Patent Description:
Grounds maintenance tasks are commonly performed using various tools and/or machines that are configured for the performance of corresponding specific tasks. Certain tasks, like snow or ice removal, are typically performed using manually operated tools or vehicles. More recently, robotic devices and/or remote controlled devices have also become options for consumers to consider. Moreover, the use of a robotic vehicle that operates either autonomously or via remote control may create a number of unique design and operational considerations that are normally not possible for manually operated devices.

Some of these design of operational considerations may require new solutions to be developed that had not previously been needed or considered helpful. Accordingly, it may be desirable to provide additional capabilities and corresponding devices or component assemblies that are designed to provide such additional capabilities.

<CIT>, of the same applicant, discloses a manual snow removal device, which may include an engine assembly operably coupled at least in part to a frame of the snow removal device. The snow removal device may further include a mobility assembly operably coupled to the frame and the engine assembly to provide mobility of the snow removal device responsive at least in part to operation of the engine assembly, an ejection assembly that includes a chute for ejecting material from the snow removal device, and a handle assembly that includes a lever assembly. The snow removal device may also include a chute rotation assembly operably coupled to the chute of the ejection assembly. The chute rotation assembly may include a cable system, the cable system operably coupling the lever assembly to the chute rotation assembly. The chute rotation assembly may also include a disc clutch assembly configured to move between an engaged position and a disengaged position in response to actuation of the lever assembly, where when the disc clutch assembly is in the disengaged position, the chute is enabled to rotate between a plurality of positions.

<CIT> describes a chute control assembly for a snow thrower having a housing, handle, and a chute, which includes a control mechanism, a connecting mechanism, and a guide mechanism. The control mechanism may include an actuator mechanism that allows an operator to manually control the orientation of the chute from a position spaced apart from the chute. The connecting mechanism may transfer the rotation of the actuator mechanism to the guide mechanism, which is attached to the chute and rotates and adjust the orientation of the chute in response to rotation of the actuator mechanism in order to change the direction that snow is thrown from the snow thrower.

<CIT> shows a snow thrower which comprises an auger housing, a chute extending from the auger housing, a first snow engaging blade rotatably supported within the auger housing opposite the chute and a second snow engaging blade rotatably supported within the auger housing on a first side of the first snow engaging blade. The first snow engaging blade and the second snow engaging blade may be rotatable at different speeds relative to one another.

Some example embodiments may therefore provide a snow removal device. The snow removal device may include a chassis supporting a power unit, a mobility assembly operably coupled to the chassis to provide mobility for the snow removal device responsive to power provision from the power unit, a working assembly configured to move snow to an ejection path responsive to power provision from the power unit, and a chute assembly forming a portion of the ejection path, the chute assembly comprising a chute and a deflector. The chute may be rotatable via a chute rotator configured to provide at least <NUM> degree automated rotation of the chute. An orientation of the deflector may be changeable via automated pivoting of the deflector via an electrically operable deflector adjuster. The chute rotator may comprise a contact plate assembly configured to rotate with the chute and interface with a brush assembly to provide power from the power unit to the deflector adjuster.

In another example embodiment, a chute assembly for a snow removal device may be provided. The chute assembly may include a chute forming a portion of an ejection path from a working assembly of the snow removal device, and a deflector disposed at a distal end of the chute. The chute may be rotatable via a chute rotator configured to provide at least <NUM> degree automated rotation of the chute responsive to power provision from a power unit. An orientation of the deflector is changeable via automated pivoting of the deflector via an electrically operable deflector adjuster. The chute rotator may comprise a contact plate assembly configured to rotate with the chute and interface with a brush assembly to provide power from the power unit to the deflector adjuster.

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Furthermore, as used herein, the term "or" is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other.

As noted above, robotic snow removal machines may enable new design options that had not previously been needed or considered helpful. For example, since a manually operated snow removal machine necessarily has an operator, the location at which the operator engages with the machine (e.g., the operator station) is essentially disqualified as a possible direction to which the discharge chute may be selected for discharging snow being ejected from the machine. Thus, even though it has long been recognized that it is desirable for operators to select the direction to which the snow should be ejected from the machine, there has always been at least one direction to which ejection would simply never be desirable.

By providing autonomous or remotely operated snow removal devices, the operator station is eliminated, and the possibility of having a snow removal device that can eject snow to any selectable direction, <NUM> degrees around the device becomes possible. Some of the design features of conventional snow removal devices for providing rotation of the discharge chute, and for controlling a deflector (e.g., at the distal end of the chute) involve cables or wires, and are therefore incompatible with a chute that can rotate continuously over a <NUM> degree range. In this regard, the wires or cables would become wrapped around components at some point and limit movement, or even be damaged.

Some example embodiments may provide a snow removal device (e.g., a remotely controllable or autonomous robotic vehicle) that employs a rotator (or rotation assembly) that is capable of continuously rotating over more than <NUM> degrees. Example embodiments may provide such a rotator that also has a deflector that is operable to change position without manual interaction by the operator and instead under electrically operable controls.

<FIG> illustrates an example of a remotely operable or autonomously operable robotic vehicle in the form of a snow removal device <NUM>, and <FIG> illustrates a block diagram of the snow removal device <NUM>. Although the snow removal device <NUM> (e.g., a snow blower or snow thrower) of <FIG> and <FIG> is shown as a robotic vehicle, it should be appreciated that example embodiments could be employed in connection with other devices that are not robotic as well. Thus, for example, walk behind power equipment may use example embodiments as well. In such cases, it may be the case that the operator station is movable, or the device may convert between manual and remote/autonomous operation. But in any case, it should be appreciated that example embodiments can be implemented on any snow removal device and not just on robotic vehicles.

In some embodiments, the snow removal device <NUM> may include a chassis <NUM> or frame to which various components of the snow removal device <NUM> may be attached. For example, the chassis <NUM> may support a power unit housing <NUM> inside which a power unit <NUM> such as an engine (e.g., a gasoline powered engine) or an electric motor and corresponding battery may be housed. The power unit <NUM> may be operably coupled to a mobility assembly <NUM> (which is a track assembly <NUM> in this example) and a working assembly <NUM> to power either or both of the mobility assembly <NUM> and the working assembly <NUM>.

The snow removal device <NUM> may include a track assembly <NUM> (or continuous tracks), wheels or any other suitable means for moving the snow removal device <NUM> as the mobility assembly <NUM>. The mobility assembly <NUM> may support a substantial portion of the weight of the snow removal device <NUM> when the snow removal device <NUM> is stationary. The mobility assembly <NUM> may also provide for mobility of the snow removal device <NUM>. In some cases, the mobility assembly <NUM> may be driven via power from the power unit <NUM> based on remote or autonomous control inputs.

In an example embodiment, the working assembly <NUM> may be a single or dual stage snow thrower. As such, for example, if dual stage, the working assembly <NUM> may include a rotatable auger (or auger blade) that is configured to work (e.g., spin, rotate, turn, and/or the like) in order to direct snow toward an impeller (or impeller blade) that also works (e.g., spins, rotates, turns, and/or the like) to direct snow toward a discharge path to be ejected from the snow removal device <NUM>. Single stage versions may only include only the auger. However, it should be appreciated that the working assembly <NUM> of some embodiments could include a power brush or other implement used to move snow toward a second stage device (e.g., the impeller) for ejection from the working assembly <NUM>. In an example embodiment, the working assembly <NUM> may be powered via operable coupling to the power unit <NUM>. The operable coupling of the working assembly <NUM> to the power unit <NUM> may be selectively engaged and/or disengaged (e.g., via a clutch, one or more selectively engageable chains/belts/pulleys, a friction wheel or other similar devices). Components of the working assembly <NUM> (e.g., the auger and the impeller) may be housed in a bucket assembly <NUM>.

As can be appreciated from <FIG>, the bucket assembly <NUM> prevents escape of snow and directs the snow into the ejection path. Thus, the bucket assembly <NUM> also protects the operator from blowback and allows for a somewhat orderly disposal of the snow that is ejected by the snow removal device <NUM>. The ejection path of the snow removal device <NUM> may be formed at least in part by the bucket assembly <NUM> and a discharge chute or chute assembly <NUM>. As such, for example, the ejection path may begin proximate to an input of the impeller, at which point snow is imparted with momentum at an output of the impeller to be pushed toward, and ultimately through, the chute assembly <NUM>.

In an example embodiment, the chassis <NUM> may also support the chute assembly <NUM>. The chute assembly <NUM> may include a chute <NUM> and a deflector <NUM>. The chute <NUM> may define an ejection path for snow propelled by or from the working assembly <NUM>. The chute <NUM> may, in some cases, be an elongated sheet (or sheets) of metal or other rigid material that may be formed to partially or fully enclose the lateral sides of the ejection path. In the example shown, the chute <NUM> encloses only three sides of the ejection path in order to minimize the material required to form the chute <NUM>. However, all four sides may be enclosed in some alternatives.

The deflector <NUM> may be disposed at a distal end of the chute <NUM> to provide an adjustable deflection surface for direction snow ejected from the distal end of the chute <NUM> at a desired angle relative to the direction of travel of the snow in the chute <NUM>. Accordingly, for example, the deflector <NUM> may be a sheet (or sheets) of metal or other rigid material that can be rotated relative to the distal end of the chute <NUM> in order to change the deflection angle for ejected snow.

As noted above, it is not uncommon for either or both of the chute <NUM> and the deflector <NUM> to be adjustable. The chute <NUM> may therefore be adjustable to another chute orientation <NUM>', and the deflector <NUM> may also be adjustable to other deflector orientations <NUM>' and <NUM>". While these adjustments of orientation are known in general terms, they are typically conducted in a context in which there are physical limits to the adjustability of the chute <NUM> (e.g., over a range of angles). The physical limits tend to facilitate (or allow) use of cables and wires for pulling and turning components for adjustment of the chute <NUM> and/or deflector <NUM>.

However, example embodiments may allow the adjustment of the chute <NUM> to the other chute orientation <NUM>' to pass through a continuous range of <NUM> degrees. Thus, the chute <NUM> could be directly adjusted from the position shown in <FIG> to the other chute orientation <NUM>' in either direction. Moreover, any number of full circles of <NUM> degrees could be conducted prior to reaching the other chute orientation <NUM>'. This continuous adjustment capability for the chute <NUM> not only renders the use of cables and wires impossible for the adjustment of the chute <NUM>, but remote adjustment of the deflector <NUM> is also disrupted by this significant modification.

In order to provide for the remote adjustment of the chute <NUM> and the deflector <NUM>, the chute assembly <NUM> of example embodiments may also include a chute rotator <NUM> and a deflector adjuster <NUM> as described in greater detail below. In this regard, the chute rotator <NUM> may be configured to enable continuous adjustment of the chute <NUM> over greater than <NUM> degrees, and the defector adjuster <NUM> may allow remote adjustment of the deflector <NUM> in the context of a fully rotatable (i.e., greater than <NUM> degrees) chute <NUM>.

<FIG> illustrates various structures of the chute rotator <NUM> and the deflector adjuster <NUM> of an example embodiment. In this regard, the chute rotator <NUM> may include a gear assembly <NUM> and a chute motor <NUM> (e.g., an electric motor such as a brushless DC (BLDC) motor). The gear assembly <NUM> may include a drive gear that receives power from the chute motor <NUM> and a driven gear that is affixed to the chute <NUM> so that when the driven gear turns, the chute <NUM> turns with the driven gear. The chute motor <NUM> may receive power from the power unit <NUM> (e.g., responsive to receipt of a rotation instruction from a local controller or remote controller of the snow removal device <NUM>) and may turn the drive gear according to the rotation instruction received (e.g., in the direction and perhaps also at the speed instructed). The drive gear may correspondingly engage the driven gear and turn the driven gear accordingly. The chute <NUM> may then be carried with the driven gear to rotate in accordance with the rotation instruction. Some embodiments may further include one or more instances of an idler gear between the drive gear and the driven gear.

As noted above, it may not normally be possible to use wires or cables to operate the deflector <NUM> under remote control when the chute <NUM> can rotate <NUM> degrees since the wires or cables will define movement limits or become tangled or damaged by the movements. In accordance with the invention, the chute rotator <NUM> may solve this problem by providing a contact plate assembly <NUM> that is configured to provide power to the deflector adjuster <NUM> even when the chute rotator <NUM> enables full continuous <NUM> degree rotation of the chute <NUM>. The contact plate assembly <NUM> may include substantially circular electrically conductive plates that have a central opening that corresponds to the ejection path defined through the chute <NUM>. Thus, the plates of the contact plate assembly <NUM> may rotate with the chute <NUM> and the driven gear, and provide consistent power connections to a deflector motor <NUM> (e.g., another electric motor such as a Brushed DC motor) of the deflector adjuster <NUM>. The deflector adjuster <NUM> may therefore receive an adjustment instruction, which may provide power to the deflector motor <NUM> via the contact plate assembly <NUM>. The deflector motor <NUM> may in turn operate to drive a linear actuator <NUM>, which may extend between the deflector <NUM> and the chute <NUM>. The driving of the linear actuator <NUM> may change the orientation angle of the deflector <NUM> relative to the distal end of the chute <NUM>. As an alternative, the deflector motor <NUM> may pull a cable or wire that is attached to the deflector <NUM> (e.g., via a pulley) to change the orientation of the deflector <NUM>. Thus, for example, the linear actuator <NUM> may be a threaded lead screw, a device capable of pulling the cable linearly in one direction or the other to actuate the deflector, or any other device that creates motion in a straight line.

In an example embodiment, controls for operation of the working assembly <NUM>, the mobility assembly <NUM>, the power unit <NUM>, and/or the chute assembly <NUM> may be handled by control circuitry <NUM> of the snow removal device <NUM>. Thus, for example, the rotation instruction for rotating the chute <NUM> and/or the adjustment instruction or pivoting the deflector <NUM> may be provided by control circuitry <NUM>. In an example embodiment, the control circuitry <NUM> may be configurable for autonomous operation of the snow removal device <NUM>, or the control circuitry <NUM> may include or otherwise be in communication with wireless communication equipment that enable remote operation of the snow removal device <NUM>.

Accordingly, using the hardware described above, no wires or cables may need to pass through the chute rotator <NUM>, which could otherwise be damaged or inhibit free movement of the chute <NUM>. Instead, the contact plate assembly <NUM> (and therefore the chute rotator <NUM>) provide power for remote operation of the deflector <NUM> even though the chute <NUM> is allowed to continuously rotate over <NUM> degrees.

<FIG> and <FIG> each illustrate a partially isolated perspective view of the components of the chute rotator <NUM> of an example embodiment. In this regard, <FIG> and <FIG> show the chute motor <NUM>, which is operably coupled to drive gear <NUM>. Drive gear <NUM> is in turn operably coupled to driven gear <NUM>. The driven gear <NUM> is concentrically formed along with a first plate <NUM> and a second plate <NUM> of the contact plate assembly <NUM>. The driven gear <NUM> is, like the first and second plates <NUM> and <NUM>, hollow in its center to define part of ejection path <NUM>, which extends into the chute <NUM>.

The first plate <NUM> and the second plate <NUM> may, for example, be positive and negative plates, respectively (or vice versa) that are separated by an insulator <NUM>. Other insulators <NUM> may also be provided on opposing axial sides of the first and second plates <NUM> and <NUM> to further isolate the first and second plates <NUM> and <NUM> electrically. In some cases, a third metallic plate <NUM> may be provided for additional structural robustness, and the chute <NUM> may be operably coupled to the third metallic plate <NUM>. Pins <NUM> may pass through the driven gear <NUM>, the first and second plates <NUM> and <NUM>, the insulators <NUM> and <NUM> and the third metallic plate <NUM> to keep all such components affixed relative to each other such that the rotation of the driven gear <NUM> (responsive to operation of the chute motor <NUM>) causes corresponding rotation of the chute <NUM>.

The first plate <NUM> may be operably coupled to a first brush <NUM> and the second plate <NUM> may be operably coupled to a second brush <NUM>. The first and second brushes <NUM> and <NUM> may form a brush assembly that provides electrical power from the power unit <NUM> through the contact plate assembly <NUM> to the deflector motor <NUM>. In an example embodiment, a first conductive roll pin <NUM> may extend from the first plate <NUM> through the third metallic plate <NUM> and the insulators <NUM> and <NUM> that are disposed between the first plate <NUM> and the chute <NUM>. An electrical wire, cable, or other conductor may extend from the first conductive roll pin <NUM> to the deflector motor <NUM>. Similarly, a second conductive roll pin <NUM> may extend from the second plate <NUM> through the third metallic plate <NUM> and the insulator <NUM> that is disposed between the second plate <NUM> and the chute <NUM>. An electrical wire, cable, or other conductor may extend from the second conductive roll pin <NUM> to the deflector motor <NUM>. The first and second conductive roll pins <NUM> and <NUM>, which are shown in <FIG>, may represent positive and negative terminals for powering the deflector motor <NUM>.

<FIG> shows a distal end of the chute <NUM> with the deflector <NUM> positioned substantially aligned with walls of the chute <NUM> to avoid deflecting snow in the ejection path. The deflector <NUM> includes a deflector bracket <NUM> and a support bracket <NUM> is disposed proximate to the distal end of the chute <NUM>. In an example embodiment, the support bracket <NUM> may support the deflector motor <NUM> of <FIG>, and the linear actuator <NUM> may operate to move the deflector bracket <NUM> along a line shown by arrow <NUM> in order to tilt the deflector <NUM> as shown by arrow <NUM>.

In an example embodiment, a robotic vehicle such as a snow removal device may be provided. The snow removal device may include a chassis supporting a power unit, a mobility assembly operably coupled to the chassis to provide mobility for the snow removal device responsive to power provision from the power unit, a working assembly configured to move snow to an ejection path responsive to power provision from the power unit, and a chute assembly forming a portion of the ejection path, the chute assembly comprising a chute and a deflector. The chute may be rotatable via a chute rotator configured to provide at least <NUM> degree automated rotation of the chute. An orientation of the deflector may be changeable via automated pivoting of the deflector via an electrically operable deflector adjuster.

The snow removal device of some embodiments may include additional features, modifications, augmentations and/or the like to achieve further objectives or enhance performance of the device. The additional features, modifications, augmentations and/or the like may be added in any combination with each other. Below is a list of various additional features, modifications, and augmentations that can each be added individually or in any combination with each other. For example, the chute rotator may include a contact plate assembly configured to rotate with the chute and interface with a brush assembly to provide power from the power unit to the deflector adjuster. In an example embodiment, the deflector adjuster may include a deflector motor and a linear actuator. In some examples, the linear actuator may be operably coupled to a deflector bracket on the deflector, and responsive to operation of the deflector motor, the linear actuator may move the deflector bracket to pivot the deflector relative to a distal end of the chute. In an example embodiment, the deflector motor may be disposed at a support bracket proximate to a distal end of the chute. In some cases, the contact plate assembly may include a first conductive plate and a second conductive plate separated from each other by an insulator. The first and second conductive plates may be operably coupled to the chute to rotate with the chute. The first conductive plate may be operably coupled to a first conductive roll pin, and the second conductive plate may be operably coupled to a second conductive roll pin. The first and second conductive pins may provide positive and negative power terminals for operation of the deflector motor. In an example embodiment, the chute rotator may include drive gear and a driven gear. The drive gear may be operably coupled to a chute motor, and the driven gear may be operably coupled to the chute. The chute may be rotated responsive to operation of the chute motor to turn the driven gear via rotation of the drive gear. In some cases, the driven gear, the first conductive plate and the second conductive plate may each be concentric with respect to each other and surround a portion of the ejection path. In an example embodiment, one or more holding members (e.g., pins, screws, rivets, etc.) may hold the first and second conductive plates, the driven gear and the insulator in fixed positions relative to each other. In some cases, the working assembly may be a single stage or dual stage snow thrower. In an example embodiment, the deflector adjuster may include a deflector motor, and the chute rotator may include a chute motor. The chute motor and the deflector motor may each be brushed DC motors.

Claim 1:
A snow removal device (<NUM>) comprising:
a chassis (<NUM>) supporting a power unit (<NUM>);
a mobility assembly (<NUM>) operably coupled to the chassis (<NUM>) to provide mobility for the snow removal device (<NUM>) responsive to power provision from the power unit (<NUM>);
a working assembly (<NUM>) configured to move snow to an ejection path responsive to power provision from the power unit (<NUM>); and
a chute assembly (<NUM>) forming a portion of the ejection path, the chute assembly (<NUM>) comprising a chute (<NUM>) and a deflector (<NUM>),
wherein the chute (<NUM>) is rotatable via a chute rotator (<NUM>) configured to provide at least <NUM> degree automated rotation of the chute (<NUM>), and
wherein an orientation of the deflector (<NUM>) is changeable via automated pivoting of the deflector (<NUM>) via an electrically operable deflector adjuster (<NUM>);
wherein
the chute rotator (<NUM>) comprises a contact plate assembly (<NUM>) configured to rotate with the chute (<NUM>) and interface with a brush assembly (<NUM>, <NUM>) to provide power from the power unit (<NUM>) to the deflector adjuster (<NUM>).