in the art that can be used as a substitute. The disposable cleaning element  12  has a solid area of electrostatic cleaning cloth  64  in the areas located directly under the bottom case  14 . The disposable cleaning element  12  follows the contours of the bottom case  14  and avoids fouling the wheels  15  and  16  or covering the clear lenses  53 . On the part of the disposable cleaning element  12  that extends away from the bottom case  14 , there are a multitude of slits  60  in the electrostatic cleaning cloth  64  to allow the cleaning element to remain flexible as the mobile robot moves. The shape of the disposable cleaning element  12  and the slits  60  are designed to minimize the possibility of the cleaning element from becoming caught in the wheels  15  and  16 . Even when sections of the cleaning element  12  are folded towards the wheels, they are unable to reach the wheels. 
         [0046]    The circular shape of the cleaning element  12  combined with the slits  60  complement the navigation programming used in the apparatus  10  and maximize the ability of the apparatus  10  to clean in small corners. When the apparatus turns in corners, the slits  60  allow the material to brush into the corner where a solid cleaning element would bunch up or lift from the surface. The circular shape is also important to the function of the cleaning element  12  and provides a more consistent brushing effect on corners than a rectangular or triangular cleaning element. When the apparatus  10  rotates the circular portion of the cleaning element  12  near a corner, the corner is brushed by each finger of the cleaning material (defined by the slits  60 ) with an approximately equal amount of force. When a cleaning element with a triangular or rectangular shape extending from the bottom case  14  was tested, the rotation of the apparatus  10  caused the material to bunch up and the cleaning effect of each finger was different, creating an inconsistent cleaning action. 
         [0047]    In  FIG. 9  is a perspective view of the upper side of a first embodiment of a disposable cleaning element  12 . The area of the cleaning element  12  that presses against the bottom case  14  contains a thin layer of plastic  61  for additional support. The plastic  61  prevents the cleaning element  12  from folding away from the bottom case  14  when in motion. In the preferred embodiment, the plastic  61  is an approximately three mil flexible film and the weight of the mobile robot  11  provides the additional force needed to hold the cleaning element  12  in place. To keep the cleaning element  12  from sliding away from the mobile robot  11 , there is an adhesive strip  62  attached to the top of the cleaning element  12 . In the preferred embodiment, the adhesive strip  62  is double-sided tape, but it is appreciated that multiple types of removable fasteners or adhesives could be used with similar results. 
         [0048]    In  FIG. 10  is a perspective view of a first embodiment of a reusable cleaning element  112 , which can be used as a substitute for cleaning element  12 . In this embodiment, the reusable cleaning element  112  is made largely of microfiber cloth  164 , however it is appreciated that there are other materials known in the art that can be used as a substitute. The microfiber cloth  164  covers the entire bottom surface of the reusable cleaning element  112 . The reusable cleaning element  112  has a similar overall shape as the disposable cleaning element  12 , but with detailed differences to optimize its performance. The material used for the reusable cleaning element  112  in this embodiment is softer and more flexible than the material used for the disposable cleaning element  12 . Because the reusable cleaning element  112  uses a softer and more flexible material, it is able to remain on the surface as the mobile robot  11  rotates without as many slits  160 . 
         [0049]    In this alternative embodiment, the reusable cleaning element  112  uses three slits  160  extending away from the bottom case  14 . One slit  160  follows the centerline of the apparatus  10 , extending rearward. The other two slits  160  extend from the rear corners of the bottom case  14  and extend rearward and to the side. These two slits  160  terminate at a point on the cleaning element  112  that is directly behind the cutouts  163  for the drive wheels. This arrangement allows the cleaning element  112  to slide against a wall easily, while still allowing the mobile robot  11  to rotate and use the rotating motion to move the cleaning element  112  through a corner. 
         [0050]    Similar to the disposable cleaning element  12 , the reusable cleaning element  112  uses a thin layer of support material  161  to increase the rigidity of the area which it is applied. The support material  161  can be a fabric or other washable material, including some plastics that are durable enough to be washed. To keep the cleaning element  112  centered on the mobile robot  11 , multiple hook and loop fasteners  162  are used that correspond to the hook and loop fasteners  73  (visible in  FIG. 7 ) fixed to the bottom cover  14 . 
         [0051]    In  FIG. 11  is a perspective view of a second embodiment of a disposable cleaning element  412 , which can be used as a substitute for cleaning elements  12  and  112 . In this embodiment, the disposable cleaning element  412  is made largely of electrostatic cleaning cloth  464 , however it is appreciated that there are other materials known in the art that can be used as a substitute. The electrostatic cleaning cloth  464  covers the entire bottom surface of the disposable cleaning element  412 . 
         [0052]    In this alternative embodiment, the disposable cleaning element  412  uses five slits  460  extending away from the bottom case  14 . One slit  460  follows the centerline of the apparatus  10 , extending rearward. Two slits  460  extend from the rear corners of the bottom case  14  and extend rearward and to the side. These two slits  460  terminate at a point on the cleaning element  412  that is behind the cutouts  463  for the drive wheels. Two slits  460  extend from the sides of the bottom case  14  and extend rearward and to the side. The disposable cleaning element  412  uses a thin layer of plastic  461  that covers the entire upper surface of the disposable cleaning element  412  to provide additional support. To keep the cleaning element  412  centered on the mobile robot  11 , an adhesive strip  462  is attached to the top of the cleaning element  412 . In the preferred embodiment, the adhesive strip  462  is double-sided tape, but it is appreciated that multiple types of removable fasteners or adhesives could be used with similar results. 
         [0053]    In  FIG. 12  is a perspective view of a second embodiment of a reusable cleaning element  512 , which can be used as a substitute for cleaning elements  12 ,  112  and  412 . In this embodiment, the reusable cleaning element  512  is made largely of microfiber cloth  564 , however it is appreciated that there are other materials known in the art that can be used as a substitute. The microfiber cloth  564  covers the entire bottom surface of the reusable cleaning element  512 . 
         [0054]    In this alternative embodiment, the reusable cleaning element  512  uses five slits  560  extending away from the bottom case  14 . One slit  560  follows the centerline of the apparatus  10 , extending rearward. Two slits  560  extend from the rear corners of the bottom case  14  and extend rearward and to the side. These two slits  560  terminate at a point on the cleaning element  512  that is behind the cutouts  563  for the drive wheels. Two slits  560  extend from the sides of the bottom case  14  and extend rearward and to the side. The reusable cleaning element  512  uses a thin layer of support material  561  that covers the entire upper surface of the reusable cleaning element  512  to provide additional rigidity to the cleaning element. The support material  561  can be a fabric or other washable material, including some plastics that are durable enough to be washed. To keep the cleaning element  512  centered on the mobile robot  11 , multiple hook and loop fasteners  562  are used that correspond to the hook and loop fasteners  73  (visible in  FIG. 7 ) fixed to the bottom cover  14 . 
         [0055]    The second embodiment of a disposable cleaning element  412  and the second embodiment of a reusable cleaning element  512  share multiple advantages over the first embodiment of a disposable cleaning element  12  and the first embodiment of a reusable cleaning element  112 . Cleaning elements  412  and  512  use a support layer  461  and  561 , respectively, that covers the entire top surface of the cleaning element. Cleaning elements  12  and  112  use a support layer  61  and  161 , respectively, that covers only the top surface of the cleaning element that is directly below the mobile robot  11 . Extending the support layer in cleaning elements  412  and  512  to the entire top surface improves contact with the floor when cleaning and reduces production costs because a single cutting die can be used for the cleaning material  464  and  564  and the support layer  461  and  561 . The number of cuts necessary to produce each cleaning element  412  and  512  can be reduced to a single cut by attaching the support layer  461  and  561  to the cleaning material  464  and  564 , respectively, prior to being cut with a cutting die. 
         [0056]    The extension of the support layer  461  and  561  also blocks dirt from collecting on the upper surface of the cleaning elements  412  and  512 , improving their appearance when used for a period of time. In comparison, cleaning elements  12  and  112  tend to collect some dirt on their visible upper surfaces when used. 
         [0057]    Cleaning elements  412  and  512  use the same number and placement of slits  460  and  560 , respectively. Using the same number and placement of slits allows cleaning elements  412  and  512  to be manufactured using a common, or substantially common, cutting die, reducing manufacturing costs. The common pattern also allows both types of cleaning elements to be dispensed from the same dispenser and fit into a substantially similar package. 
         [0058]    In  FIG. 13  is a functional block diagram of the major components contained within the apparatus  10 . The block diagram is separated by location, with the components mounted on the power PCB  32 , the components included in the engine compartment  46 , the components mounted on the sensor PCB  37  and the components included in the battery compartment  59  shown in separate groups. The power PCB  32  includes a micro-controller  33  that directs the operations of the cleaning robot. The micro-controller  33  is directly connected to the power board  34 , motor driver  35 , cleaning mode switch  50 , piezo speaker  58 , status light  27  and trouble light  26 . The motor driver  35  is also connected to the left drive motor  40  and the right drive motor  41 . The motor driver  35  can control the speed of the left drive motor  40  and right drive motor  41  independently in forward and reverse. The power board  34  provides power to the components contained in the apparatus from the rechargeable battery  30 . The charging jack  36  completes the circuit between the rechargeable battery  30  and power board  34  when a charging cord is not plugged into the charging jack. When a power cord is plugged into the charging jack  36  to recharge the rechargeable battery  30 , the charging jack breaks the electrical connection with the power board  34  and directs the power to the rechargeable battery. The power switch  23  is connected to the power board  34  and provides a means for a user to turn the apparatus  10  on or off when a power cord is not plugged into the charging jack  36 . In the preferred embodiment, when a power cord is plugged into the charging jack  36 , the power board does not receive power from either the charging jack  36  or the rechargeable battery  30 . 
         [0059]    The components on the sensor PCB  37  are connected directly to and controlled by the micro-controller  33  with the exception of the running lamp  56 . The running lamp  56  is energized when the power board is providing power to the micro-controller  33  from the rechargeable battery  30 . While the components on the sensor PCB  37  are controlled by the micro-controller  33 , they receive power from the power board  34  through an electrical connection not shown in  FIG. 13 . Incorporated as part of the sensor PCB  37  are the upward facing object sensors  22 , the collision detectors  38  and the fall detectors  52 . The upward facing ultrasonic sensors  22  are mounted to a controller that is electrically connected to the sensor PCB  37 . In the preferred embodiment, the upward facing sensors  22  are capable of sensing objects up to 20 feet above the sensors, however, in this application, the range of the sensors is limited through the software to approximately two feet. The apparatus  10  targets areas in a room with less than 10-12 inches of overhead clearance for cleaning, making it unnecessary to use the full range of the ultrasonic sensors  22  in this embodiment. While the range of the ultrasonic sensors  22  are being limited by the software in this embodiment, it is appreciated that there may be other applications where it would be preferable to use up to the full range of the ultrasonic sensors  22 . A larger range from the ultrasonic sensors would be necessary if the apparatus  10  was programmed to target areas with between a 10-12 inch and 20 foot overhead clearance or for the apparatus  10  to detect features above, such as a door frame. 
         [0060]    The collision detectors  38  are micro-switches with spring loaded levers. The spring loaded levers push the bumper forward to its resting position and are compressed when the bumper comes in contact with an obstruction. The fall detectors  52  are infrared transmitters and receivers mounted to the bottom of the apparatus  10 . The fall detectors  52  send out a signal and time the response back to determine if the ground is directly under the front of the apparatus  10 . While infrared transmitters and receivers are used in the preferred embodiment, it is appreciated that there are other types of sensors that would be adequate for this function, including ultrasonic sensors. 
         [0061]    The use of infrared sensors as the fall detectors  52  reduces the overall size of and the cost to manufacture the apparatus  10 . A challenge with infrared sensors is that they are sensitive to the color and sheen of the floor surface as well as the amount of ambient light. Certain types of floors with large variations in color, such as a black and white tile floor, generate a large number of false positives on cleaning robots in the prior art. Instead of automatically changing the sensitivity of the infrared sensors, the cleaning robots in the prior art require the user to manually reduce the overall sensitivity of the fall sensors to allow the cleaning robot to travel over surfaces that would otherwise trigger false positives of falling, effectively disabling the fall detection system. To reduce the occurrence of false positives while maintaining the functionality of the fall detectors in all conditions, the preferred embodiment uses the first three seconds of operation to calibrate the infrared sensors. During the first three seconds of the cleaning cycle, the micro-controller  33  records the high values taken from the fall detectors  52  to obtain a range of normal values for the floor type and current lighting conditions. By using the range of values obtained by the infrared sensors in the current cleaning cycle, the apparatus  10  is able to adapt to the current conditions and reduce the chance of false positives that it is falling. 
         [0062]    In  FIGS. 14-19  are flow charts showing the operations carried out by the apparatus  10  in the preferred embodiment. Steps in each flow chart that are defined further in a separate figure are denoted by a bold box. The flow charts shown are exemplary in nature and are capable of being changed or modified within the scope of the invention. 
         [0063]    In  FIG. 14  is a flow chart showing the functions carried out by the micro-controller  33  during a full cleaning cycle. After the start  200  of the flow chart and before any functions are carried out by the micro-controller  33 , the apparatus goes through a hardware based sequence  201 . The hardware based sequence can occur at any point during the cleaning cycle and does not require explicit checking by the micro-controller  33  to sense a change in the hardware based settings. The first step in the hardware based sequence  201  is to determine whether a charger is connected  202 , specifically, whether a charging cord is plugged into the charging port. When a power cord is plugged in, the apparatus powers down and charges the battery  203 . When a power cord is not plugged in, the apparatus then checks whether the power switch has been pressed  204 . If the power switch has been pressed, the flow chart exits the hardware based sequence  201  and continues to the software based sequence that makes up the majority of a full cleaning cycle. 
         [0064]    With power flowing to the micro-controller, the first software step in the sequence is to play a startup melody, initialize the CPU and sensors and start the loop timer  205 . The micro-controller then detects whether the under cleaning mode has been selected by the user  206 . The under cleaning mode (also referred to as the “clean under” mode herein) directs the apparatus to clean areas of a room under objects. As stated earlier, the preferred embodiment considers an overhead obstruction height of less than approximately 10-12 inches over the top of the apparatus as being located under an object. The under cleaning mode is selected by the user through the selector switch  50  (visible in  FIGS. 3 &amp; 4 ). If the user has selected the under cleaning mode, the micro-controller sets the seeking job flag to true  207 . If the under cleaning mode has not been selected, the micro-controller sets the seeking job flag to false  208 . The seeking job flag status is used at various points in the clean step  213  to optimize the path of the apparatus according to the user&#39;s cleaning preference. The micro-controller then checks whether the user has changed the duration of the cleaning cycle  209 . In the preferred embodiment, the user is able to change the length of the cleaning cycle during the first ten seconds after the power switch has been pressed by triggering the collision sensors (by pressing the bumper). When the user has changed the duration by pressing the bumper, the duration of the cleaning cycle is adjusted as the loop timer that initially started in step  205  is restarted  210 . When more than ten seconds have elapsed on the loop timer  211 , the apparatus sounds a tone to announce the duration of the cleaning cycle  212  and then begins to clean  213 . 
         [0065]    The clean step  213  is further defined in  FIG. 15  to detail the specific steps that are included in the sequence. When the clean step  213  is complete, the apparatus stops the motors and restarts the loop timer  214 . The apparatus then plays a finished melody and then flashes the status light for 10 seconds  215  to alert the user that the cleaning cycle is complete and continues to do so until more than 15 minutes have elapsed on the loop timer  216 . During the 15 minute delay, the user can either shut the apparatus off using the hardware based sequence  201  by pressing the power switch or by letting the loop timer pass 15 minutes  216 . When the loop timer passes 15 minutes  216 , the apparatus shuts off the lights and powers down  217 , ending the full cleaning cycle  220 . 
         [0066]    In  FIG. 15  is a flow chart detailing the sequence used by the apparatus under the clean step  213  in  FIG. 14 . After the clean step starts  221 , the micro-controller starts the duration timer  222 . The micro-controller then initiates the move forward step  223 . The move forward step is further defined in  FIG. 17  to detail the specific steps that are included in the sequence. When the move forward step  223  is complete, the apparatus checks whether there is a pending fall  224  indicated by the fall sensors or if there has been a bump detected by the collision sensors  227 . If either of these conditions exist, the micro-controller turns on the trouble light  225  and initiates the backup and spin sequence  226 . 
         [0067]    When the move forward step  223  is complete and a fall is not pending  224  and a bump has not been detected  227 , the apparatus checks whether the clean under mode has been selected by the user  228 . When the clean under mode has been selected, the apparatus checks whether the seeking job flag is set to true  229 . If the seeking job flag is set to true, it then uses the upward facing ultrasonic sensors  22  (visible in  FIGS. 1 &amp; 2 ) to determine if the apparatus is located under an object  230 . If the apparatus is under an object, the micro-controller sets the seeking job flag to false  231 . 
         [0068]    When the apparatus is not seeking a job in step  229 , the apparatus uses the upward facing ultrasonic sensors  22  (visible in  FIGS. 1 &amp; 2 ) to determine if the apparatus is located under an object. If under an object, the micro-controller continues to the next step. If not under an object, the apparatus will backup and spin  233 , a process explained in further detail in  FIG. 16 . After the backup and spin step  233 , the apparatus will again check whether it is under an object  234 . If under an object, the micro-controller will move along to the next step. If not under an object, the micro-controller will decide whether to set the seeking job flag to true before continuing  235 . In the preferred embodiment, the micro-controller decides to set the seeking job flag to true in step  235  approximately 40% of the time. The micro-controller can alternatively decide to set the seeking job flag to true in step  235  at a different frequency, such as approximately 25% of the time. 
         [0069]    The next step in the clean flow chart is a check by the micro-controller if the duration timer that was started in step  222  is less than the cleaning cycle selected by the user in step  209  (in  FIG. 14 ). If the duration timer has not exceeded the length of the cleaning cycle selected by the user, the micro-controller will loop back to the move forward step  223 . If the duration timer has exceed the length of the cleaning cycle, the micro-controller will determine once again whether it is under an object  237 . To avoid having the apparatus end a cleaning cycle under an object, the micro-controller will loop back to the move forward step  223  if located under an object at the end of the cycle. When the apparatus is not under an object and the duration timer has exceeded the duration of the cleaning cycle selected by the user, the clean step will end  240 . 
         [0070]    In  FIG. 16  is a flow chart detailing the backup and spin function  226  and  233  in  FIG. 15 . When the backup and spin flow chart has been initiated  241 , the micro-controller first stops the motors  242 . The micro-controller will then decide a direction to begin a spin  243 . Approximately 70% of the time, the chosen spin direction will be in a different direction than the last spin. The micro-controller then decides on a spin speed by directing each motor to spin in an opposite direction at between 70 and 100 percent  244 , where the percentage indicates the shaft speed of the motor in relation to its maximum shaft speed under load. The variable spin rates help the apparatus free itself when it is stuck or in danger of being stuck. 
         [0071]    To reduce the chances of the apparatus backing off or spinning off a ledge, the micro-controller then checks if it has had a recent pending fall  245 . A recent pending fall will take the form of a recent event where the downward facing infrared sensors  52  (visible in  FIG. 4 ) have sensed a fall or a lack of ground under the front of the apparatus. When a recent fall has been detected, the micro-controller will direct a less aggressive backup and spin, choosing a backup time of between 0.75 to 1.50 seconds  250  and a spin time of between 0.75 and 1.50 seconds  251 . 
         [0072]    If a recent fall has not been detected in step  245 , the micro-controller will then check if the apparatus appears to be stuck  246 . The apparatus does not need to be physically unable to move for the micro-controller to consider it stuck, but rather can be merely moving in a small partially enclosed area, such as under a chair or under a piece of furniture in a corner. The apparatus considers itself to be stuck when there have been four hits on the bumper  24  (visible in  FIG. 1 ) within the previous four seconds of forward motion and the last period of forward motion was less than two seconds. The micro-controller starts a timer each time the apparatus moves forward and keeps the previous four forward elapsed times in memory on a rolling basis. When the micro-controller determines that the apparatus is stuck in step  246 , the apparatus plays a trouble melody  247  and chooses an extended backup time of between 0.50 and 3.00 seconds  248  and an extended spin time of 0.50 to 7.50 seconds  249 . If the apparatus is not stuck, the micro-controller chooses an intermediate backup time of 0.50 to 2.00 seconds  252  and an intermediate spin time of 0.25 to 5.00 seconds  253 . The micro-controller chooses an extended backup and spin time when the apparatus is stuck to remove itself from the partially enclosed area that has obstructed its movement over the previous four periods of forward motion. 
         [0073]    Once the backup and spin times have been selected by the micro-controller, the apparatus executes the selected backup  254 . While the micro-controller will select a power level for each motor and a duration, in the preferred embodiment, the motor does not run at the selected power level for precisely the duration selected. To avoid stressing the motor and gears, the motor speeds are increased over a span of milliseconds rather than instantaneously. After the backup is complete, the micro-controller turns off the trouble light  255  (if it was energized) and directs the apparatus to execute the selected spin  256 . Once the spin is complete, the backup and spin sequence is complete  260 . 
         [0074]    In  FIG. 17  is a flow chart detailing the move forward step  223  in  FIG. 15 . After the move forward sequence begins  261 , the micro-controller starts the forward timer  262 . The forward timer runs for the entire duration of each move forward sequence and provides the basis for the forward elapsed times used to choose the duration of the backup and spin in  FIG. 16 . The micro-controller then polls the sensors to determine if the apparatus is about to fall  263  or if the collision sensors have been triggered  264 . Either event causes the trouble light to turn on  265 , the motors to stop  280  and the move forward sequence to end  281 . 
         [0075]    If neither a pending fall nor bump are detected, the micro-controller determines if the duration timer that was started in step  222  (in  FIG. 15 ) is less than three seconds. If the duration timer is less than three seconds, the micro-controller will calibrate the fall detectors  267  by calculating and storing the maximum values recorded during the first three seconds of the duration timer. In the preferred embodiment, the fall detectors calculate a value based on the amount of time elapsed between the transmission and receipt of an infrared pulse and the intensity of the return pulse. The precise values generated by the fall detectors will depend on the specific infrared sensors (or other type of sensor capable of detecting distance) used in the application. For infrared sensors in general, surfaces that are further away generate higher values. Darker and matte surfaces generate higher values because they reflect less light than lighter and glossy surfaces, making them appear further away to an infrared sensor. The apparatus will continue to operate during the time when the micro-controller is calibrating the fall detectors to ensure that multiple areas of the surface to be cleaned are sensed in the initial calibration. 
         [0076]    If the apparatus is stopped at step  268 , the micro-controller will start a heading timer and direct the apparatus to move forward at full speed  269 . If the apparatus is not stopped in step  268 , the micro-controller will move directly to the next step where it determines if the under cleaning mode has been selected by the user  270 . If the under cleaning mode has been selected by the user, the micro-controller will initiate the forward under sequence  274  that is shown in further detail in  FIG. 18 . 
         [0077]    If the under cleaning mode has not been selected in step  270 , the micro-controller will then determine if the heading timer has run for more than four seconds  271 . When the heading timer has run for more than four seconds, 70 percent of the time, the micro-controller will select a new forward speed, setting both motors forward at 100 percent and 30 percent of the time, the micro-controller will select a new forward speed, setting each motor forward at 60 to 100 percent  272 . Once the new forward speed is selected in step  272 , the micro-controller restarts the heading timer and directs the apparatus to move forward at the selected speed  273 . 
         [0078]    In the next step in the move forward sequence, the micro-controller determines if the forward timer that began in step  262  has exceeded “X” seconds  275 . In the preferred embodiment, the micro-controller sets “X” to 25 so that in step  275 , the micro-controller determines whether the forward timer has exceeded 25 seconds. The micro-controller can alternatively decide to set “X” as a different value, such as 60. 
         [0079]    When “X” seconds have elapsed, the micro-controller stops the motors  280  and the move forward sequence is ended  281 . If the forward timer has not exceeded “X” seconds in step  275 , the micro-controller then begins to determine whether the apparatus is operating in a large open space, such as under a bed or in a large room. The micro-controller first polls the upward facing ultrasonic sensors to determine if the apparatus is located under an object  276 . If under an object, the micro-controller checks if the last four forward times have all exceeded “Y” seconds  277 . In the preferred embodiment, the micro-controller sets “Y” to two so that in step  277 , the micro-controller determines whether the last four forward times have all exceeded two seconds. The micro-controller can alternatively decide to set “Y” as a different value, such as three. 
         [0080]    If the previous four forward times have exceeded “Y” seconds, the micro-controller initiates the spiral outward sequence  279  which is shown in further detail in  FIG. 19 . If the apparatus is not under an object in step  276 , the micro-controller checks if the last four forward times have all exceeded “Z” seconds  278  and uses this threshold to determine whether to initiate the spiral outward sequence  279 . In the preferred embodiment, the micro-controller sets “Z” to four so that in step  278 , the micro-controller determines whether the last four forward times have all exceeded four seconds. The micro-controller can alternatively decide to set “Y” as a different value, such as five. The move forward sequence will continue to loop back to step  263  until a pending fall  263  or bump is detected  264  or until the forward timer has exceeded “X” seconds  275 . 
         [0081]    In  FIG. 18  is a flow chart detailing the forward under step  274  in  FIG. 17 . After the forward under sequence starts  285 , the micro-controller determines if the seeking job flag is set to true  286 . If set to true in step  286 , the micro-controller then determines if the apparatus is located under an object  287 . When under an object, the micro-controller starts a loop timer and directs the motors to move forward at full speed  288 . The apparatus will continue to move forward at full speed unless a pending fall is detected  294 , triggering the trouble light  297 ; unless a bump is detected  295 , also triggering the trouble light  297 ; unless the apparatus is no longer under an object  296  or if more than two seconds have passed on the loop timer  298  that was started in step  288 . When the loop timer exceeds two seconds in step  298 , the micro-controller clears the seeking job flag, restarts the forward timer that was started in step  262  in  FIG. 17 , and chooses a forward speed between 60 to 100 percent for each motor  299 . The micro-controller then starts the heading timer and directs the motors to move forward at the selected speed or speeds  300 . 
         [0082]    If the apparatus is not seeking a job in step  286 , the micro-controller determines whether the apparatus is located under an object  289 . If not under an object, 60 percent of the time, the micro-controller will set the forward timer to greater than “A” seconds to cause the forward run to end after the move forward sequence ends in step  303  and 40 percent of the time, the micro-controller will set the seeking job flag to true  301 . In the preferred embodiment, the micro-controller sets “A” to 25 so that in step  301 , the micro-controller sets the forward timer to greater than 25 seconds 60% of the time. The micro-controller can alternatively decide to set “A” as a different value, such as 60. 
         [0083]    If the apparatus is under an object in step  289 , the micro-controller determines whether the forward timer is 10 or more seconds greater than the longest recent elapsed forward time  290 . The micro-controller records four previous elapsed forward times and compares the present forward timer to these stored values. When the forward timer is greater than 10 seconds longer than the longest recent elapsed forward time, the micro-controller sets the forward timer to greater than “B” seconds  302  to end the forward run after the forward under sequence ends  303 . In the preferred embodiment, the micro-controller sets “B” to 25 so that in step  302 , the micro-controller sets the forward timer to greater than 25 seconds. The micro-controller can alternatively decide to set “B” as a different value, such as 60. 
         [0084]    If the forward timer is not greater than 10 seconds longer than the longest recent forward elapsed time  290  or if the apparatus is seeking a job  286  and is not under an object  287 , the micro-controller will check if the heading timer is greater than four seconds  291 . When the heading timer exceeds four seconds, 70 percent of the time, the micro-controller chooses a forward speed of 100 percent for both motors and 30 percent of the time, the micro-controller chooses a forward speed of 60 to 100 percent for each motor  292 . Once the forward speed is selected, the micro-controller starts the heading timer and directs the motors to operate at the chosen speed  293 , thus ending the forward under sequence  303 . When the heading timer has not exceeded four seconds in step  291 , the forward under sequence is ended  303 . 
         [0085]    In  FIG. 19  is a flow chart showing the spiral outward step  279  in  FIG. 17  in further detail. After the spiral outward sequence is started  305 , the micro-controller starts the loop timer and directs the motors to both move forward at full speed  306 . The micro-controller then determines whether a fall is pending  307  or if a bump has been detected  308 , either event causing the trouble light to turn on  309 . If neither event has been detected, the micro-controller determines if the loop timer is greater than half the average of the last four forward spans  310 . The micro-controller will loop back to step  307  until the loop timer exceeds half of the average of the last four forward spans in step  310 . Once the loop timer does exceed half the average of the last four forward spans, the micro-controller stops the motors and restarts the loop timer  311 . To increase the randomization of the paths taken by the apparatus, the micro-controller determines the direction of the last turn taken by the apparatus  312  and selects a first turn to the left  313  or right  314  based on it being in the opposite direction to the direction of the previous turn. The apparatus also begins its turn to the left or right in steps  313  and  314 , respectively. 
         [0086]    As the apparatus moves, the micro-controller checks whether a fall is pending  315  or a bump has been detected by the collision sensors  316 , either event causing the trouble light to turn on  317 . If the duration timer started in step  222  (in  FIG. 15 ) has not exceeded the duration set by the user in step  209  (in  FIG. 14 )  318 , the apparatus will continue to move forward and slowly reduce the rate at which it is turning  320 . When initiating the first sharp turn in steps  313  and  314 , the micro-controller directs the inboard motor to stop and the outboard motor to move forward at 100 percent. To reduce the rate at which the apparatus turns, the micro-controller slowly increases the forward rate of the inboard motor (from an initial setting of zero), creating an expanding spiral shaped path. 
         [0087]    In step  320 , the micro-controller stops and reverses the motors at regular intervals for a short duration. Stopping and reversing the motors at regular intervals during step  320  reduces the possibility of the apparatus becoming stuck on an obstruction for the remainder of the cleaning cycle. In the preferred embodiment, the micro-controller stops the motors every 10 to 20 seconds of spiraling, operates the motors in reverse for a half second to two seconds and then continues forward as before. 
         [0088]    When the duration timer exceeds the duration set by the user  318 , the micro-controller stops the motors and clears the stored forward span counters  319 . The micro-controller then determines if the clean under mode has been selected  321  and if selected, sets the seeking job flag to true  322  prior to ending the sequence  323 . 
         [0089]    What has been described is an apparatus for automatically cleaning floors. In this disclosure, there are shown and described only the preferred embodiments of the invention, but, as aforementioned, it is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein.

Technology Classification (CPC): 0