Robot Bumper Hall Sensor Layout for Precise Impact Zone Detection
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Solution Overview
Problem
Autonomous floor-cleaning robots face limitations in detecting the location and force of impacts with obstacles due to the limited number of switches and suspension points, which restricts the number of detectable zones and inability to determine the degree or force of impact effectively.
Innovation Solution
The use of Hall sensors oriented at different angles to generate signals responsive to the movement of a bumper frame relative to the robot body, allowing for the identification of multiple impact regions and determination of impact force without the need for additional sensors, by coupling sensors with magnets to detect changes in magnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional switches and suspension points are used for obstacle detection, then the robot can detect impact events, but the number of detectable zones is limited and the force of impact cannot be determined effectively
Solution Approach 1:
The patent changes the detection parameter from mechanical switch activation to magnetic field sensing. Hall effect sensors detect changes in magnetic field strength caused by bumper frame movement, enabling continuous measurement of impact force and position without requiring multiple discrete mechanical switches. This parameter change allows a single sensor to provide multiple detection zones and force measurement capabilities.
2Loss of information
If multiple sensors are added to increase the number of detectable zones, then obstacle detection coverage improves, but device complexity and cost increase
Solution Approach 1:
The Hall effect sensor serves multiple functions simultaneously: it detects the position of the bumper frame to identify impact zones, measures the magnitude of frame movement to determine impact force, and provides continuous data for navigation decisions. This multi-functionality allows a single sensor type to replace what would traditionally require multiple specialized sensors.
Solution Approach 2:
The patent adds a magnetic field detection dimension to the traditional mechanical switching approach. By sensing changes in magnetic field strength and orientation, the system extracts positional and force information without adding mechanical complexity. The magnetic field serves as an additional detection dimension that enriches the data from a single sensor.
3Strength
If rigid bumpers with high impact force requirements are used, then impact energy is absorbed by springs, but the sensor triggering requires several millimeters of deflection which delays detection
Solution Approach 1:
The patent replaces the mechanical switch-triggering system with a magnetic field sensing system. Instead of relying on mechanical switches that require several millimeters of bumper deflection to activate, Hall effect sensors detect the magnetic field changes caused by bumper frame movement. This substitution eliminates the mechanical threshold requirement and enables earlier detection of impact events while maintaining the mechanical bumper's strength and energy absorption properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables the robot to accurately identify impact zones and determine the force of impact, allowing for improved navigation and obstacle detection with increased precision, potentially identifying up to five or more impact regions and locating obstacles with accuracy within centimeters.
Implementation Method 1
a first sensor at a first orientation with respect to the bumper frame that is configured to generate a first signal in response to a magnitude and a direction of movement of the bumper frame relative to the robot body
Data Source
AI summary
A mobile cleaning robot can include a robot body, a bumper, and a bumper impact system. The bumper can be connected to and supported by the robot body. The bumper impact system can include a first sensor connected to the body in a first orientation with respect to the body and the bumper. The bumper impact system can include a second sensor connected to the body in a second orientation with respect to the body and the bumper different from the first orientation. The first sensor and the second sensor can together be configured to sense an impact region of the bumper based on a magnitude and a direction of movement of the bumper relative to the robot body.