US20020124343A1 - Controlled self operated vacuum cleaning system - Google Patents

Abstract

A controlled self operating vacuum cleaning system which comprises a stationary housing for the storage of a mobile vacuum cleaner apparatus and where the housing is provided with an automatically openable and closable closure allowing exit and entry of the mobile vacuum cleaner unit. The mobile unit is driven by an internal drive motor which is powered by one or more batteries carried by the mobile vacuum cleaner unit. At preestablished times and preestablished time intervals, the closure of the housing will automatically open providing for ingress and egress and the mobile vacuum cleaner unit will exit and randomly clean the carpet of a certain specified area for a predetermined time period. The mobile vacuum cleaner unit is provided with obstacle detectors for causing the mobile unit to move beyond an obstacle, if it contacts an obstacle, as well as detectors for detecting the edge of a staircase and the edge of a carpet to cause the mobile unit to remain on the carpeted area. Upon return to the housing after the predetermined time interval, the mobile vacuum cleaner unit is automatically connected to a recharging electrical circuit for recharging the batteries of the mobile vacuum cleaner unit and simultaneously an additional vacuum dirt collection system causes evacuation of the dirt collected by the mobile cleaner unit.

Description

BACKGROUND OF THE INVENTION
• 1. Field of the Invention[0001]
• This invention relates in general to certain new and useful improvements in vacuum cleaner systems and more particularly, to a vacuum cleaning system which is automatically operable at preselected times and for preselected time intervals requiring little or no manual intervention.[0002]
• 2. Brief Description of the Related Art[0003]
• Although electrically operated carpet and rug cleaning vacuum cleaners have been commercially available for more than fifty years, very few significant advances have been made in the art of these vacuum cleaners. The advances made since the inception of the original vacuum cleaner are generally involved in superior motors, better brushes and to a large degree, enhanced aesthetics. However, in essentially all cases, commercially available rug and carpet vacuum cleaners still require a substantial amount of manual attention in both operation and periodic maintenance.[0004]
• In essentially all cases, one must manually remove the vacuum cleaner from a storage location, such as a garage or a closet, plug the vacuum cleaner into a source of electrical power and physically move the vacuum cleaner across a selected carpet area. When the user has finished cleaning a selected area, the user must then disconnect and wind up the electrical cord and carry the vacuum cleaner to the same storage location. Frequently, the user must remove the debris collection bag and empty the same and then reinstall the bag into the vacuum cleaner. Thus, a great deal of manual intervention is necessarily required in the cleaning of a carpet or a rug.[0005]
• There has been one proposal for a somewhat automatically operable vacuum cleaner set forth in U.S. Pat. No. 5,341,540 dated Aug. 30, 1994 to Soupert, et al. The apparatus in the Soupert, et al. patent, which is described as an autonomous apparatus for the automatic cleaning of ground areas is essentially a preprogrammed, controlled vacuum cleaner operating much in the same manner as a numeric controlled tool or a computer controlled tool. In Soupert, et al., the vacuum cleaner is pre-programmed with a series of instructions stored in a computer memory in the apparatus. The apparatus is then caused to move in a prescribed path and only in that prescribed path relative to a fixed reference beam. In fact, the apparatus can only operate in response to location control from that fixed reference beam.[0006]
• Although the device in the Soupert, et al. patent does have means for moving on its own stored source of power, it does not have means to exit a housing at a prescribed time and randomly cover an entire carpeted area and does not have other features as for example, recharging, automatically cleaning of the debris from the vacuum cleaner and the like.[0007]
• There have also been developed in the prior art various types of bumper obstacle detection sensors. One such bumper obstacle detection sensor is described in U.S. Pat. No. 4,968,878 dated Nov. 6, 1990 to Pong et al. This obstacle detector system in the Pong et al. apparatus relies upon transceiver directed light beams and reflectors for detecting the presence of an obstacle. U.S. Pat. No. 5,208,521 dated May 4, 1993 to Aoyama discloses a control system for a self moving vehicle which is actually in the nature of a vacuum cleaner for the cleaning of carpeted areas. However, the Aoyama patent is primarily concerned with the control system itself for purposes of correcting yaw, speed of the device, etc. A complex feedback and error signal control means is used to achieve this precise control. To this extent, Aoyama does disclose a self moving vacuum cleaner, although the vacuum cleaner must move in response to pre-programmed control signals for control of direction and the like, but beyond this is not automatically operable, as such.[0008]
• There have also been many robotic-type apparatus used for performing a variety of tasks. One such robotic apparatus is described as a robotic decontamination apparatus in U.S. Pat. No. 5,147,002 dated Sep. 15, 1992 to Hughes. This apparatus is specifically designed to decontaminate an area which would be hazardous to the presence of a human being and thus, must be robotically controlled. However, there has not been any effective robotically controlled vacuum cleaner, or for that matter any vacuum cleaner having automatic features, except for those described herein.[0009]
• There has been a need for an effective robotic-type cleaning apparatus which can actually operate on its own, without manual intervention, and which will not damage or destroy other furniture or items which may be in the path of the robotic-type cleaning apparatus. Further, there has been a need for an apparatus of this type which would not allow for inadvertent destruction of itself, as for example, by means of falling off of steps, drop-offs, or the like. Such an apparatus would find highly effective use for those parties desiring to clean a selected area while the party may not even be present in that selected area.[0010]
• A robotic-type cleaning apparatus which is essentially self operating without any substantial manual intervention could be used highly effectively in commercial institutions, such as hotels and the like. In addition, such an apparatus would find highly effective widespread home use in that home users who are occupied, for example, during the daylight hours with school, employment, or the like, could self-program the cleaning apparatus to operate in their absence and without a fear of attendant damage to furniture or other items within the environment.[0011]
OBJECTS OF THE INVENTION
• It is, therefore, one of the primary objects of the present invention to provide a substantially fully automated vacuum cleaning system for the cleaning of rugs and carpets and which requires only periodic manual intervention on a limited basis.[0012]
• It is another object of the present invention to provide a substantially fully automated carpet cleaning system of the type stated which include a bumper operated sensory control system for detecting and avoiding obstacles in a carpet cleaning operation.[0013]
• It is a further object of the present invention to provide a substantially fully automated vacuum cleaning system of the type stated which allows for random movement across a selected area and which thereby effectively covers the entire area and does not require pre-programming for direction, speed and the like.[0014]
• It is an additional object of the present invention to provide a substantially fully automated vacuum cleaning system of the type stated which allows a self controlled and self moving vacuum cleaning apparatus to exit a housing, clean a selected area for a predetermined time interval and at predetermined times and automatically return to the housing without any manual intervention.[0015]
• It is another salient object to provide an automatic vacuum cleaning system of the type stated which includes auxiliary features for automatic recharging of stored energy power systems and automatic removal of debris collected by the self moving vacuum cleaning apparatus.[0016]
• It is still another object of the present invention to provide a substantially fully automated carpet vacuum cleaning system which can be constructed at a relatively low cost and is highly reliable and effective in operation.[0017]
• It is yet another object of the present invention to provide a method for conducting carpet cleaning operations on an automated basis with little or no manual intervention except for a periodic maintenance and debris removal.[0018]
• With the above and other objects in view, my invention resides in the novel features of form, construction, arrangement and combination of parts and components presently described and pointed out in the claims.[0019]
BRIEF SUMMARY OF THE INVENTION
• The present invention relates in general terms to a substantially fully automated carpet cleaning system which is effectively pre-programmed to operate at a selected time and for a selected time interval without any manual intervention whatsoever. The carpet cleaning system comprises a self powered and self moving carpet cleaning apparatus, commonly referred to as a “vehicle” or “mobile unit” which will move randomly across an entire carpeted area and clean the same during this pre-programmed and predetermined time interval.[0020]
• The carpet cleaning system of the present invention is primarily designed for the cleaning of carpets although the term “carpet” is used in a broad sense to include rugs and other fabric material floor coverings. Moreover, it should be understood that the system of the present invention is easily adaptable to the cleaning of other floor areas, such as non-carpeted work areas and the like.[0021]
• The vacuum cleaning system of the present invention includes a stationary housing for the storage of a self moving and self controlled vacuum cleaning apparatus, sometimes referred to as a vehicle, as aforesaid, or as a mobile vacuum cleaner unit. The housing is provided with an openable and a closable door which will automatically open at the preselected time interval and allow the vacuum cleaner vehicle to perform a cleaning operation. Upon return of the vacuum cleaner vehicle to the housing, the door will then close, in a manner to be hereinafter described in more detail.[0022]
• The mobile vacuum cleaner unit is comprised of an outer casing which contains one or more drive motors for driving rotatable drive wheels and a stored source of electrical power, such as one or more batteries. The batteries are sufficient to drive the self powered vehicle through the predetermined carpet cleaning time cycle and are capable of being recharged, in a manner to also be hereinafter described in more detail. The casing or body of the self moving vacuum cleaner unit is further provided with relays, a control circuit and the like for the complete operation of the vacuum cleaner vehicle.[0023]
• The mobile vacuum cleaner unit is also provided with sensory means for detecting the presence of an obstacle. In a preferred embodiment, the sensory means are bumper controlled sensory means which cause the vehicle to alter its movement path when contacting a fixed obstacle. Thus, if the mobile vacuum cleaner unit should contact a piece of furniture, its driving movement will automatically stop. A control mechanism will cause an immediate change in driving direction, such as a reverse driving and then a change in direction, to cause the vacuum cleaner vehicle to leave the area of the obstruction.[0024]
• It has been found in connection with the present invention that a random cleaning pattern is effective to cover an entire carpeted area, much in the same manner as pool cleaners randomly clean a surface of a swimming pool, in a specific time period. The mobile vacuum cleaner unit will generally traverse substantially all of the surface area of the carpet which requires cleaning except for those portions which are covered by obstacles.[0025]
• The mobile vacuum cleaner unit of the present invention is also provided with other sensors to insure that the vehicle remains only on the carpeted area. Thus, for example, sensors on the vehicle will detect the edge of a carpet and thereby change the direction of movement of the vehicle to cause the vehicle to remain only on the carpeted area. Stairwell and depression detection means is also provided to preclude the vehicle from driving down a stairwell or otherwise a potentially damaging drop-off.[0026]
• The mobile vacuum cleaning unit includes a storage area for the temporary storage of the debris, such as the dust and dirt which is collected during a vacuum cleaning operation. The housing also contains a debris collection station. Thus, when the mobile vacuum cleaner unit moves back into the housing and the door to the housing closes, the debris collection station automatically causes a suction tube to be connected to the temporary debris collection member in the vehicle and removes the debris from the vehicle so that it is available for the next cleaning operation. Periodically, the debris collected by the collection station in the housing must be cleaned. Beyond this, and any needed repair-type maintenance, the system is effectively self operating.[0027]
• The housing also includes a recharging mechanism. When the mobile unit returns to the housing, a sensory mechanism causes automatic alignment of the vehicle so that a recharging connection on the vehicle will automatically align with and connect to a recharging connector on the housing. In this way, the battery source of power in the mobile unit will be automatically recharged when the unit enters the housing.[0028]
• The advantages of this type of carpet cleaning system are quite substantial. In areas such as hotels, the mobile unit can be programmed to clean preselected areas during night periods where most of the occupants of the hotel are sleeping. This eliminates a manual chore which previously required a substantial manpower. In a multi-floor hotel with substantial square footage, numerous carpet cleaning personnel were required to daily clean the floors. In this case, a limited number of these carpet cleaning systems can perform the same task, thereby freeing personnel for other occupations or jobs.[0029]
• In the case of home use, the immediate benefits are obvious in that with a family where the adult people are occupied during the daytime, as for example, in working occupations, school or the like, the carpet cleaning operation can take place automatically, thus freeing the occupants of this household from this otherwise daily and time consuming task.[0030]
• This invention possesses many other advantages and has other purposes which will become more fully apparent from a consideration of the forms in which it may be embodied. A practical embodiment of the system and the method of cleaning carpets on an automated basis is illustrated in the accompanying drawings and described in the following detailed description. However, it should be understood that these drawings and the following detailed description are set forth only for purposes of illustrating the general principles of the invention and are not to be taken in a limiting sense.[0031]
BRIEF DESCRIPTION OF THE DRAWINGS
• Having thus described the invention in general terms, reference will now be made to the accompanying drawings in which:[0032]
• FIG. 1 is a perspective view of a stationary housing forming part of the vacuum cleaning system of the present invention;[0033]
• FIG. 2 is a side elevational view of the stationary housing with a side panel of the housing removed and showing the components in the interior thereof as well as a mobile carpet cleaning unit forming part of the system stored therein;[0034]
• FIG. 3 is a front elevational view of the stationary housing of FIGS. 1 and 2, with the front door thereof removed and also showing the mobile carpet cleaning unit forming a part of this system, stored within the housing;[0035]
• FIG. 4 is a perspective view of the mobile carpet cleaning vehicle unit forming part of the system of the present invention;[0036]
• FIG. 5 is a top plan view largely broken away and showing the interior portion of the mobile carpet cleaning unit of the present invention;[0037]
• FIG. 6 is a side elevational view, largely broken away, of the mobile carpet cleaning unit of the present invention;[0038]
• FIG. 7 is a fragmentary, somewhat schematic side elevational view of a portion of the debris collection and removal system used in the mobile carpet cleaning unit;[0039]
• FIG. 8 is a fragmentary side elevational view showing a portion of a stationary vacuum cleaning system for removing debris from the mobile unit and forming part of the housing of the present invention;[0040]
• FIG. 9 is a fragmentary perspective view showing part of an obstruction sensory system forming part of the mobile unit in the present invention;[0041]
• FIG. 10 is a perspective view of a drop-off sensory mechanism forming part of the mobile unit of the present invention;[0042]
• FIG. 11 is a side elevational view, partially in section, and showing a portion of the obstruction sensory system of the invention;[0043]
• FIG. 12 is a schematic electrical circuit view showing the electrical circuit used for accomplishing homing functions of the mobile unit;[0044]
• FIGS. 13A and 13B are truth tables showing high and low conditions in response to the detection of a homing beacon;[0045]
• FIG. 14 is an schematic electronic circuit diagram showing the electronic components forming part of the housing of the present invention;[0046]
• FIG. 15 is a schematic electronic circuit diagram showing the electronic components and portions of the mechanical assembly forming part of the vehicle mobile unit of the present invention;[0047]
• FIG. 16 is a schematic chart showing the sequence of operation when the vehicle unit contacts an obstruction on the left-hand side thereof;[0048]
• FIG. 17 is a schematic chart showing the sequence of operations when the vehicle unit contacts an obstruction on the right-hand side thereof;[0049]
• FIG. 18 is a schematic chart showing the sequence of operations when the vehicle unit detects an obstacle on both sides thereof;[0050]
• FIG. 19 is a schematic chart showing the sequence of operations when the vehicle unit contacts an obstruction for an extended period of time; and[0051]
• FIG. 20 is a schematic chart showing a sequence of operations on the housing of the vehicle unit in the housing forming a part of the system of the present invention.[0052]
DETAILED DESCRIPTION
• Referring now in more detail and by reference characters to the drawings which illustrate a preferred embodiment of the present invention, C designates a carpet cleaning system comprising a main housing or[0053]cabinet20 for receiving a vacuum cleaning vehicle or “cleaner apparatus” or so-called “mobile unit”22. Located within thehousing20 is abattery recharging mechanism24 which is hereinafter described in more detail and adebris collection station26, as shown in FIG. 2 and which is also hereinafter described in more detail.
• The[0054]cabinet20 is comprised of anouter housing28 having an openable and closable segmentedfront door30 which can be opened and closed to permit ingress and egress of the mobilevacuum cleaner unit22. Theouter housing28 is comprised of aback wall32 and a pair of transversely extending spaced apart endwalls34 and together with atop wall35 and abottom wall36 along with thefront door30 to form aninterior compartment38.
• The[0055]cabinet20 is also provided in theinterior compartment38 with ashelf39 for supporting thedebris collection station26 in the manner as best illustrated in FIG. 2 of the drawings. It is not necessary in connection with the present invention to have a bottom wall, such as thebottom wall36 since theentire cabinet20 could rest entirely on a carpet surface if desired. If thebottom wall36 is provided, however, it should also include a slight front ramp or beveled edge (not shown) in order to enable themobile unit22 to enter into and exit theinterior compartment38 without sensing thebottom wall36 as an obstruction.
• The[0056]front door30 of thecabinet20 is preferably, although not necessarily, a segmented door, that is, comprised of a plurality of horizontally located slats or ribs which allow the door to bend and travel through an arcuate path. In the embodiment of the invention, as illustrated, thefront door30 is capable of moving along atrackway40 located on the underside of thetop wall35 and a correspondingchannel42 located adjacent to the interior surface of theback wall32. Thus, as thefront door30 opens, it will move through an arcuate path along thetrackway40 and into thechannel42 adjacent the back wall, as shown in FIG. 2, When the door moves to the closed position, it will follow the reverse path and move to the fully closed position, as best shown in FIG. 2 of the drawings.
• The[0057]front door30 is operated by adoor motor mechanism44, as best shown in FIGS. 2 and 3 of the drawings. Thedoor motor mechanism44 comprises a small AC operateddrive motor45 which drives a connectinglinkage arrangement46, includingdoor rollers47, for raising and lowering the door in a conventional manner. Mechanisms of this type are frequently used on a larger scale for raising and lowering garage doors. Accordingly, this mechanism is neither illustrated nor described in any further detail herein.
• The door operating mechanism, as shown in FIGS. 2 and 3, will also include door pressure rollers or so-called[0058]guide rollers48 for guiding the movement of the door during its opening and closing movements. Further, door position switches49 are also located adjacent the trackway in order to detect the position of the door and ensure proper opening and closing movement. The door position switches49 are also operable to effectively stop the movement of themotor45 when the door has reached the fully opened and fully closed positions. Finally, a manuallyoperable door switch50 and aduty switch51 are also located on the top wall of the cabinet, as best shown in FIGS. 2 and 3 of the drawings.
• It should be understood in connection with the present invention that other types of door arrangements could be used. Thus, a hingedly mounted door with a linkage mechanism to open and close a hingedly mounted door could also be provided. Again, mechanisms of this type are frequently used as gate openers and are commercially available.[0059]
• As indicated previously, a manually[0060]operable door switch50 and themain duty switch51 are located on thetop wall35 of thehousing20. However, the system of the present invention is adapted for automatic operation. For this purpose, a multi-dayprogrammable timer55 is employed, as, for example, a seven-day programmable timer. This timer would be manually setable by a user of the system to cause the mobile unit to exit and perform a carpet cleaning operation on selected days and/or at selected times and moreover, for selectable time periods of cleaning. In this way, the entire system is automatically operable. The programmer timer is a simple device which can be easily programmed by setting dial switches or the like, much in the same manner as a programmable water sprinkler system.
• Also located within the[0061]interior compartment38 are the electrical components used in the operation of the cleaning system C. Certain of these electrical components will include, for example, acircuit box52 which houses the circuit boards and other electrical circuitry used in the operation of the system. Fuses, sensors, transmitters and the =like would also be located in thiscircuit box52. Included within thecircuit box52 is acentral processing unit53 which may contain motor driving circuits and the like.
• The[0062]cabinet20 could be a basic housing for the components of the system as described herein. However, it should also be understood that the cabinet itself could be made into a piece of furniture or otherwise, it could form a part of another piece of furniture. Thus, the entire cleaning system would not consume a great deal of storage space, such as closet space which is sometimes at a premium in certain dwelling establishments.
• The mobile self driven[0063]vacuum cleaner unit22 is more fully illustrated in FIGS.4-11 and15 of the drawings and comprises an outer casing or so-calledvehicle chassis54 mounted on a main frame. The frame itself is not shown in any detail in the drawings and actually may be integrated with the actual casing orvehicle chassis54. Theouter casing54 and the main frame are typically a single unit and may be an integrated unit, if desired. Furthermore, this casing and the main frame together are frequently referred to as a “body”.
• A conventional vacuum cleaner chassis could be employed and modified for use in the present invention. Further, some of the components which are conventionally found in vacuum cleaners will only be briefly mentioned herein since, to that extent, conventionally employed components can be used in the mobile[0064]cleaner apparatus22. For example, brush rollers of the type conventionally used in vacuum cleaners will be described to the extent that they exist in the mobile unit of the present invention, but the actual construction of such brush rollers will not be described.
• The mobile[0065]vacuum cleaner unit22 comprises a pair ofdrive wheels58 which are driven by one ore more battery powered DC drivemotors60, as best shown in FIG. 5 of the drawings. In the embodiment of the invention as illustrated, aseparate drive motor60 is used for driving each of theindividual drive wheels58 so that the two can be operated either in tandem or individually at different speeds and in different directions. In the embodiment of the invention as shown, aseparate drive motor60 is provided for driving eachwheel58. This type of separate drive motor arrangement is preferred in that it easily and inexpensively provides driving control over each of the individual drive wheels.
• The[0066]drive motors60 are preferably powered by means of one or morerechargeable batteries62 mounted within thechassis54. These batteries could be wet-celled batteries if required, although dry-celled batteries are preferred in order to eliminate any potential damage by virtue of the use of a battery fluid. Thebatteries62 are provided with and connected to a recharging plug64 (as best shown in FIG. 3) for periodically recharging of the batteries after a self cleaning operation by themobile unit22 with thebattery recharging mechanism24.
• The recharging[0067]plug64 on the mobile unit is operated in conjunction with abattery recharger circuit66 and apower supply68 which are also connected to or form part of thebattery recharging mechanism24. Therecharger circuit66 andpower supply68 are also mounted on theshelf39 within thehousing20, as best shown in FIG. 3 of the drawings. Thisbattery recharging plug64 is adapted for releasable connection to a rechargingassembly70 having a front nose portion or probe (frequently referred to as a “socket”)72 which receives and causes a recharging coupling to the rechargingplug64. Thus, when the mobile unit enters into thehousing20 in the manner as shown in FIG. 2, thenose72 will automatically connect to the rechargingconnector64 on the mobile unit and thereby enable a recharging of the batteries in the mobile unit. For this purpose, thebattery recharger66 is electrically connected to the rechargingconnector70 by means of electrical conductors (not shown).
• Mounted within the forward end of the[0068]mobile unit22 is a cleaningbrush76 which extends through anelongate slot78 formed in the bottom of the chassis ormobile unit cabinet54. The cleaning brush can be conveniently journaled on the sides of the chassis. Furthermore, the cleaningbrush76 is conventionally provided withbristles82, as best shown in FIGS. 5 and 6 of the drawings. Mounted at one end of the driven and rotatable cleaning or so-called “agitator”brush76 is adrive pulley78 and which is connected to a suitableroller drive motor80 by means of adrive belt83, again all as best shown in FIGS. 5 and 6 of the drawings.
• It should be understood that the[0069]drive motor80 can be powered by the same battery source ofpower62. However, separate batteries could also be provided for operating theroller drive motor80, which is a DC drive motor. Although the vacuum cleaner is provided with a cleaning brush or so-called “agitator brush76”, driven by a separateagitator brush motor80, it should also be understood that theagitator brush76 could be driven by any one of thedrive motors60, if desired. Theagitator brush motor80 is typically a small electric battery powered motor. For this purpose, themotor80 should be driven from the same battery source ofpower62.
• Although only a pair of[0070]drive wheels58 are illustrated in the drawings, it should be understood that additional idler wheels or castors could be employed on the apparatus. In one embodiment, the apparatus is constructed so that the combination of the cleaning roller and the pair of drive wheels is sufficient to stabilize the apparatus during movement.
• The mobile[0071]vacuum cleaning unit22 is also provided with atemporary storage compartment90 which operates in conjunction with the debris collection station, or so-calledstationary vacuum device26, in themain housing20, as hereinafter described. Thetemporary storage compartment90 is formed by acontinuous enclosing wall92, and anupper guide plate94 and which is in communication with the drive roller cleaningagitator brush76. Thus, as debris is collected from the carpet, a vacuum created in thestorage compartment90 will cause any dust or debris to move into thestorage compartment90. A vacuum is formed in thestorage compartment90 by means of asuction fan96 operable by a suitableelectric motor98. Again, thesame motor80 which drives the cleaningbrush76 could be used for operating thesuction fan96, if desired. Thesuction fan96 is surrounded by ashroud99, which forms a debris collecting area, and the latter, having openings therein for effectively creating a vacuum through the storage compartment andshroud98, as hereinafter described. In this way, the dust and debris collected by theagitator brush76 is moved into thestorage compartment90.
• Located in front of the[0072]shroud99 is afilter cage100 and also holds afilter102, such as a replaceable conventional filter cloth. In this way, none of the debris which is drawn into thewaste chamber90 can be drawn into thesuction fan motor98.
• The[0073]debris collection station26 includes a stationaryvacuum cleaner canister91 and which is mounted on the horizontally disposedshelf39 mounted within thehousing20, as best shown in FIGS. 2 and 3. Thevacuum cleaner canister91 is provided with an internal chamber and an internal vacuum motor and fan arrangement (not shown) required for creation of the vacuum. However, any conventional means for forming the vacuum in thecanister91 may be employed in accordance with the present invention.
• A[0074]debris outlet104 on themobile unit22 comprises anopening106 formed in the chassis and which is covered by a rubber flapper-type valve108. The rubber flapper-type valve or so-called “flapper” may also be provided with an outwardly strucktab110 for purposes presently more fully appearing and as best shown in FIG. 4.
• The[0075]debris collection station26 within thehousing20 is provided with aflexible tube114 connected to a source of vacuum within the canister91 (see FIGS. 2 and 8). Moreover, thevacuum tube114 is connected at its outer end to arigid arm116 having a perpendicularly arrangedstub section118 terminating in adebris collection inlet120, as best shown in both FIGS. 2 and 8 of the drawings. Thedebris collection inlet120 is surrounded by a rubber ring or seal122, as also shown in FIGS. 2 and 8.
• When the[0076]mobile cleaning unit22 is moved into thehousing20, the debris collection station will be automatically energized through the control system, as hereinafter described. Thisdebris collection station26 includes a somewhatuniversal pivot124 having a plurality of mechanical hose position switches126 which detect and provide information as to the knowledge of therigid arm116 which is often referred to as a “mechanical hosed”. An extendablegear motor assembly128 is comprised of a screw-type jack arrangement130 and anelectric drive motor132. As themotor132 is energized by the control system, thescrew jack arrangement130 will cause a lowering of therigid arm116 and thestub section118 such that thedebris collection inlet120 will move toward theflapper value108 anddebris outlet104 in the mobile unit. As this occurs, theflapper valve108 is caused to open by a suction or vacuum created through the vacuum tube orvacuum hose114 and therigid arm116 andstub arm118. This will cause a removal of debris temporarily stored in thechamber90 of the mobile unit and cause a relocation of this debris in a storage chamber (not shown) in thestationary vacuum unit91.
• The operation of removing the debris from the mobile unit and relocating same in the[0077]stationary vacuum unit91 is caused by a sensory arrangement on the mobile unit and on the housing. As an example, when the mobile unit reaches the nested position as shown in FIG. 2, it connects with the cabinet connector. This will cause a signal to the microprocessor to thereupon enable operation of thedebris collection station26.
• It should also be understood that discharge of debris from the mobile unit could be initiated by causing energization of the[0078]fan96 in the reverse direction, and thereupon causing air to blow the debris in thecanister91 outwardly through thedebris outlet104 of the mobile unit. It can be seen that energization of thefan96 in the reverse direction will cause an air flow through theshroud98 and filter arrangement.
• The aforesaid construction is highly effective in that it only requires the mobile unit to maintain a relatively small temporary debris storage area. This is due to the fact that the[0079]storage area91 will be cleaned and the debris will be removed therefrom on each occasion when the mobile unit returns to themain housing20 or otherwise on a periodic basis. In addition, thedebris collection station26 may be sufficiently large so that it only requires cleaning and emptying on an occasional periodic basis. As a simple example, the mobile unit may be operated for seven to ten days, or more, and the debris from the mobile unit collected in the main stationary vacuumcleaner station chamber91 such that only very infrequent cleaning of thechamber91 is required. Moreover, thecannister91 may be conveniently removable from theshelf39 for purposes of emptying the same on a periodic basis.
• The[0080]universal pivot mechanism124, as shown in FIGS. 2 and 8, is also operable with the plurality of position switches126 and which will control the operation of theelectric motor132. Thus, after therigid arm116 is raised to a certain position, it will contact one of the position switches126 which will, in turn, cause a de-energization of themotor132. It should also be understood that themotor132 will be operable from a suitable source of electrical current supplied to themain housing20, as hereinafter described.
• The[0081]stub118 is provided on each of its opposite sides with positioning guides136, or so-called “feelers”, as best shown in FIGS. 2 and 3 of the drawings. These positioning guides136 will bear against a pair of upstanding locating rods138 (see FIGS. 2, 3 and4) located on thevehicle chassis54. Thus, as thestub118 is lowered, the positioning guides136 will bear against the interior surface of these locatingrods138 and cause the debris collection inlet to be properly oriented with respect to theoutlet108.
• It can be seen that this universal pivot assembly, as best shown in FIGS. 2 and 3, allows the[0082]stub118 andring seal122 and hence the inlet to be moved from side to side, in order to compensate for the varying angles that the mobile unit may achieve when homing into the housing. Moreover, this assembly also allows for correction of the vertical positioning of thestub118 when positioning with respect to theoutlet104. Theflapper valve104 is opened when the mechanical assembly, including thestub118 is shifted downwardly, by pressing against theguide arms138. These guidearms138 are mounted in such manner that they also operate as feeler switches which sense the downward movement of the hose assembly toward theopening104. These feelers could be arranged to cause energization of theelectric motor98 and hence thefan96, if desired.
• The mobile unit may also be provided on the[0083]chassis56 with a pair of upstanding homingarms142. These homing arms could also be electrically connected to thedrive motor60, causing selective energization and de-energization of thesedrive motors60 to thereby further guide the mobile unit into a homing position. Also, additionalinfrared detectors143 could be mounted at the upper end of thesearms142.
• In addition to the foregoing, the stationary vacuum source within the[0084]cabinet20 can also be activated in order to cause a suction and hence an opening of theflapper valve100 through the action of theguide arms138. Therubber ring seal108 will allow a tight-fitting disposition around thedebris outlet104 thereby maximizing the air flow through the filter and waste chamber. In this respect, theshroud98 may also operate as a filter, as well.
• The mobile unit also comprises a pair of on-board infrared sensors or so-called[0085]detectors140 and which are, in turn, secured to thechassis54. These infrared sensors operate in conjunction with an infraredhomecoming beacon mechanism144 within thehousing20, as best shown in FIG. 2. The infrared homecoming beacon operates in conjunction with an infraredsignal generating mechanism146 mounted within the housing and the front surface of which may serve as a bumper for engaging the forward end of the mobile unit, as also shown in FIG. 2.
• Upon completion of a duty cycle or so-called “cleaning cycle”, the infrared homecoming beacon, which may be in the form of light emitting diodes, will generate infrared signals. As these signals are detected by the on-board[0086]infrared sensors140, the mobile unit will be instructed to immediately return to the cabinet. Moreover, the infrared beams which are generated by thebeacon144 will cause the mobile unit to move into the cabinet in substantially the precise desired orientation so that it aligns properly for connection to other components, as hereinbefore and hereinafter described.
• When the mobile unit has reached its so-called “home” or “nesting” position, as illustrated in FIGS. 2 and 3, the battery source of[0087]power62 will be automatically energized through the rechargingsocket72. In this case, the rechargingplug64 is adapted to engage and to extend into the charge receptacle of thissocket72 mounted within the housing, as also best shown in FIG. 2. Thus, it is not necessary for the mobile unit to be precisely aligned inasmuch as the charge receptacle is somewhat funnel-shaped and will guide the charging plug directly into the funnel-shapedcharge receptacle socket72.
• By reference to FIG. 4, it can be seen that the[0088]charge plug64 is mounted on a frusto-conically shapedsection152 on the mobile unit and is connected to thebattery62 by means of acable154.
• If for some inexplicable reason, the on-board infrared sensors on the mobile unit did not detect the homing beam emitted by the infrared beacon in the housing, there would be no cause for concern since the battery source of[0089]power62 would ultimately drain and the mobile unit would halt so that the user thereof could manually reposition the mobile unit in the housing, if required.
• When the infrared beam is generated by the[0090]beacon144 to enable a homing of themobile unit22, the mobile unit will cross the homing beacon beam. That beam will, in turn, be detected by one or both of theinfrared sensors140. If the infrared homing beam is detected by the right-hand sensor140, power will be cut to theright drive wheel58. In like manner, if the beam is detected only by theleft sensor140, power will be temporarily cut to theleft drive wheel58. This will cause the mobile unit to turn towards the infrared homing beacon. When both detectors sense the homing beacon, no signal is sent to relays controlling either of the drive wheels and the unit will then move toward the housing. If the mobile unit happens to veer too far to the right, only the left sensor will sense the presence of the beam and the left wheel will temporarily stop rotating, again until both sensors or detectors further sense the homing infrared beam, at which point, motion is restarted again.
• FIGS.[0091]9-11 more fully illustrate anobstruction detection system160 forming part of themobile unit22. The obstruction detection system in this embodiment of the invention relies upon a pair ofbumper pads162 at the forward end of the mobile unit vehicle as shown in FIG. 4. Thesebumper pads162 usually include a soft flexible exterior surface, such as a foam exterior surface to preclude any marring or other damage to a piece of furniture or other item, if they should engage such other item.
• Located immediately behind each of the[0092]bumper pads162 are bumper contacts164 (FIG. 9) which are electrically connected to relays and which, in turn, control themotors60 operating thedrive wheels58. These contacts are, in turn, electrically wired together and to electrical relays which are contained within anelectrical circuitry box226 as hereinafter described, (see FIG. 15) and located within thechassis54 of themobile unit22. If the mobile unit should be traveling in a generally forward direction and one of thebumper pads162 contacts an obstruction, such as a piece of furniture, it will immediately close the associatedcontact164 thereby opening the relay to thedrive motor60 associated with thatbumper pad162. Thus, if theright bumper pad162 contacts the obstruction, the left bumper remains neutral. Theright drive motor60 will reverse direction and cause themobile unit22 to move in a different angulated direction. This will potentially enable the mobile unit to move beyond the obstruction which it contacted. In like manner, if theleft bumper pad162 contacts an obstruction, the same action will take place except on the left-hand side of the mobile unit. This operation is described in more detail hereinafter.
• If both bumper pads should engage an obstruction, substantially at the same time, then relays to both drive[0093]motors60 will be de-energized thereby momentarily stopping movement of the mobile unit. One of the drive motors will then be caused to reverse in direction so that the mobile unit again moves in a different direction. Even though the mobile unit may engage the same obstruction on a few subsequent occasions, continued operation of the obstruction detection system will ultimately cause the mobile unit to move in a path sufficiently different from that which would again cause engagement with the same obstruction. Moreover, due to the fact that there is a soft covering on the front surface of thebumper pads162, there is little or no chance of any damage to a piece of furniture or other item which may constitute the obstruction.
• Closely associated with the[0094]obstruction detection system160 is a drop-off detection system166 which is more fully illustrated in FIG. 10 of the drawings. The drop-off detection system166 comprises a somewhatU-shaped sensing member168 which is loosely retained ineyelets170 mounted on the sides of one or both of thebumpers162. In this respect, it should be understood that a separate drop-off detecting mechanism will normally be located on each of theopposite bumpers162 on the mobile vehicle. The detectingmember168 will normally remain in a position very closely located to the ground surface on which the unit is riding. Moreover, theU-shaped member168 is provided with anupper retaining arm172 limiting the downward movement of the detectingmember168. Moreover, it can be observed that each of the drop-off detectors166 are located toward the forward end of the mobile unit in advance of the drivingwheels58.
• If the mobile unit should be moving toward an area where there is a drop-off, as for example, in a set of stairs, or even a single stair, the[0095]detector member168 will immediately sense a drop in that the lower portion thereof which normally engages the ground surface will be caused to lower even further. As this occurs, the retainingarm172 will engage ascrew contact174 which will immediately de-energize both of theelectric drive motors60 and thereby immediately stop rotation of thedrive wheels58. Thereafter, the control circuitry will cause a sequence of operations which are similar to those when the mobile unit contacts an obstruction. However, the control circuitry could be configured to cause a reversal of thedrive motors60 and hence thedrive wheels58 to cause the mobile unit to move away from the drop-off, if desired. Further, one of the motors will then be operated while the other is temporarily halted so that the mobile unit will move into a different path. If the mobile unit should still move toward the drop-off, the same sequence of actions will take place as when an obstruction is contacted, until the mobile unit is sufficiently angulated to a different path so that it avoids the drop-off.
• By further reference to FIGS. 9 and 10, it can be seen that the drop-[0096]off detection system166 and theobstruction detection system160 are both electrically connected together. By reference to FIG. 11, it can also be seen that a tie-down cord176 is used to anchor the bumper pads in a suspended fashion around the contacts in such manner that they do not engage the contacts until an obstruction is engaged. The tie-down is preferably an electrically non-conductive nylon string or the like. In this construction, the bumper pads will be spaced from the electrical contact, such as thecontacts164, until they engage an obstruction and this obstruction causes the movement of the bumpers into electrical engagement with the contacts.
• But with reference to the drop-[0097]off detection system166, the height of the drop-off connectors can be adjusted by means of an adjustment bolts, as hereinafter described, to thereby raise or lower the position of the bumper pad and thereby adjust the normal riding position of the drop-off detection.
• A tie-[0098]down mechanism180 is more fully illustrated in FIG. 11 of the drawings and shows the relationship of thebumper pad162 relative to the front portion of thechassis54. It can be seen that thebumper pad162 is spaced from thechassis54 by means ofcompressible springs182 between thechassis54 andbumper pad162. Each spring is, in turn, secured to thebumper contacts164. Moreover, it can be seen that tie-down cable176 effectively holds the bumper pads in a suspended position around the various contacts but spaced apart from the contacts.
• FIG. 12 illustrates in schematic format, a NAND gate arrangement which causes the operation of the[0099]drive motors60 and hence thedrive wheels58 in response to operation by theinfrared homing detectors143. FIG. 13 more specifically illustrates afirst NAND gate190 which receives an input from theright homing detector143 designated by “R-143” in FIG. 13. Asecond NAND gate192 receives an input directly from the leftinfrared homing detector143 designated as “L-143” in FIG. 13. Moreover, theNAND190 receives an input from the left homing detector L-143 and theNAND gate192 similarly receives an input from the output of theNAND gate190, but does not receive an input directly from the right-hand homing detector R-143.
• There is a[0100]further NAND gate194 which receives an input from the right-hand detector R-143 and from the output of theNAND gate190, as also shown in FIG. 12.
• In accordance with this NAND gate arrangement of FIG. 13, it is possible to set up truth tables which will control the driving movement of the right-hand drive wheel, for this purpose designated as R-[0101]58, or the left-hand drive wheel, for this purpose designated as L-58, in FIGS. 13A and 13B of the F: drawings. In accordance with the truth tables shown in FIGS. 13A and 13B, if a high “H” is generated, thedrive motor60 for thatdrive wheel58 will be energized. In like manner, if a low “L” is generated, then an L drive signal will discontinue power to thedrive motor60 associated with that particular drive wheel.
• Returning again to FIG. 13A, it can be seen that if the right-hand detector R-[0102]143 is positive, and the left-hand detector L-143 is negative, a pair of lows L will result which will, in turn, operate in a high H for motor operation of the right-hand drive wheel. In like manner, if the right-hand detector R-143 is negative, and the left-hand detector L-143 is positive, a high will be generated and in which case, the right-hand motor will be energized. The same holds true for the remaining two possibilities in FIG. 13A.
• Returning to FIG. 13B, it can also be seen that if the detector R-[0103]143 and L-143 are both negative, lows L will be generated and the left-hand motor60 which drives the left drive wheel L-58 will be energized. In like manner, if the right-hand detector R-143 does not detect a homing signal but the left-hand detector L-143 does detect a homing signal, then there will be a low for the left-hand drive motor L-58 such that it will not be energized. Again, the remaining two possibilities in the truth table of FIG. 13B show a high or energization of the left-hand drive motor L-58.
• In short, when a detector on one side detects an infrared signal, and the other side does not, then power to one motor will be discontinued to turn the mobile unit. Thus, power to the right drive motor is discontinued only when the right hand detector sees an infrared beam. Power to the left drive motor is cut only when the left detector sees an infrared beam. If both detectors detect the infrared signals, both drive motors will remain powered. In all other conditions, both wheels are powered. By following the truth tables of FIGS. 13A and 13B, it can be seen how the[0104]drive motors60 will cause movement of thedrive wheels58 to thereby cause the mobile unit to change its drive path.
• It can be seen that the AND gate circuit of FIG. 12 along with the associated truth tables of FIGS. 13A and 13B control the operation of the drive motors and hence, the guiding movement of the mobile unit for purposes of homing the unit into the cabinet. However, similar arrangements of this type could also be used for driving the drive wheels in response to external conditions. As an example, a similar AND gate arrangement, along with an associated truth table, could be employed to control movement of the drive wheels in response to the bumper pads engaging an obstruction. Thus, if the left-bumper pad contacted at an obstructions, a similar AND gate arrangement would cause operation of one of the drive motors in preference to the other of the drive motors.[0105]
• FIG. 14 represents a simplified schematic electrical diagram showing connection of the major components forming part of the[0106]housing20 and FIG. 15 is a similar simplified schematic electrical circuit view showing the connection of those components forming part of themobile unit22 of the cleaning system of the present invention. In this respect, it should be understood that many of the components, as for example, a battery recharger, power supply, relays and the like are conventional and are therefore neither illustrated nor described in any detail herein. However, it is the actual combination of these various components which does produce the unique results in accordance with this invention.
• Turning now to FIG. 14, it can be seen that the[0107]housing20 includes the plurality of door position switches49 (three as shown) which detect and control the movement of thedoor30. In the preferred embodiment, three of the door positions switches49 are employed where one is used to control the closing and opening position, the second is used for a duty cycle and the third is used for maintenance. However, if desired, all three door positions which could operate successively to control movement of the door between the fully closed and fully opened positions. Thus, if all threeswitches49 are closed as the doors move to the opened position, then thedoor motor47 will automatically become de-energized. In like manner, if the right-hand end of the threeswitches49, as illustrated in FIG. 14, is opened or otherwise closed (depending upon the mode of connection) then thedoor30 will have reached the fully closed position, as now shown in FIG. 14.
• The electrical circuitry also includes a[0108]central processing unit200, which may be a microprocessor, which controls the operation of the major components in thehousing20 and may also control themobile unit22, as well, if desired, through remote control. Thecentral processing unit200 operates in conjunction with a plurality of relays, two of which are illustrated in FIG. 14, as hereinafter described. One of these relays is a timer relay202 which controls thedoor motor47. Moreover, connected to the relay202 is theprogrammable timer55. In accordance with this construction, the user of the system can program those times in which it is desired to have the mobile unit automatically start a cleaning operation and end a cleaning operation. In the same respect, the user can program the amount of time during which a cleaning cycle will last.
• The microprocessor or[0109]central processing unit200 could also be used to control many of the operations of the mobile unit and the overall housing. For example, the microprocessor could be used to receive detect signals from bumper pads and the like or for that matter detect or non-detect signals from the homing detectors. The microprocessor would thereupon be used to control operation of thedrive motors60. Again, the microprocessor could be used to perform other control functions, as described herein.
• The starting circuitry, which includes the[0110]door motor47 and the relay202, as well as thetimer55, also includes themain duty switch51. In this way, it is possible to de-energize the entire system by opening theduty switch51 and leaving the same in the opened position.
• The housing is further provided with the[0111]door switch50 which allows the user to temporarily hold thedoor30 in a fully opened position. This is desirable for cleaning and maintenance, as well as to clean out the reservoir of the stationarydebris collection station26.
• The electronic circuitry in the main housing includes a[0112]power supply204 of generally conventional construction and which is designed to operate the various components forming part of thehousing20 at a pre-determined voltage level. Further, the power supply, as well as some of the other components, are connected directly to aconductor206 for connection to a suitable source of electrical power. In like manner, abattery recharger208, is connected directly to the charge receptacle orconnector70, and is also connected directly to thepower supply204.
• The stationary[0113]debris collection station26 includes afan motor210 operating afan212 to create the vacuum through the hose ortube114, as previously described. Thefan motor210 is connected to avacuum relay214 operable by thecentral processing unit200 and which is also connected directly to theconductor216 for receiving a source of electrical power, such as one hundred and ten volt electrical power.
• The[0114]arm116 of the mechanical hose assembly is operable by themotor132, which is connected directly to thecentral processing unit200 and the actual position of which is controlled by the mechanical position switches126.
• Finally, the infrared lighting emitting diode which generates the homing[0115]beacon144 is also connected directly to thecentral processing unit200 for controlling the operation when the mobile unit has reached the nesting position. If desired, the light emitting diode could be operated from a separate generator connected directly to a relay, which is, in turn, operated by thecentral processing unit200.
• It should be understood that the[0116]central housing20 would also include other electrical components normally conventionally found in control circuits, as for example, twelve volt transformers, battery control circuits and the like. However, these components are essentially conventional and are therefore not described in further detail herein. The control circuitry would also include fuses and potentially other electrical control elements.
• The mobile unit control circuitry is set forth in FIG. 15 which also constitutes a simplified electrical circuitry diagram. Certain switches and relays which form part of the circuitry, both in the[0117]main housing20 and in themobile unit22, have been deleted from FIGS.4-10 in order to maintain clarity. Furthermore, it should be understood that other circuit arrangements could be used in accordance with the present invention. Thus, and in this respect, many of the components could be substituted by electronic components which may-also be included within the central processing unit, as hereinafter described.
• The[0118]agitator brush76 is operated by theagitator brush motor80 and thevacuum fan96 is operated by thefan motor98, as previously described. Amain power switch220 may also be provided on the mobile unit in order to temporarily stop any operation of the mobile unit or to cause automatic starting of the operation of this mobile unit. The mobile unit includes arelay222 which is a normally energized relay and operates in conjunction with a circuit breaker andbeeper combination224. By reference to FIG. 15, it can be seen that the circuit breaker is connected directly to the battery source ofpower62.
• The mobile unit also includes its own[0119]central processing unit226 which, in effect, is somewhat of a slave to thecentral processing unit200. Thecentral processing unit226, as well as thecentral processing unit200 both operate as control units and as motor drivers, as well. In this respect, thecentral processing unit226 controls the operation of thedrive motors60 in response to inputs from thebumper switch contacts164, as shown in FIG. 15 of the drawings.
• The mobile unit has a[0120]connector board230 which connects to asimilar connector board232 on thecabinet20, when the mobile unit reaches a home or nested position within thecabinet20, also as shown in both FIGS. 14 and 16 of the drawings.
• The timing for operation of the various components is more fully set forth in FIGS.[0121]16-20 of the drawings. FIGS. 16 and 17 specifically illustrate the operation of causing the mobile unit to move in different directions in response to contacting of an obstruction. In this respect, thecentral processing unit226 of themobile unit22 includes a plurality of timing circuits which control the driving of themotor60 either in a forward or a rearward direction or in a stall. Thus, if the left bumper contacts an obstruction, it will cause an activation of theright drive motor60, a timer and a backup timer in the central processing unit. The backup timer will thereupon reverse both drivewheels58 for two time periods and will then return to forward rotation, as shown in FIG. 16. The leftwheel drive motor60 will be activated by the backup timer and reverse in direction for one time period, as shown in FIG. 16. As a result, the mobile unit detects the obstacle, backs up and then turns away from the obstacle.
• The timing circuit of FIG. 17 shows a similar operation if the right bumper detects that obstacle. In this case, the timing arrangements are set forth for back up of the mobile unit and turning away from the obstacle. In the diagrams as shown in FIGS. 16 and 17, the time periods are approximately each one second. The back up times in actual operation, are shortened to approximately one-half second every ninth time. This will increase the turning times which eliminates repeating patterns and assists the mobile unit in maneuvering out of a tight position when contacting a plurality of obstructions.[0122]
• FIG. 18 shows the timing arrangement when both bumpers detect obstacles at essentially the same point in time. Here again, the timing diagrams are self explanatory and show how the mobile unit backs up and moves away from the obstruction.[0123]
• FIG. 19 illustrates the timing arrangement when the mobile unit detects an obstacle for an extended period of time, as for example, if the mobile unit were in a tightly confined area with a plurality of obstructions. Thus, if, for example, the left bumper detects an obstacle, the right bumper remains neutral. The back up timer will reverse both wheels for one time period and thereafter resets. The[0124]right drive motor60 will reverse the right drive wheel for the same extended duration as the bumper detects the obstacle. In this case, it can be seen, for example, that the right timer will remain activated and cause right drive wheel to reverse operation for four time periods. The left drive wheel will reverse for one direction when activated by the left drive wheel back up timer. As a result, the mobile unit will back up then keep turning away from the obstacle until it is completely clear of the obstacle.
• FIG. 20 more fully illustrates the operations of the components in the[0125]main cabinet20. In this case, the main duty switch will control the operation of the control cabinet by a manual operation. A timer, such as thetimer52, will control the desired cleaning time for each cleaning operation. In like manner, thedoor motor47 is similarly controlled by a timer which may be included within themain processing unit200. It can be observed that the infrared homing beacon will be energized to cause a homing operation of the mobile unit. If the mobile unit is in a cleaning operation, upon detecting the homing beacon, the mobile unit will immediately head to a homing position. As it reaches the home position, it will automatically connect with therecharger208. Moreover, the automaticdebris collection station26 will be operated and thehose114 will be lowered to ultimately connect to the mobile unit. The vacuum will then be turned on in thedebris collection station24 in order to clean the contents of the temporary storage compartment.
• The carpet cleaning system C of the present invention is highly effective to maintain and to clean carpeted areas on a periodic basis, almost completely without any manual intervention or supervision for extended periods of time. The carpet cleaning system of the invention needs only the stationary cabinet and the roving, or moving automated vacuum cleaner mobile unit for cleaning relatively flat carpeted areas. Moreover, the stationary[0126]debris collection station26 removes all of the dust and debris which has been picked-up by the mobile unit. Furthermore, a means is provided for recharging the battery source ofpower62 which operates the various drive motors in the mobile unit.
• The user of the present invention can set vacuum operation start times and end times using the[0127]timer52 mounted within thecabinet20. When a vacuum start time is obtained, the mobile unit is fully charged with electrical power and cleaned so that debris may be collected in the storage compartment of thedebris collection station26. Themobile unit22 will immediately become energized and under its own power will immediately detach the charge connector plug64 from thecharge receptacle70. This will enable the mobile unit to immediately move out under its own power rearwardly from the cabinet onto the carpeted area to be cleaned. At that point, the drive motors for the wheels will reverse direction and enable the mobile unit to be moved over the carpeted area and only guided by its on-board circuitry.
• The mobile unit with move in a generally straight path until it contacts an obstruction or an obstacle with its rather sensitive obstruction detection system. At that point, the mobile unit will reverse direction and turn to either the right or left, according to its orientation set forth in the truth tables of FIGS. 13A and 13B. This creates a rather surprisingly thorough criss-cross pattern which essentially covers the entire carpeted area to be cleaned, much in the same manner as a conventional swimming pool cleaner will traverse a swimming pool in a random path and still clean the entire swimming pool surface area.[0128]
• The[0129]mobile unit22 also detects the obstructions, as indicated, and moves in a direction to avoid those obstructions. In addition, the mobile unit will detect the presence of a drop-off, such as stairs, or for that matter an uncarpeted area, by sensing irregularities in carpet height. At that point, the mobile unit will again turn its direction and move in a different path.
• When the pre-established time period for conducting a vacuum cleaning operation ends, the[0130]infrared homing beacon44 will be energized in thecabinet20 emitting an essentially invisible infrared light beam across the carpeted area. The mobile unit will almost inevitably be contacted by that infrared homing beam when energized. Even if it does not immediately see the infrared homing beam, it will continue to move in its random path until such time as it does detect the infrared homecoming beam. At that point, thedrive motors60 will be properly energized to drive the mobile unit toward thecabinet20.
• When the mobile unit arrives at the cabinet, its recharging[0131]plug64 will immediately be guided into and extend into the rechargingreceptacle70. Moreover, all of the motors in the mobile unit will then be automatically de-energized while thebattery62 is being recharged. Furthermore, in approximately one second after return to its home position, and connection to the recharging system, the mechanical hose assembly, previously described comprising theflexible hose144 will be lowered and connected to the mobile unit at which point the stationaryvacuum cleaner motor210 in thestation26 is energized. This will, in turn, clean out the debris and dust collected in thetemporary storage compartment90 of the mobile unit. After a predetermined time period, typically about thirty seconds, the stationary vacuum motor in thestation26 will become de-energized and the entire hose assembly will retract to its upper position. This will, in turn, leave themobile unit22 clear of any obstructions and free to recharge within the cabinet until it is again energized at the next vacuum start period.
• It is also possible to operate the cleaning system of the present invention using a hand-held remote control unit. A conventional television or a VCR remote control unit has literally been found to be effective for this purpose. Thus, one could initiate a start and end of a cleaning cycle with a remote control system. In like manner, it is possible to control the actual guiding of the mobile unit during driving activities by using certain buttons or control elements which would cause a left or right drive movement. As an example, the number “[0132]2” push button switch could be used to control left-hand movement and the number “3” push button switch could be used to control right-hand drive movement. Further, if desired, a specially designed hand-held remote control unit could be provided with the cleaning system of the present invention.
• The cleaning system of the present invention allows numerous advantages over conventional vacuum cleaners, as well as other automated cleaning systems. The use of the debris collection and storage mechanism allows the mobile unit to be cleaned after each carpet cleaning operation thereby reducing the size of the temporary storage area. Not only does this decrease the overall size of the mobile unit, but it concomitantly increases the maneuverability and the ability of the mobile unit to move under and behind a much greater number of obstacles. The small size of the mobile unit also is less intrusive, thereby adding to its appeal.[0133]
• The[0134]programmable timer52 with the cleaning system allows the user to set a permanent vacuum schedule, including the start time and end time. This will allow the mobile unit to vacuum a selected area of an environment, even in the absence of the user.
• This system provides a unique advantage in that it permits cleaning of a selected carpeted area in a commercial establishment after closing hours. Moreover, and for a dwelling environment, it allows the occupants of the dwelling to permit a cleaning operation to be conducted in their absence, thereby freeing them of the necessity to engage in a laborious periodic carpet cleaning operation. Further, the carpet cleaning system of the present invention is particularly effective for the elderly and disabled who do not have the necessary ability or strength to engage in continuous carpet cleaning operations.[0135]
• The automatic homing system and the recharging system previously described allows the mobile unit the advantage of returning to its home position and to be recharged completely on its own operation without any manual intervention. Further, even the cleaning of the temporary storage area in the mobile unit allows cleaning without any manual intervention. It is only necessary for the user to periodically clean the[0136]debris collection station26 in themain housing20.
• Thus, there has been illustrated and described, a unique and novel carpet cleaning system which utilizes a stationary housing and a mobile carpet cleaning unit which requires no manual control of the same during operation thereof. The present invention also provides a unique method of cleaning carpeted areas without manual intervention. The present invention thereby fulfills all of the objects and advantages which have been sought. It should be understood that many changes, modifications, variations and other uses and applications will become apparent to those skilled in the art after considering this specification and the accompanying drawings. Therefore, any and all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention.[0137]

Claims (37)

Having thus described the invention, what I desire to claim and secure by Letters Patent is:

1. An automatically operable vacuum cleaning apparatus capable of movement in a specified area at predetermined time intervals, said cleaning apparatus comprising:

a) a mobile cleaning apparatus having a body which is powered for driving movement in the specified area and in a non-controlled randomly operated path;

b) drive means in said body for generating a powered movement and driving the mobile cleaning apparatus in the specified area;

c) contact means associated with said body which is actuated when the body contacts a fixed structure; and

d) control means operatively connected to said contact means and said drive means to cause said drive means to alter the driving movement of the apparatus in another non-controlled randomly generated path which is different from the path followed by the apparatus when contacting the fixed structure until the apparatus thereby moves beyond the fixed structure.

2. The automatically operable vacuum cleaning apparatus ofclaim 1 further characterized in that said contact means comprise a plurality of spaced apart contacts which, are separately actuated when the body contacts a fixed structure in the region of the contact, and that the contact means which is actuated will cause a drive movement different than if another contact means is actuated.

3. The automatically operable vacuum cleaning apparatus ofclaim 1 further characterized in that said contact means comprises a shiftable bumper on said body and which will actuate a sensor associated with that bumper when the bumper contacts a fixed structure.

4. The automatically operable vacuum cleaning apparatus ofclaim 1 further characterized in that the drive means comprises a drive motor mounted in the body and which is connected to wheels on the body for positively driving same.

5. The automatically operable vacuum cleaning apparatus ofclaim 4 further characterized in that the drive motor is a bi-directional drive motor to enable the drive motor to drive the apparatus in a forward direction and in a rearward direction.

6. The automatically operable vacuum cleaning apparatus ofclaim 5 further characterized in that a pair of drive wheels are mounted on said body and a separate drive motor is connected to each of said drive wheels.

7. An automatically operable vacuum cleaning apparatus capable of movement in a specified area at predetermined time intervals, said cleaning apparatus comprising:

a) a movable cleaning apparatus body which is powered for movement in the specified area;

b) drive means carried with said body for causing a powered movement of the apparatus body in the specified area;

c) control means associated with the body for energizing the drive means and causing the apparatus to move in the specified area under its own control and without any external drive control at predetermine time intervals.

8. The automatically operable vacuum cleaning apparatus ofclaim 7 further characterized in that said control means comprises a microprocessor which is programmed to cause the energization of the drive means at specified time intervals.

9. The automatically operable vacuum cleaning apparatus ofclaim 8 further characterized in that said drive means comprises a drive motor means in said body, and wheels on said body operatively connected to said drive motor means and where the control means is operatively connected to the drive motor means to cause energization at the selected time intervals.

10. The automatically operable vacuum cleaning apparatus ofclaim 9 further characterized in that a pair of drive wheels are mounted on said body and a separate drive motor is connected to each of said drive wheels.

11. The automatically operable vacuum cleaning apparatus ofclaim 7 further characterized in that:

a) contact means is associated with said body and which is actuated when the body contacts a fixed structure; and

b) said control means is operatively connected to said contact means and said drive means to cause said drive mens to alter the driving movement of the apparatus and thereby move the apparatus beyond the fixed structure.

12. The automatically operable vacuum cleaning apparatus ofclaim 11 further characterized in that said control means comprises a plurality of spaced apart contacts which are separately actuated when the body contacts a fixed structure in the region of the contact, and that the contact means which is actuated will cause a drive movement different than if another contact means is actuated.

13. The automatically operable vacuum cleaning apparatus ofclaim 12 further characterized in that said contact means comprises a shiftable bumper on said body and which will actuate a sensor associated with that bumper when the bumper contacts a fixed structure.

14. An automatically operable vacuum cleaning system with automatic recharging means for recharging a source of stored energy forming part of the apparatus, said vacuum cleaning system comprising:

a) a movable cleaning apparatus body which is powered for movement;

b) drive means in said body for causing powered movement of the apparatus body;

c) a battery source of power carried by said apparatus body and being connected to the drive means for causing the powered movement;

d) a housing for storage of said apparatus body when not in use; and

e) recharging means associated with said housing for automatically connecting to said battery source of power without any manual intervention when said apparatus is moved into said housing to thereby automatically recharge the battery source of power.

15. The automatically operable vacuum cleaning system ofclaim 14 further characterized in that said recharging means is located within said housing.

16. The automatically operable vacuum cleaning system ofclaim 15 further characterized in that said recharging means comprises electrical contactors in said housing and cooperating electrical contactors on said apparatus body which automatically connect to one another when the body is moved into the housing, and conductor means connecting the contactors on the body to the battery source of power.

17. The automatically operable vacuum cleaning system ofclaim 16 further characterized in that the homing means is associated with said body to cause the contactors on the body to become electrically connected to the contactors on the housing when the body is moved into the housing.

18. The automatically operable vacuum cleaning system ofclaim 14 further characterized in that the drive means causes powered movement in a specified and limited area, and control means is operatively connected to said drive means to cause the battery source of power to energize the drive means and thereby cause the apparatus to move in the specified area under its own control without any manual guidance thereof.

19. The automatically operable vacuum cleaning system ofclaim 18 further characterized in that:

a) contact means is associated with said body which is actuated when the body contacts a fixed structure, and

b) control means is operatively connected to said contact means and said drive means to cause said drive means to alter the driving movement of the apparatus and thereby move beyond the fixed structure.

20. The automatically operable vacuum cleaning system ofclaim 19 further characterized in that said contact means comprises a plurality of spaced apart contacts which are separately actuated when the body contacts a fixed structure in the region of the contact, and that the contact means which is actuated will cause a drive movement different than if another contact means is actuated.

21. The automatically operable vacuum cleaning apparatus ofclaim 20 further characterized in that each said contact means comprises a shiftable bumper on said body and which will actuate a sensor associated with that bumper when the bumper contacts a fixed structure.

22. An automatically operable vacuum cleaning system with a stationary debris collection station capable of receiving debris collected by a movable carpet cleaner apparatus and temporarily stored in a temporary storage chamber of the apparatus, said apparatus comprising:

a) a movable cleaning apparatus body which is powered for movement;

b) drive means in said body causing powered movement of the apparatus body;

c) a temporary storage means carried by said apparatus for collecting debris picked-up by the apparatus during a cleaning operation;

d) valve means associated with said apparatus body for being openable to discharge the debris collected in the temporary storage means; and

e) a stationary debris collection station in a housing for said apparatus body and automatically removing debris from the temporary storage area when the movable apparatus body is stored in said housing.

23. The automatically operable vacuum cleaning system ofclaim 22 further characterized in that said apparatus body comprises a means for creating a vacuum therein to draw debris collected by the apparatus body into the temporary storage area.

24. The automatically operable vacuum cleaning system ofclaim 22 further characterized in that said stationary debris collection system comprises an arm which is movable when the body is stored within the housing and includes a head and connectable to the valve means of said apparatus body for withdrawing debris temporarily stored in the temporary storage means.

25. The automatically operable vacuum cleaning system ofclaim 24 further characterized- in that said stationary debris collection system further comprises a storage chamber for holding the debris withdrawn from the temporary storage means.

26. An automatically operable vacuum cleaning system which enables a mobile unit to be moved into and out of a housing for that mobile unit, said apparatus comprising:

a) a mobile cleaning unit which is self-powered for movement;

b) drive means in said mobile unit for randomly driving said mobile unit in a selected area;

c) a housing means for temporarily storing said mobile unit when not in use;

d) door means on said housing and being automatically openable upon initiation of a cleaning cycle which is preprogrammed into said housing and allowing said mobile unit to exit said housing; and

e) a means enabling said mobile unit on its own power to re-enter said housing after a cleaning cycle and to enable closing of the door on said housing.

27. The automatically operable vacuum cleaning system ofclaim 26 further characterized in that said system comprises a programmable timer which allows a user of the system to program a vacuum cleaning start and a vacuum cleaning end.

28. The automatically operable vacuum cleaning system ofclaim 26 further characterized in that said mobile unit comprises drive wheels and drive motors therein for driving the mobile unit in a random path during a cleaning operation.

29. The automatically operable vacuum cleaning system ofclaim 26 further characterized in that said housing has recharging means for automatically recharging the mobile unit when it returns to the housing after the cleaning cycle.

30. The automatically operable vacuum cleaning system ofclaim 29 further characterized in that said housing comprises means for automatically removing any debris collected by the mobile unit when the mobile unit re-enters the housing after a cleaning operation.

31. An automatically operable vacuum cleaning apparatus capable of movement in a specified area at predetermined time intervals and which is capable of avoiding driving into and over a drop-off, said apparatus comprising:

a) a mobile cleaning apparatus having a body which is powered for driving movement in the specified area;

b) drive means in said body for generating a powered movement and driving the mobile cleaning apparatus in the specified area;

c) a sensor capable of sensing a floor surface and being adapted for vertical shifting movement in response to variations in said floor surface; and

d) a driving control means for causing said drive means to move the mobile unit away from a drop-off in the floor surface sensed by said sensing means.

32. The automatically operable vacuum cleaning apparatus ofclaim 30 further characterized in that said sensing means comprises an arm capable of riding on or being spaced from a floor surface in very close proximity thereto.

33. The automatically operable vacuum cleaning system ofclaim 31 further characterized in that said drive means comprises a pair of drive wheels and with a separate motor driving each of said drive wheels, said driving correction means being operable to cause selected energization and de-energization of the separate drive motors in response to detection of a drop-off.

34. The automatically operable vacuum cleaning system ofclaim 33 further characterized in that said body is provided with contact means actuated when the body contacts a fixed structure and a control means connected to the contact means and to the drive means to cause the drive means to alter driving movement of the mobile unit in a path which is different from that previously followed by the mobile unit when contacting a fixed structure.

35. The automatically operable vacuum cleaning system ofclaim 34 further characterized in that said mobile unit moves in a non-controlled randomly generated path.

36. An automatically operable vacuum cleaning system with means for cleaning a mobile unit forming part of said system upon completion of a cleaning cycle, said vacuum cleaning system comprising:

a) a movable mobile unit which is powered for movement in a selected area for creating a vacuum cleaning of that area;

b) drive means in said mobile unit for causing powered movement of said mobile unit;

c) means in said mobile unit for creating a vacuum and withdrawing debris from a floor surface and storing same in said mobile unit;

d) a housing for storage of said mobile unit when not in a cleaning operation; and

e) a means for automatically removing any debris collected from said mobile unit upon completion of a cleaning operation and when said mobile unit is located within said housing.

37. The automatically operable vacuum cleaning system ofclaim 36 further characterized in that said debris collection means comprises an arm which automatically moves to the mobile unit and connects to the mobile unit upon entry of the mobile unit into the housing and thereupon withdraws any debris collected by the mobile unit during a vacuum cleaning operation.

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