Modular Coverage Robot Architecture for Easy Module Replacement
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Solution Overview
Problem
Existing coverage robots face significant serviceability issues due to the need for entire unit replacement when individual components fail, leading to high repair costs or premature disposal, as they lack modular design for component replacement and maintenance.
Innovation Solution
A modular coverage robot design allowing for the independent removal and replacement of components such as the cleaning head, wheel modules, vacuum bin, and battery, with tool-less electrical connections and secure fastening, enabling easy maintenance and extension of the robot's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the robot is designed as a non-modular unit, then the structure is simpler and easier to manufacture, but the serviceability deteriorates and the entire robot must be replaced or sent for repair when individual components fail
Solution Approach 1:
The robot is divided into distinct modular components including a base unit, cleaning head, battery pack, and removable modules. Each module can be independently removed, replaced, or serviced without affecting the entire robot system, directly improving ease of repair while managing complexity through standardized interfaces
Solution Approach 2:
The base unit is designed with universal receptacles that can accept multiple different module types (cleaning modules, polishing modules, charging modules). This multi-functionality allows the same base unit to serve various purposes through module interchangeability, improving serviceability without proportionally increasing overall system complexity
2Ease of manufacture
If the robot is designed as a non-modular unit, then the manufacturing process is simpler, but the manufacturing cost increases due to complete unit replacement requirements
Solution Approach 1:
The robot system is segmented into reusable base units and replaceable modules. When a module wears out or fails, only that specific module is replaced rather than the entire robot, significantly reducing material waste while keeping manufacturing processes relatively simple through standardized mass-producible modules
Solution Approach 2:
The modular design enables selective discarding and recovery of components. Worn modules can be discarded or sent for refurbishment while the base unit and other modules are recovered and reused, reducing overall material consumption and manufacturing costs associated with complete unit replacement
3Adaptability or versatility
If the robot lacks modular components, then the structure is more integrated and stable, but the adaptability deteriorates and functional changes require complete robot replacement
Solution Approach 1:
The base unit incorporates universal receptacles designed to accommodate multiple types of modules through standardized interfaces. This allows the robot to adapt to different cleaning needs (sweeping, vacuuming, polishing) by simply changing modules while maintaining structural stability through the consistent base unit design
Solution Approach 2:
The system is segmented into a stable base unit and interchangeable functional modules. The base unit maintains structural stability with its fixed receptacles, while the removable modules provide functional adaptability, allowing users to swap between different cleaning head types without affecting the overall structural integrity
4Duration of action of moving object
If the robot uses fixed components, then the design is more straightforward and reliable, but the operational life deteriorates due to complete replacement requirements
Solution Approach 1:
The robot is segmented into a long-lasting base unit and replaceable wear modules. The base unit can remain in service for extended periods while only the consumable modules (cleaning heads, brushes, filters) are periodically replaced, significantly extending the overall operational life of the robot system
Solution Approach 2:
The modular architecture enables selective recovery and reuse of the base unit and functional modules. When one module reaches end-of-life, it can be discarded or refurbished while the base unit and other modules continue operating, extending the total operational lifespan compared to fixed-component designs
Data Source
AI summary
A coverage robot including a chassis, multiple drive wheel assemblies disposed on the chassis, and a cleaning assembly carried by the chassis. Each drive wheel assembly including a drive wheel assembly housing, a wheel rotatably coupled to the housing, and a wheel drive motor carried by the drive wheel assembly housing and operable to drive the wheel. The cleaning assembly including a cleaning assembly housing, a cleaning head rotatably coupled to the cleaning assembly housing, and a cleaning drive motor carried by cleaning assembly housing and operable to drive the cleaning head. The wheel assemblies and the cleaning assembly are each separately and independently removable from respective receptacles of the chassis as complete units.