Autonomous floor cleaning system and related methods

Abstract

An autonomous floor cleaning system includes an interlocking feature for physically interlocking an autonomous floor cleaner with a docking station. The interlocking feature selectively engages when the autonomous floor cleaner is docked at the docking station and may automatically engage when predetermined locking criteria are met. The interlocking feature may remain engaged until predetermined unlocking criteria are met. A method for docking an autonomous floor cleaner with a docking station is disclosed.

Description

Technical Field

[0001] The present disclosure generally relates to docking of an autonomous floor cleaner with a docking station. Background Art

[0002] Autonomous or automatic floor cleaners can move to clean floor surfaces without the help of a user or operator. For example, a floor cleaner can be configured to vacuum or sweep dirt (including dust, hair and other debris) into a collection box carried on the floor cleaner. Some floor cleaners are also configured to apply and extract liquids to wet clean bare floors, carpets, rugs and other floor surfaces. The floor cleaner can move randomly on the surface while cleaning the floor surface, or use a map / navigation system to guide navigation on the surface. Many autonomous floor cleaners need to return to a docking station to charge their batteries and / or empty the collection box. Summary of the invention

[0003] The present disclosure relates to an autonomous floor cleaner and a docking station for an autonomous floor cleaner. Various methods for docking an autonomous floor cleaner with a docking station are described herein.

[0004] In one aspect, an autonomous floor cleaner includes an autonomously movable housing, a drive system for autonomously moving the housing over a surface to be cleaned, a controller for controlling operation of the autonomous floor cleaner, and interchangeable modules for different operating modes.

[0005] In another aspect, an autonomous floor cleaner includes an autonomously movable housing, a drive system for autonomously moving the housing over a surface to be cleaned, a controller for controlling operation of the autonomous floor cleaner, and one of a lockable member or a lock engaged by a lock on a docking station that engages with the lockable member on the docking station.

[0006] In another aspect, a docking station for an autonomous floor cleaner includes one of a lock that engages with a lockable member on the autonomous floor cleaner or a lockable member that engages with a lock on the autonomous floor cleaner.

[0007] In another aspect, a docking station for an autonomous floor cleaner includes a foldable portion movable between a docking position and a stowed position. In the docking position, the autonomous floor cleaner can dock with the docking station. In the stowed position, the foldable portion moves to lift the autonomous floor cleaner off a floor surface. When moved from the docking position to the stowed position, an interlocking feature can physically interlock the foldable portion and the autonomous floor cleaner together.

[0008] In another aspect, the present disclosure is directed to an autonomous floor cleaning system that includes an autonomous floor cleaner and a docking station. An interlocking feature can physically interlock the autonomous floor cleaner with the docking station when docked.

[0009] In another aspect, a method for docking an autonomous floor cleaner with a docking station includes docking the autonomous floor cleaner at the docking station; determining whether a predetermined locking criterion is satisfied; and interlocking the autonomous floor cleaner with the docking station if the predetermined locking criterion is satisfied.

[0010] In another aspect, a method for docking an autonomous floor cleaner with a docking station includes docking the autonomous floor cleaner at the docking station; interlocking the autonomous floor cleaner with the docking station; determining whether a predetermined unlocking criterion is satisfied; and unlocking the autonomous floor cleaner from the docking station if the predetermined unlocking criterion is satisfied.

[0011] In another aspect, a method for docking an autonomous floor cleaner with a docking station includes docking the autonomous floor cleaner at the docking station; interlocking the autonomous floor cleaner with the docking station; and moving the autonomous floor cleaner to a stowed position.

[0012] Before explaining the embodiments of the present invention in detail, it should be understood that the present invention is not limited to the details of the operations described in the following description or shown in the drawings or the details of the construction and arrangement of the components. The present invention can be implemented in various other embodiments and can be practiced or executed in alternative ways not explicitly disclosed herein. Similarly, it should be understood that the words and terms used herein are for the purpose of description and should not be considered restrictive. The use of "include" and "comprise" and their variations is intended to cover the items listed thereafter and their equivalents, as well as other items and their equivalents. In addition, enumeration can be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be interpreted as limiting the present invention to any specific order or number of components. The use of enumeration should also not be interpreted as excluding from the scope of the present invention any other steps or components that may be combined or merged with the enumerated steps or components. Any claim element referred to as "at least one of X, Y and Z" means to include any one of X, Y or Z alone, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In the attached picture:

[0014] Figure 1 is a schematic diagram of an autonomous floor cleaning system according to one embodiment of the present invention, the system comprising at least an autonomous floor cleaner or robot and a docking station;

[0015] Figure 2 is used for Figure 1 A perspective view of one embodiment of an autonomous floor cleaner or robot of the system;

[0016] Figure 3 yes Figure 2 Schematic diagram of the robot;

[0017] Figure 4 is an enlarged view of a portion of the robot, showing the installation of a dry module on the robot;

[0018] Figure 5 is an enlarged view of a portion of the robot, showing the installation of the wet module on the robot;

[0019] Figure 6 is used for Figure 1 A front perspective view of one embodiment of a docking station for a system;

[0020] Figure 7 is a flow chart illustrating one embodiment of a method for docking performed by a robot;

[0021] Figure 8 is a schematic diagram of an autonomous floor cleaning system according to another embodiment of the present invention, the system comprising at least an autonomous floor cleaner or robot and a docking station, showing the robot docked with the docking station, and the docking station in a lower position;

[0022] Fig. 9 yes Figure 8 A schematic diagram of an autonomous floor cleaning system of FIG. 1 showing the docking station and the robot in a stowed position; and

[0023] Fig.10 is a flow chart illustrating one embodiment of a method for docking performed by a robot. DETAILED DESCRIPTION

[0024] Figure 1 is a schematic diagram of an autonomous floor cleaning system 10 according to one embodiment of the present invention. The autonomous floor cleaning system 10 includes an autonomous floor cleaner, also referred to herein as a robot 12, and a docking station 14 for the autonomous floor cleaner. The robot 12 can clean a variety of floor surfaces, including bare floors (such as hardwood, tile, and stone) and soft surfaces (such as carpets and rugs). Optionally, the autonomous floor cleaning system 10 can include an artificial barrier system (not shown) for containing the robot 12 within user-determined boundaries.

[0025] The robot 12 can be interlocked with the docking station 14 and can remain locked (preventing the robot 12 from being separated from the docking station 14) unless certain criteria are present or until predetermined criteria are met. The autonomous floor cleaning system 10 includes an interlock feature 16 for physically interlocking the robot 12 and the docking station 14. Figure 1 As shown, the interlocking feature 16 may include a locking mechanism including a lock 18 located on the docking station 14 that selectively engages the robot 12 when the robot 12 is docked (i.e., parked at the docking station 14). The robot 12 may have a lockable member 20 engaged by the lock 18. In another embodiment, the lock 18 may be provided on the robot 12, and the lockable member 20 may be provided on the docking station 14.

[0026] In one embodiment, the lock 18 may include a shackle or U-shaped member that wraps around and back into the housing of the docking station 14. When the robot 12 is docked, the shackle or U-shaped member may wrap around or pass through a lockable member 20 on the robot 12. For example, the lockable member 20 may include an opening through which the shackle may pass. Other configurations of the lock 18 and the lockable member 20 are possible. For example, the lock 18 may include an L-shaped member that engages with the lockable member 20 on the robot 12.

[0027] In one embodiment, the robot 12 can be a deep cleaning robot that includes: a fluid delivery system for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned; and a fluid recovery system for removing cleaning fluid and debris from the surface to be cleaned and storing the recovered cleaning fluid and debris. The fluid delivery system can be configured to deliver liquid, steam, mist, or vapor to the surface to be cleaned.

[0028] In another embodiment, the robot 12 can be a wet mopping or sweeping robot that includes: a fluid delivery system for storing and delivering a cleaning fluid to a surface to be cleaned; and a mopping or sweeping system for removing the cleaning fluid and debris from the surface to be cleaned without using suction. The fluid delivery system can be configured to deliver a liquid, steam, mist, or vapor to the surface to be cleaned.

[0029] In another embodiment, the robot 12 can be a dry vacuum cleaning robot, which includes at least one vacuum collection system for generating a partial vacuum to suck debris (which may include dirt, dust, soil, hair and other debris) from the floor surface and collect the removed debris in a space provided on the robot for subsequent processing.

[0030] In yet another embodiment, the robot 12 may be a dry cleaning robot including a cleaning system for removing dry debris from the surface to be cleaned without using suction, and collecting the removed debris in a space provided on the robot for subsequent processing.

[0031] Figures 2 to 3 Shown for Figure 1 An embodiment of the robot 12 of the autonomous floor cleaning system 10. It should be noted that Figures 2 to 3 The robot 12 shown in FIG. 1 is only one example of an autonomous floor cleaner that may be used with the autonomous floor cleaning system 10 and the docking station 14 , and other autonomous floor cleaners may be used with the autonomous floor cleaning system 10 and the docking station 14 .

[0032] The robot 12 mounts components of various functional systems of an autonomous floor cleaner in an autonomously movable unit or housing 22, optionally including components of a collection system 24, a fluid delivery system 25, a drive system 26, a navigation / mapping system 28, or any combination thereof. A controller 30 is operably coupled to the various functional systems of the robot 12 to control the operation of the robot 12. The controller 30 may be a microcontroller unit (MCU) including at least one central processing unit (CPU).

[0033] As shown, the housing 22 of the robot 12 may be a circular piece having a first end 32 and a second end 34. The first end 32 defines the front of the robot 12 and may optionally include a bumper 36. As described in further detail below, the second end 34 may define the rear of the robot 12 and optionally include a module receiver. Other shapes and configurations of the robot 12 are possible, including a D-shaped housing.

[0034] Figure 3 Is from Figure 2 Schematic diagram of the robot 12. The collection system 24 may include a working air path through a unit having an air inlet and an air outlet, a suction nozzle 38, a suction source 40 in fluid communication with the suction nozzle 38 and for generating a working airflow, and a collection box 42 for collecting dirt and / or liquid from the working airflow for later processing. The suction nozzle 38 may define an air inlet of the working air path, wherein the inlet opening of the suction nozzle 38 is disposed on the lower side 44 ( Figure 1) and facing the surface to be cleaned. The suction source 40 may include a vacuum motor 46 carried by the housing 22 and upstream of the fluid of the air outlet (not shown), and may define a portion of the working air path. The collection box 42 may also define a portion of the working air path and include a dirt box inlet (not shown) in fluid communication with the suction nozzle 38. Optionally, a separator (not shown) may be formed in a portion of the collection box 42 to separate the fluid and entrained dirt from the working air flow. Some non-limiting examples of separators include cyclone separators, filter screens, foam filters, HEPA filters, filter bags, or combinations thereof. Optionally, a motor pre-filter and / or a motor post-filter (not shown) may also be provided in the working air path. The working air path may further include various conduits, ducts, or tubes for fluid communication between the various components of the collection system 24. The vacuum motor 46 may be located downstream or upstream of the fluid of the collection box 42 in the working air path.

[0035] The collection system 24 may also include at least one agitator for agitating the surface to be cleaned. The agitator may be in the form of a brush roll 48 mounted to rotate about an axis that is generally horizontal relative to the surface on which the robot 12 moves. A drive assembly including a brush roll motor 50 may be provided within the robot 12 to drive the brush roll 48. Other agitators or brush rolls may also be provided, including one or more stationary or non-moving brushes, or one or more brushes that rotate about a substantially vertical axis.

[0036] The suction nozzle 38 may be placed proximate to the brush roll 48 to collect liquid and debris directly from the brush roll 48. In other embodiments, the suction nozzle 38 may be positioned facing the surface to be cleaned to remove liquid and debris from the surface instead of the brush roll 48.

[0037] Reference Figure 2 Optionally, the robot 12 includes at least one edge brush 94 that can clean hard-to-reach spaces, such as along the edges and corners of a room, including edges or corners created by walls, baseboards, cabinets, furniture, etc. The edge brush 94 can sweep debris under the housing 22 and toward the suction nozzle 38. The edge brush 94 may include one or more different agitation or cleaning elements that are configured to brush, sweep, whisk, wipe, or otherwise move debris on the surface to be cleaned. Some non-limiting examples of cleaning elements for edge cleaning brushes include scrapers, bristles, paddles, scrapers, wings, microfiber materials, fabrics, dusting pads, etc.

[0038] Reference Figure 3 A drive assembly including an edge brush motor 96 may be provided within the robot 12 to drive the edge brush 94. The edge brush motor 96 is configured to drive at least a portion of the edge brush 94 about a rotation axis that is substantially vertical relative to the surface to be cleaned.

[0039] In another embodiment, the collection system 24 can be configured as a sweeping system that removes dry debris from the floor surface without using suction. In this case, the suction source 40 may not be provided.

[0040] The fluid delivery system 25 may include a supply tank 52 for storing the supplied cleaning fluid and at least one fluid distributor 54 in fluid communication with the supply tank 52 to deposit the cleaning fluid onto the surface. The cleaning fluid may be a liquid such as water or a cleaning solution specially formulated for hard surface cleaning or soft surface cleaning. The fluid distributor 54 may be one or more nozzles disposed on the housing 22, the nozzle having an orifice of sufficient size so that debris is not easily blocked by the nozzle. Alternatively, the fluid distributor 54 may be a manifold having a plurality of distributor outlets.

[0041] A pump 56 may be disposed in the fluid path between the supply tank 52 and the at least one fluid dispenser 54 to control the flow of fluid to the at least one fluid dispenser 54. The pump 56 may be driven by a pump motor 58 to move the liquid at any flow rate useful for a cleaning operation cycle.

[0042] Various combinations of optional components may also be incorporated into the fluid delivery system 25, such as a heater 60 or one or more fluid control and mixing valves. The heater 60, for example, may be configured to heat the cleaning fluid before it is applied to the surface. In one embodiment, the heater 60 may be an in-line fluid heater between the supply tank 52 and the fluid distributor 54. In another example, the heater 60 may be a steam generating assembly. The steam assembly is in fluid communication with the supply tank 52 so that some or all of the liquid applied to the floor surface is heated to steam.

[0043] The drive system 26 may include a drive wheel 64 for driving the robot 12 across the surface to be cleaned. The drive wheel 64 may be operated by a common wheel motor 66 or a single wheel motor 66 coupled to the drive wheel 64 through a transmission, which may include a gear train assembly or another suitable transmission. Based on input from the navigation / mapping system 28 for an autonomous operating mode, or based on input from a smart phone, tablet computer or other remote device for an optionally manual operating mode, the drive system 26 may receive input from the controller 30 for driving the robot 12 on the floor. The drive wheel 64 may be driven in a forward and backward direction to move the autonomous mobile unit forward or backward. In addition, the drive wheel 64 may be operated simultaneously at the same speed for linear motion, or independently at different speeds to move the robot 12 in a desired direction. Although the drive system 26 is shown herein as including the drive wheel 64, it should be understood that the drive system 26 may include an alternative traction device to move the robot 12 on the surface to be cleaned.

[0044] like Figure 1 As shown, in addition to the drive wheels 64 or other traction devices, the robot 12 may also include one or more additional wheels 62 supporting the housing 22, such as casters located at the center, rear portion of the underside 44 of the housing 22.

[0045] The controller 30 may receive input from the navigation / mapping system 28 or from a remote device such as a smartphone (not shown) to guide the robot 12 over the surface to be cleaned. The navigation / mapping system 28 may include a memory 68 that may store any data useful for navigation, mapping, or performing an operation cycle, including, but not limited to, maps used for navigation, inputs from various sensors used to guide the movement of the robot 12, etc. For example, a wheel encoder 70 may be placed on the drive shaft of the drive wheel 64 and configured to measure the distance traveled by the robot 12. The distance measurement may be provided as an input to the controller 30.

[0046] In the autonomous operation mode, the robot 12 can be configured to travel in any pattern useful for cleaning or disinfecting (including boustrophedon or alternating rows (i.e., the robot 12 travels from right to left and from left to right in alternating rows), spiral trajectories, etc.) using input from various sensors to change direction or adjust its route as needed to avoid obstacles while cleaning the floor surface. In the optional manual operation mode, the movement of the robot 12 can be controlled using a mobile device such as a smartphone or tablet.

[0047] The robot 12 may include any number of motors for performing motion and cleaning, and any number of motor drivers for controlling the motors. In the illustrated embodiment, a vacuum motor driver 72, a brush roll motor driver 74, a wheel motor driver 76, a pump motor driver 78, and an edge brush motor driver 79 may be provided to control the vacuum motor 46, the brush roll motor 50, the wheel motor 66, the pump motor 58, and the edge brush motor 96, respectively. The motor drivers may act as an interface between the controller 30 and their respective motors. The motor drivers may be integrated circuit chips (ICs). It is also conceivable that a single wheel motor driver 76 may control multiple wheel motors 66 simultaneously.

[0048] The motor drive can be electrically coupled to a battery management system 80 that includes a rechargeable battery 81, which can include a battery pack. In one example, the battery pack can include multiple packages with lithium-ion cells. Batteries of other battery cell chemistries, such as nickel-metal hydride and nickel-cadmium, can also be used. Electrical contacts or charging contacts 82 for the battery 81 can be provided on an outer surface of the robot 12. In one embodiment, the charging contacts 82 are provided on the underside 44 of the robot 12. In another embodiment, the charging contacts 82 are provided on the second end 34 or rear side of the robot 12.

[0049] In one embodiment, the positive and negative charging contacts 82 are used to detect a complete circuit when the robot 12 is docked with the docking station 14. In other embodiments, a single charging contact 82 or more than two charging contacts 82 may be utilized. The additional charging contacts will provide redundancy if one of the other charging contacts becomes dirty, blocked, or damaged. In other embodiments of the robot 12, additional contacts may be used to transfer data and information between the robot 12 and the docking station 14.

[0050] The controller 30 may also be operatively coupled to a user interface 84 on the robot 12 to receive input from a user. The user interface 84 may be used to select an operating cycle of the robot 12 or otherwise control the operation of the robot 12. The user interface 84 may have a display 86 (e.g., an LED display) to provide visual notifications to the user. A display driver 88 may be provided to control the display 86, and the display driver serves as an interface between the controller 30 and the display 86. The display driver 88 may be an IC. The robot 12 may be provided with a speaker (not shown) to provide auditory notifications to the user.

[0051] The user interface 84 may also have one or more switches 90 actuated by the user to provide input to the controller 30 to control the operation of various components of the robot 12. A switch driver 92 may be provided to control the switches 90 and serve as an interface between the controller 30 and the switches 90.

[0052] The robot 12 may be provided with one or more cameras or stereo cameras (not shown) to obtain visible notifications from the user. In this way, the user may convey instructions to the robot 12 through gestures. For example, the user may wave their hands in front of the camera to instruct the robot 12 to stop or move away. In one embodiment, the user may perform a gesture in front of the camera to instruct the robot 12 to dock with the docking station 14.

[0053] The robot 12 may include an onboard Wi-Fi connection configured to allow for control of the robot 12 via a mobile device (e.g., a smartphone or tablet) or via a voice-controlled remote device (e.g., an Amazon-based Amazon Cloud Voice Services or Amazon Echo or Google with Google Assistant or Google Home ) remotely control the robot 12. For example, a user with a smart speaker device can speak a command, such as "Alex, ask [robot] to start cleaning," and via a Wi-Fi and / or Internet connection, the robot 12 can begin a cleaning operation cycle.

[0054] The smart device application for the robot 12 executed on the mobile device or remote device may include other command and control features, including but not limited to a scheduling feature to enable the user to select when the robot 12 will clean. Other functions of the smart device application may include a display of the robot's cleaning history, a landing page with current blogs and support videos related to the robot 12, and controls to automatically re-order accessories for the robot 12 when needed. The smart device application may also be configured to provide detailed notifications directly to the user regarding diagnostics, error warnings, and other information.

[0055] The controller 30 may be operatively coupled to various sensors on the robot 12 to receive inputs about the environment and inputs from the docking station 14, and may use the sensor inputs to control the operation of the robot 12. The sensors may detect features of the robot 12's surrounding environment (including, but not limited to, the docking station 14, walls, floors, chair legs, table legs, footstools, pets, consumers, and other obstacles). The sensor inputs may further be stored in the memory 68 or used to develop a map via the navigation / mapping system 28. Some exemplary sensors are Figure 3 Although it will be appreciated that not all of the sensors shown may be provided, additional sensors may be provided, and all possible sensors may be provided in any combination.

[0056] The robot 12 may include one or more distance sensors for position / proximity sensing. The distance sensors may be mounted to the housing 22 of the robot 12 (e.g., on the front of the housing 22) to determine the distance to obstacles in front of the robot 12. When an object is detected, the input from the distance sensors may be used to slow down, turn, and / or adjust the path of the robot 12. In one embodiment, the robot 12 may dock with the docking station 14 based on the input from the distance sensors.

[0057] The robot 12 may include one or more of collision sensors, wall sensors, cliff sensors, inertial measurement units (IMUs), lift sensors, box or tank sensors, and floor condition sensors, including any combination or multiples thereof.

[0058] The collision sensor determines a frontal or side impact to the robot 12 and may be integrated with the housing 22, such as with the bumper 36 ( Figure 2 The output signal from the collision sensor provides input to the controller 30 for selecting an obstacle avoidance algorithm.

[0059] Along-wall sensors (also called side wall sensors) may be located near the sides of the housing 22 and may include side-facing position sensors that provide distance feedback and control the robot 12 so that the robot 12 can follow near a wall without contacting the wall. Along-wall sensors may be optical, mechanical, or ultrasonic sensors, including reflectance or time-of-flight sensors. In another embodiment, no along-wall sensors are provided, and distance sensors are used as along-wall sensors.

[0060] The cliff sensor may be a ground-facing position sensor that provides distance feedback so that the robot 12 can avoid excessive falls on stairs, ledges, etc. The cliff sensor may be an optical, mechanical, or ultrasonic sensor, including a reflectance or time-of-flight sensor.

[0061] The IMU can use a combination of at least one accelerometer, gyroscope, and optionally a magnetometer or compass to measure and report the robot's acceleration, angular velocity, or magnetic field around the robot 12. The IMU can be an integrated inertial sensor located on the controller 30, and can be a nine-axis gyroscope or accelerometer to sense linear, rotational, or magnetic field acceleration. The IMU can use acceleration input data to calculate changes in velocity and attitude and communicate these changes to the controller 30 to navigate the robot 12 around the surface to be cleaned.

[0062] The lift sensor can detect when the robot 12 is lifted off the surface to be cleaned, for example, if a user picks up the robot 12. This information is provided as input to the controller 30, which can stop the operation of the vacuum motor 46, the brush roll motor 50, the pump motor 58, and the wheel motor 66 in response to the detected lift event. The lift sensor can also detect when the robot 12 is in contact with the surface to be cleaned, for example, when the user places the robot 12 back on the ground. Based on such input, the controller 30 can resume operation.

[0063] The robot 12 may optionally include one or more bin or tank sensors to detect characteristics or status of the collection bin 42 or supply tank 52. In one example, one or more pressure sensors may be provided for detecting the weight of the collection bin 42 or supply tank 52. In another example, one or more magnetic sensors may be provided for detecting the presence of the collection bin 42 or supply tank 52. In a non-limiting example, this information is provided as an input to the controller 30, which may prevent operation of the robot 12 until the collection bin 42 is emptied, the supply tank 52 is filled, or both are properly installed on the housing 22. The controller 30 may also direct the user interface 84 to provide a notification to the user that the collection bin 42 is full, the supply tank 52 is empty, or neither is installed.

[0064] The floor condition sensor detects the condition of the surface to be cleaned. For example, the robot 12 may be provided with an infrared (IR) dirt sensor, a stain sensor, an odor sensor, or a wet mess sensor. The floor condition sensor provides input to the controller 30, which may direct the operation of the robot 12 based on the condition of the surface to be cleaned, for example, by selecting or modifying a cleaning cycle. Optionally, the floor condition sensor may also provide input for display on a smartphone.

[0065] The robot 12 may have at least one receiver to detect a signal sent from the docking station 14. In one embodiment, a docking signal from the docking station 14 may be sent to the robot 12 and received by the receiver to guide the robot 12 to the docking station 14.

[0066] The robot 12 can operate in one of a set of modes. These modes can include at least a dry mode and a wet mode. During the wet operating mode, liquid is applied to the floor surface. During the dry operating mode, no liquid is applied to the floor surface.

[0067] In one embodiment, the robot 12 has interchangeable dry modules 120 and wet modules 122 for dry mode and wet mode, respectively. The dry modules 120 and wet modules 122 can each be installed and removed from the housing 22 as a unit. The housing 22 of the robot 12 includes a module receiver 124 in which the dry modules 120 and wet modules 122 can be installed one at a time. In the illustrated embodiment, the module receiver 124 can be located at the second end 34 of the housing 22 for installing or removing the module through the rear of the robot 12. Other locations of the module receiver 124 are also possible.

[0068] When the robot 12 is docked and interlocked with the docking station 14, the dry module 120 and the wet module 122 can be removed from the module receiver 124. In one embodiment, the interlocking feature 16 can be configured to physically interlock the housing 22 of the robot with the docking station without physically interlocking with the dry module 120 and the wet module 122. For example, the lockable member 20 can be provided at a position on the housing 22 where engagement of the lock 18 does not interfere with removal of the dry module 120 and the wet module 122. In another embodiment, the lock 18 is provided on the robot 12 and the lockable member 20 is provided on the docking station 14, and the lock 18 can be provided at a position on the housing 22 where movement of the lock 18 and engagement of the lock with the lockable member 20 does not interfere with removal of the dry module 120 and the wet module 122. In either case, when the robot 12 is docked and interlocked with the docking station 14 , the dry module 120 and the wet module 122 may be removed from the housing 22 for emptying or refilling while the housing 22 remains locked to the docking station 14 .

[0069] Reference Figure 4 , the dry mode module or dry module 120 may include a collection box 42. The dry module 120 may optionally include a dry module latch 126 or other mechanism for securing the dry module 120 within the module receiver 124. The dry module 120 is inserted into the module receiver 124 to operate the robot 12 in the dry mode. During the dry operating mode, a partial vacuum may be generated by the suction source 40 at the suction nozzle 38 to collect liquid and / or debris in the collection box 42. During the dry operating mode, the brush roller 48 and / or the edge brush 94 may rotate. In the illustrated embodiment, the brush roller 48 and the edge brush 94 remain on the housing 22 in both modes. In alternative embodiments, one or both of the brush roller 48 and the edge brush 94 may be included on the dry module 120.

[0070] The wet mode module or wet module 122 may include a supply tank 52. The wet module 122 may optionally include a wiping assembly. The wiping assembly may include at least one wiping pad 130 to wipe the floor surface. The wiping pad 130 may include one or more different agitation or cleaning elements configured to wipe the surface to be cleaned. Some non-limiting examples of cleaning elements for the wiping pad 130 include a microfiber pad or a wet scrubbing pad. The wiping pad 130 may be disposable or reusable. In the illustrated embodiment, the wiping assembly includes two wiping pads 130.

[0071] Reference Figure 3, a drive assembly including at least one wiping pad motor 132 may be provided within the wet module 122 to drive at least one wiping pad 130. In the illustrated embodiment with a plurality of wiping pads 130, the wiping pads 130 may be operated by a common wiping pad motor 132 or a single wiping pad motor 132. The wiping pad motor 132 is configured to drive at least a portion of the wiping pad 130 around a rotation axis that is substantially vertical relative to the surface to be cleaned. A wiping pad motor driver 134 may be provided to control each wiping pad motor 132. The wiping pad motor driver 134 may serve as an interface between the controller 30 and its corresponding motor. The wiping pad motor driver 134 may be an integrated circuit chip (IC). It is also contemplated that a single wiping pad motor driver 134 may control a plurality of wiping pad motors 132 simultaneously.

[0072] The wet module 122 may optionally include a wet module latch 136 or other mechanism for securing the wet module 122 within the module receiver 124. The wet module 122 is inserted into the module receiver 124 to operate the robot 12 in the wet mode.

[0073] During the wet operation mode, liquid from the supply tank 52 is applied to the floor surface, and the wiping pad 130 can rotate. In one embodiment, the wiping assembly can remove cleaning fluid and debris from the surface to be cleaned without using suction. The cleaning fluid and debris can be collected by the wiping pad 130. In another embodiment, during the wet mode, a partial vacuum can be generated by the suction source 40 at the suction nozzle 38 to collect liquid and / or debris in a space on the robot 12. In one example, the wet module 122 may include a collection chamber for recovered liquid and / or debris.

[0074] The module receiver 124 may include suitable connections to establish the flow of air, debris, cleaning fluid, and power between the modules and components within the housing 22 as needed. For example, the module receiver 124 may include suitable connections to establish the flow of air and debris between the suction nozzle 38, the suction source 40, and the collection box 42, i.e., the working air path through the collection system 24. The module receiver 124 may include suitable connections to establish the flow of cleaning fluid between the supply tank 52 and the fluid distributor 54, i.e., the supply path through the fluid delivery system 25. The module receiver 124 may also include suitable connections to establish the flow of power between the battery 81 and one or more wiping pad motors 132 of the wet module 122.

[0075] Figure 6 Shown for Figure 1 An embodiment of the docking station 14 of the autonomous floor cleaning system 10. It should be noted that Figure 6The illustrated docking station 14 is just one example of a docking station that may be used with the autonomous floor cleaning system 10 and the robot 12 , and other docking stations may be used with the autonomous floor cleaning system 10 and the robot 12 .

[0076] The docking station 14 can charge the power source (e.g., battery 81) of the robot 12. In one example, the docking station 14 can be connected to a household power source such as an A / C power outlet and can include a converter 142 for converting AC voltage to DC voltage to charge the power source on the robot 12.

[0077] The docking station 14 may include various sensors and transmitters (not shown) for monitoring the status of the robot 12, thereby enabling autonomous docking functions, communication with the robot 12, and network and / or Bluetooth connectivity features.

[0078] In another embodiment, in addition to or as an alternative to charging the robot 12, the docking station 14 may perform service, maintenance, or diagnostic checks on the robot 12. For example, the docking station 14 may be configured to automatically empty the collection bin 42 and / or automatically fill or refill the supply tank 52. To perform service, maintenance, and / or diagnostic checks on the robot 12, the docking station 14 may first engage the lock 18 to physically interlock the robot 12 and the docking station 14, and then proceed to perform at least one service, maintenance, and / or diagnostic check on the robot 12.

[0079] The docking station 14 includes a housing 144 and electrical contacts or charging contacts 146 disposed on the housing 144, which are adapted to cooperate with charging contacts 82 on the outer surface of the robot 12 to charge the battery 81 of the robot (see Figure 3 ).

[0080] The housing 144 of the docking station may have a base plate 148 and a back guard 150. The base plate 148 may extend generally horizontally to be arranged on a floor support. The back guard 150 is generally perpendicular to the floor surface on which the base plate 148 is placed. Other shapes and configurations of the housing 144 are possible.

[0081] The robot 12 may be docked by at least partially driving onto the base plate 148, optionally until the robot 12 encounters the backstop 150. The charging contacts 146 of the docking station 14 may be located on the base plate 148, thereby allowing the charging contacts of the docking station to contact corresponding charging contacts 82 on the underside 44 of the robot 12 when the robot 12 is driven onto the base plate 148. Alternatively, the charging contacts 146 may be provided on the backstop 150 or on other portions of the housing 144.

[0082] In one embodiment, the positive and negative charging contacts 146 are used to detect a complete circuit when the robot 12 is docked with the docking station 14. In other embodiments, a single charging contact 146 or more than two charging contacts 146 may be utilized. The additional charging contacts will provide redundancy if one of the other charging contacts becomes dirty, blocked, or damaged. In other embodiments of the docking station 14, additional contacts may be used to transfer data and information between the robot 12 and the docking station 14.

[0083] The docking station 14 may include a portion of an interlocking feature 16 for physically interlocking the robot 12 and the docking station 14. Figure 1 As shown, the docking station 14 may include a lock 18, which may be disposed on a base plate 148. The lockable member 20 engaged by the lock 18 may be disposed on the underside 44 of the robot 12. In another embodiment, the lock 18 may be disposed on the underside 44 of the robot 12, and the lockable member 20 may be disposed on the base plate 148 of the docking station 14. In yet another embodiment, the lock 18 may be disposed on a backstop 150, and the lockable member 20 may be disposed on a side of the robot 12. In yet another embodiment, the lock 18 may be disposed on a side of the robot 12, and the lockable member 20 may be disposed on the backstop 150.

[0084] In one embodiment, when the wet module 122 is installed and the robot 12 is docked with the docking station 14, the interlock feature 16 secures the robot 12 to the docking station 14 until a predetermined criterion is met. The predetermined criterion may be the removal of the wet module 122 from the housing 22 and the installation of the dry module 120. This may prevent a user from attempting to fill the supply tank 52 under a tap while the wet module 122 is installed on the robot 12, which may cause water to spill into the interior of the robot 12. Conversely, the interlock feature 16 encourages the user to separate the wet module 122 from the robot 12 before refilling by preventing the robot 12 from being separated from the docking station 14 while the wet module 122 is still installed. When the wet module 122 is removed and the dry module 120 is installed in its place, the lock 18 may disengage the lockable member 20, thereby allowing the robot 12 to be separated from the docking station 14. Optionally, if the dry module 120 is installed when the robot 12 is docked with the docking station 14, the lock 18 does not engage the lockable member 20.

[0085] An activation switch 152 may be provided for controlling the lock 18 and may be operable to move between an on and off position. When the activation switch 152 is on, the lock 18 is engaged. When the activation switch 152 is off, the lock 18 is disengaged. When the robot 12 is docked with the docking station 14, the activation switch is configured to be actuated, i.e., moved to the on position.

[0086] In one embodiment, the activation switch 152 may include an optical switch on the docking station 14 that is obstructed by the wet module 122 but not by the dry module 120 to indicate the presence of the wet module 122 in the robot 12. When the robot 12 is docked with the dry module 120, the optical switch is not obstructed and the lock 18 is not engaged.

[0087] In another embodiment, the activation switch 152 may include a mechanical switch on the docking station 14 that is physically engaged by the robot 12 to move to the on position. In yet another embodiment, the wet module 122, rather than the dry module 120, may include a switch actuator that physically engages the activation switch 152 when the robot 12 is docked with the docking station 14. In such an embodiment, when the robot 12 is docked with the dry module 120, the mechanical activation switch 152 is not physically engaged and the lock 18 is not engaged.

[0088] Optionally, an override may be provided on the robot 12, the docking station 14, and / or a smart device application executing on a mobile or remote device to disengage the interlock feature 16 even if the predetermined criteria are not met.

[0089] Figure 7 1 is a flow chart illustrating one embodiment of a method 200 for docking a robot 12 on a docking station 14. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, may include additional or intermediate steps, or the described steps may be divided into multiple steps without departing from the present invention.

[0090] At step 202, the robot 12 is docked with the docking station 14. At step 204, it is determined whether a wet module 122 is present on the robot 12. If a wet module 122 is not present, the method 200 proceeds to step 206, and the interlocking feature 16 remains disengaged. If a wet module 122 is present, the method 200 proceeds to step 208, and the interlocking feature 16 is engaged. Subsequently, if a dry module 120 is replaced with a wet module 122, and it is determined at step 210 that a dry module 120 is now present on the robot 12, the interlocking feature 16 is disengaged at step 212.

[0091] Figures 8 to 9 FIG. 1 is a schematic diagram of an autonomous floor cleaning system 10 having an alternative embodiment of a docking station 14 according to another embodiment of the present invention. The docking station 14 can be folded down to receive the robot 12, such as Figure 8 As shown, and can be folded upward to move the robot 12 to a substantially vertical position, or alternatively to another off-the-ground position, such as Fig. 9The interlocking feature 16 (shown in phantom) can physically interlock the robot 12 and the docking station 14 so that the robot 12 and the docking station 14 can be moved from the lower position or docking position (an example of which is shown in FIG. Figure 8 ) to a stowed position (an example of which is shown in Fig. 9 The foldable docking station 14 and interlocking features 16 improve the stowability of the docked robot 12. For a more compact profile, the docking station 14 can also be folded when the robot 12 is not docked, which can allow the robot 12 to clean more floor space around the docking station 14.

[0092] In one embodiment, the base plate 148 of the docking station 14 can be rotated upward for storage. The base plate 148 of the docking station 14 can be folded up and down automatically or manually. If it is automatic, the docking station 14 can rotate downward and release the robot 12 for cleaning. Cleaning can be manually initiated by the user, or it can be automatically initiated during the planned cleaning time. In the event of a return-to-dock, for example, when cleaning is completed, the battery 81 needs to be charged, the collection box 42 (if any) needs to be emptied and / or the supply tank (if any) needs to be filled, the robot 12 docks with the docking station 14, and the base plate 148 rotates upward to stow the robot 12 until the next cleaning, the battery 81 is charged, the collection box 42 (if any) is emptied and / or the supply tank (if any) is filled.

[0093] Fig.10 The robot 12 is docked at the reference Figures 8 to 9 Flowchart of one embodiment of the method 300 at the docking station 14. The order of the steps discussed is for illustrative purposes only and is not meant to limit the method in any way, as it should be understood that the steps may be performed in a different logical order, may include additional steps or intermediate steps, or the described steps may be divided into multiple steps without departing from the invention.

[0094] At step 302, a return docking event occurs. Examples of return docking events include, but are not limited to, completion of a cleaning cycle of operation, the battery 81 being below a predetermined level, a user commanding the robot 12 to dock (e.g., by pressing a dock or home button on the robot 12 or mobile device), the collection bin 42 being filled, or the supply tank 52 being empty. At step 304, the docking station 14 is moved to a lower position or docking position, if necessary. At step 306, the robot 12 is docked with the docking station 14. At step 308, the interlocking feature 16 is engaged. At step 310, the docking station 14 is moved with the robot 12 to a stowed position. This lifts the robot 12 off the floor surface.

[0095] Optionally, upon completion of the return docking event at step 312, the docking station 14 may be moved to a lower position or docking position, thereby lowering the robot 12 back to the floor surface. At step 316, the interlocking feature 16 may be disengaged. The robot 12 may now be free to leave the docking station 14.

[0096] Examples of completion of the return docking event of step 312 include, but are not limited to, the start of a cleaning operation cycle, the battery 81 has been charged, the user has commanded the robot 12 to undocking, the collection bin 42 is empty, or the supply tank 52 has been filled.

[0097] Any of the embodiments of the docking station 14 disclosed herein may include a waste discharge feature that moves debris from the robot 12 into a larger container with a plastic bag.

[0098] Any of the embodiments of the docking station 14 disclosed herein may include a drain conduit for moving liquids from the robot 12 into a larger container or a household drain line.

[0099] Any of the embodiments of the docking station 14 disclosed herein may include a supply feature for supplying cleaning fluid to the robot 12 .

[0100] To the extent not already described, the different features and structures of the various embodiments of the present invention may be used in combination with each other as desired, or may be used alone. The fact that an autonomous floor cleaning system, robot, or docking station is described herein as having the described features does not mean that all of these features must be used in combination, but is done so here for the sake of brevity. Any of the disclosed docking stations may be provided independently of any of the disclosed robots, and vice versa. In addition, although multiple methods are disclosed herein, one of the disclosed methods may be performed independently, or more than one of the disclosed methods may be performed by a robot or docking station, including any combination of the methods disclosed herein. Therefore, whether or not new embodiments are explicitly described, the various features of different embodiments may be mixed and matched in various cleaning equipment configurations as desired to form new embodiments.

[0101] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 944,602, filed on December 6, 2019, the entire contents of which are incorporated herein by reference.

[0102] The above description relates to general and specific embodiments of the present disclosure. However, without departing from the spirit and broader aspects of the present disclosure as defined in the appended claims, various changes and variations may be made, which will be interpreted according to the principles of patent law including the doctrine of equivalents. In this way, the present disclosure is proposed for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the present disclosure, or the scope of the claims should not be limited to the specific elements shown or described in conjunction with these embodiments. For example, any reference to an element in the singular form using the article "one", "an", "the" or "said" should not be interpreted as limiting the element to the singular form.

[0103] Likewise, it should also be understood that the appended claims are not limited to the expressions and specific components or methods described in the detailed description, which may vary between specific embodiments falling within the scope of the appended claims. With respect to any Markush group relied upon herein to describe specific features or aspects of various embodiments, different, special and / or unexpected results may be obtained from each member of the respective Markush group independent of all other Markush members. Each member of the Markush group may be relied upon individually or in combination and provides adequate support for a specific embodiment within the scope of the appended claims.

Claims

1. An autonomous floor cleaning system comprising: An autonomous floor cleaner comprising an autonomously movable housing, a drive system configured to autonomously move the housing over a surface to be cleaned, and comprising a controller, a battery, and a first charging contact; a docking station configured to dock the autonomous floor cleaner and comprising second charging contacts adapted to cooperate with the first charging contacts to charge a battery of the autonomous floor cleaner; as well as an interlocking feature to physically interlock the autonomous floor cleaner and the docking station, the interlocking feature comprising a lockable member and a lock engageable with the lockable member to interlock the autonomous floor cleaner to the docking station; wherein the autonomous floor cleaner includes one of the lockable member and the lock, and the docking station includes the other of the lockable member and the lock; Wherein, the autonomous floor cleaner comprises interchangeable modules, and the interchangeable modules comprise at least: a wet mode module including a supply tank configured to contain a liquid, the autonomous floor cleaner being operable in a wet mode of operation in which the autonomous floor cleaner applies a cleaning fluid to a floor surface; and a dry mode module including a collection bin configured to contain collected debris, the autonomous floor cleaner being operable in a dry mode of operation in which the autonomous floor cleaner does not apply cleaning fluid to the surface to be cleaned; wherein the autonomously movable housing comprises a module receiver configured to receive one of the interchangeable modules at a time, each of the interchangeable modules being installable to and removable from the autonomously movable housing as a unit; and Wherein the docking station includes a lock activation switch configured to activate the lock to engage the lockable member, wherein the lock activation switch includes an optical switch configured to be obstructed by the wet mode module and configured to be unobstructed by the dry mode module.

2. The autonomous floor cleaning system of claim 1, wherein: The lock includes a shackle, and the lockable member includes an opening through which the shackle can pass.

3. The autonomous floor cleaning system of claim 1, wherein: The lock includes a U-shaped member on the docking station, and the lockable member includes an opening on the autonomous floor cleaner through which the U-shaped member can pass.

4. The autonomous floor cleaning system of claim 1, wherein: The autonomous floor cleaner comprises at least one of: a fluid delivery system configured to store a cleaning fluid and deliver the cleaning fluid to a surface to be cleaned, wherein the fluid delivery system comprises a supply tank and at least one fluid dispenser in fluid communication with the supply tank; and The collection system includes a working air path passing through the autonomously movable housing and having an air inlet and an air outlet, a suction nozzle defining the air inlet, a suction source in fluid communication with the suction nozzle, and a collection box.

5. The autonomous floor cleaning system of claim 1, wherein: The wet-mode module includes at least one wiping pad configured to wipe a surface to be cleaned.

6. The autonomous floor cleaning system of claim 1, wherein: The interlock feature is configured to physically interlock the autonomously movable housing to the docking station without physically interlocking the wet mode module to the docking station such that the wet mode module can be removed from the module receiver with the lock engaged with the lockable member.

7. The autonomous floor cleaning system of claim 1, wherein: The docking station includes a housing having a base plate extending substantially horizontally to be arranged on a floor support and a back member substantially perpendicular to the floor support on which the base plate is arranged.

8. The autonomous floor cleaning system of claim 7, wherein: The autonomous floor cleaner includes one of the lockable member and the lock on an underside of the autonomously movable housing, and a base plate of the docking station includes the other of the lockable member and the lock.

9. The autonomous floor cleaning system of claim 1, wherein: The docking station includes a lock activation switch configured to activate the lock to engage the lockable member, and the lock activation switch is configured to be automatically actuated by docking of the autonomous floor cleaner with the docking station.

10. The autonomous floor cleaning system of claim 1, wherein: The docking station includes a lock activation switch, wherein the lock activation switch is operable to move between a first position in which the lock is engaged with the lockable member and a second position in which the lock is disengaged from the lockable member, wherein the lock activation switch is configured to be automatically moved to the first position by docking of the autonomous floor cleaner with the docking station.

11. The autonomous floor cleaning system of claim 1 , wherein: The docking station includes a foldable portion movable between a docking position in which the autonomous floor cleaner can dock with the docking station and a stowed position in which the autonomous floor cleaner is lifted off a floor surface.

12. A method for docking the autonomous floor cleaner of the autonomous floor cleaning system according to any one of claims 1 to 11 with the docking station, the method comprising: docking the autonomous floor cleaner on the docking station; as well as The autonomous floor cleaner is interlocked with the docking station by engaging a lock on one of the autonomous floor cleaner and the docking station with a lockable member on the other of the autonomous floor cleaner and the docking station.

13. The method according to claim 12, comprising: determining whether predetermined lockout criteria are met; Wherein, interlocking the autonomous floor cleaner with the docking station by locking the autonomous floor cleaner to the docking station comprises automatically interlocking the autonomous floor cleaner with the docking station if the predetermined locking criteria are met.

14. The method according to claim 13, wherein: Determining whether the predetermined locking criteria are met includes: determining whether a wet mode module is present on the autonomous floor cleaner, the wet mode module being a supply tank configured to contain a liquid, and wherein automatically interlocking the autonomous floor cleaner with the docking station by locking the autonomous floor cleaner to the docking station if the predetermined locking criteria are met includes: automatically interlocking the autonomous floor cleaner with the docking station by locking the autonomous floor cleaner to the docking station if the wet mode module is present on the autonomous floor cleaner.

15. The method according to claim 13, comprising: determining whether predetermined unlocking criteria are met; as well as If the predetermined unlocking criterion is met, the autonomous floor cleaner is automatically unlocked from the docking station.

16. The method according to claim 15, wherein: Determining whether the predetermined unlocking criteria are met includes: determining whether a dry mode module is present on the autonomous floor cleaner, the dry mode module including a collection box configured to hold collected debris, and wherein automatically unlocking the autonomous floor cleaner from the docking station if the predetermined unlocking criteria are met includes: automatically unlocking the autonomous floor cleaner from the docking station if the dry mode module is present on the autonomous floor cleaner.

17. The method according to claim 12, comprising: determining whether predetermined unlocking criteria are met; as well as If the predetermined unlocking criterion is met, the autonomous floor cleaner is automatically unlocked from the docking station.

18. The method according to claim 17, wherein: Determining whether the predetermined unlocking criteria are met includes: determining whether a dry mode module is present on the autonomous floor cleaner, the dry mode module including a collection box configured to hold collected debris, and wherein automatically unlocking the autonomous floor cleaner from the docking station if the predetermined unlocking criteria are met includes: if the dry mode module is present on the autonomous floor cleaner, automatically unlocking the autonomous floor cleaner from the docking station if the predetermined unlocking criteria are met.

19. The method of claim 17, wherein determining whether the predetermined unlocking criteria are met comprises determining whether a back-docking event is complete, and wherein: Automatically unlocking the autonomous floor cleaner from the docking station if the predetermined unlocking criteria is met includes automatically unlocking the autonomous floor cleaner from the docking station upon completion of the return-to-docking event.

20. The method according to claim 17, wherein: The predetermined unlocking criteria include at least one of: a cleaning operation cycle is started, a battery has been charged, a user has commanded the autonomous floor cleaner to undock, a collection bin of the autonomous floor cleaner is empty, or a supply tank of the autonomous floor cleaner has been filled.

21. The method of claim 12, comprising moving the autonomous floor cleaner from a docked position to a stowed position after interlocking the autonomous floor cleaner with the docking station.

22. The method according to claim 21, wherein: Moving the autonomous floor cleaner from the docked position to the stowed position includes folding upward a portion of the docking station and lifting the autonomous floor cleaner to a substantially upright storage position.

23. The method according to claim 21, comprising: determining whether predetermined unlocking criteria are met; as well as If the predetermined unlocking criterion is met, the autonomous floor cleaner is moved back to the docked position.

24. The method according to claim 12, wherein: Docking the autonomous floor cleaner at the docking station includes driving the autonomous floor cleaner at least partially onto a base plate of the docking station until the autonomous floor cleaner encounters a backstop of the docking station.

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