Sweeper Bin Optical Fill Detection for Coverage Robots

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Solution Overview

Problem

Autonomous coverage robots lack an effective method to detect when their cleaning bins are full, leading to inefficient operation and potential interruption of autonomous tasks.

Innovation Solution

The implementation of a bin-full detection system using a signal emitter and receiver within the cleaning bin, where the accumulation of debris blocks the signal, triggering a bin full indicator, and a controller monitors the signal to determine when the bin needs servicing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bin-full detection system is implemented using an emitter and receiver, then the robot can detect bin fullness accurately and maintain continuous operation, but the device complexity increases due to additional sensors and control mechanisms

Engineering Contradiction:

Improvebin fullness detection accuracyVSAvoiddetection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical level sensors or manual inspection methods with an optical detection system using an emitter and receiver. The optical system detects debris accumulation by measuring light transmission or reflection changes, providing automated bin fullness detection without mechanical contact, thereby improving reliability while maintaining relatively simple device architecture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Area of stationary object

If the emitter and receiver are disposed remotely within the bin, then the detection system can monitor the entire bin volume, but the signal may be blocked by debris accumulation before reaching the receiver

Engineering Contradiction:

Improvebin volume coverageVSAvoidsignal blockage by debris

Core Design Contradiction:

Area of stationary objectVSDifficulty of detecting and measuring

Solution Approach 1:

The patent positions the emitter and receiver at specific locations within the bin (remotely disposed on interior surfaces) to maximize the detection volume. The system leverages the local optical properties of debris accumulation - as debris fills the bin, it progressively blocks the optical path between the remotely positioned emitter and receiver, enabling volume-wide monitoring through strategically placed sensors.

Inventive Principle:

Principle #3Local quality

3Ease of operation

If a human perceptible indicator is added to notify users of bin fullness, then the system provides clear service requirements, but the device complexity increases with additional indicator components

Engineering Contradiction:

Improveuser notification clarityVSAvoidindicator system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent employs a human perceptible indicator that likely utilizes color changes or visual signals to notify users of bin fullness. This provides clear, intuitive service requirements without complex electronic interfaces or multiple notification components, maintaining ease of operation while minimizing added device complexity through simple visual feedback mechanisms.

Inventive Principle:

Principle #32Color changes

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 system allows for timely intervention and maintenance, ensuring continuous operation by detecting bin fullness accurately and providing a human perceptible indicator for service requirements.

Implementation Method 1

The sweeper bin includes an emitter disposed on an interior surface of the bin and a receiver disposed remotely from the emitter on the interior surface of the bin. The receiver is configured to receive a signal emitted by the emitter.

Methodology Applied

Scientific EffectSignal emission and detection: Light

Implementation Method 2

The emitter and the receiver are disposed such that a threshold level of accumulation of debris in the sweeper bin blocks the receiver from receiving emissions from the emitter.

Methodology Applied

Scientific EffectSignal blocking by debris accumulation: Absorption (EM radiation)

Data Source

PatentUS10244915B2Coverage robots and associated cleaning bins

Publication Date: 2019.04.02 IROBOT CORP

AI summary

An autonomous coverage robot includes a chassis, a drive system configured to maneuver the robot, and a cleaning assembly. The cleaning assembly includes a cleaning assembly housing and at least one driven sweeper brush. The robot includes a controller and a removable sweeper bin configured to receive debris agitated by the driven sweeper brush. The sweeper bin includes an emitter disposed on an interior surface of the bin and a receiver disposed remotely from the emitter on the interior surface of the bin and configured to receive an emitter signal. The emitter and the receiver are disposed such that a threshold level of accumulation of debris in the sweeper bin blocks the receiver from receiving emitter emissions. The robot includes a bin controller disposed in the sweeper bin and monitoring a detector signal and initiating a bin full routine upon determining a bin debris accumulation level requiring service.