ROBOTIC CLEANER WITH DUST CUP DOOR

Abstract

A robotic cleaner including a dust cup door and door actuator. The door actuator is configured to move the dust cup door to an open position when the robotic cleaner is in a horizontal orientation to allow debris on a surface to be cleaned to be drawn into the dust cup, and to move the dust cup door to a closed position when the robotic cleaner is rotated from the horizontal orientation to a rotated orientation to substantially prevent debris in the dust cup from exiting the robotic cleaner.

Claims

1. A robotic cleaner comprising: a chassis defining an air inlet; a dust cup defining a debris inlet and a cavity for receiving debris through the debris inlet; a suction motor configured to generate suction airflow in a suction airflow path extending between the air inlet and the debris inlet; a dust cup door disposed in the suction airflow path and movable between an open position and a closed position; and a door actuator coupled to the dust cup door, the door actuator configured to move the dust cup door to the open position when the robotic cleaner is in a horizontal orientation to allow debris on a surface to be cleaned to be drawn into the dust cup through the debris inlet by the suction airflow, and the door actuator configured to move the dust cup door to the closed position when the robotic cleaner is rotated from the horizontal orientation to a rotated orientation to substantially obstruct the suction airflow path to prevent debris in the dust cup from exiting the robotic cleaner through the air inlet.

2. The robotic cleaner of claim 1, wherein the door actuator is configured to move the dust cup door to the closed position when the robotic cleaner is rotated from the horizontal orientation by a pre-determined non-zero angle.

3. The robotic cleaner of claim 2, wherein the predetermined non-zero angle is 5 degrees or more from the horizontal orientation.

4. The robotic cleaner of claim 1, wherein the door actuator comprises a motor operatively coupled to the door and configured to move the dust cup door to the closed position or the open position.

5. The robotic cleaner of claim 4, wherein the door actuator comprises: a door trigger coupled to a dust cup door shaft, the dust cup door being coupled to the dust cup door shaft, wherein the motor is coupled to the door trigger and configured to operate the door trigger to move the dust cup door to the closed position or the open position.

6. The robotic cleaner of claim 5, wherein the door actuator further comprises a spring coupled to the door trigger to bias the dust cup door into the open position.

7. The robotic cleaner of claim 5, wherein the door actuator further comprises: a pulley rotatably coupled to the motor; and a wire having a first end coupled to the pulley and a second end coupled to the door trigger.

8. The robotic cleaner of claim 7, wherein the door actuator further comprises an input gear coupled to the motor and to the pulley.

9. The robotic cleaner of claim 8, wherein the input gear is coupled to the pulley through a clutch.

10. The robotic cleaner of claim 4 further comprising: a gear train coupled to an output shaft of the motor, the gear train having an output member; and an agitator coupled to the output member and configured to contact the surface to be cleaned, whereby rotation of the output shaft causes motion of the agitator against the surface to be cleaned.

11. The robotic cleaner of claim 10 further comprising an intermediate gear coupled to the gear train and wherein the door actuator further comprise an input gear coupled to the intermediate gear.

12. The robotic cleaner of claim 11, wherein the input gear is coupled to the pulley through a clutch.

13. The robotic cleaner of claim 1, wherein the door actuator comprises a pivoting member coupled to the dust cup door and the chassis for rotation about an axis under the force of gravity.

14. The robotic cleaner of claim 13, wherein the door actuator is configured to move the dust cup door to the open position in response to rotation of the pivoting member under the force of gravity about the axis in a first direction and to move to the closed position in response to rotation of the pivoting member under the force of gravity about the axis in a second direction opposite from the first direction.

15. The robotic cleaner of claim 13, wherein the pivoting member comprises: a pivoting tray defining a cavity for receiving a weight movable between a first end of the pivoting tray and a second end of the pivoting tray under the force of gravity; and cam coupled to the pivoting tray, the cam defining a cam slot, wherein the dust cup door is coupled to a link arm having a pin extending therefrom, the pin being slidably disposed in the cam slot, and wherein the dust cup door is configured to move to the open position when the weight moves to the first end of the pivoting tray and to move to the closed position when the weight moves to the second end of the pivoting tray.

16. The robotic cleaner of claim 15, wherein the cam is disposed between the pivoting tray and the dust cup door.

17. A robotic cleaning system comprising: a robotic cleaner comprising a dust cup defining a debris inlet and a cavity for receiving debris through the debris inlet, a suction motor configured to generate suction airflow in a suction airflow path extending between the air inlet and the debris inlet, a dust cup door disposed in the suction airflow path and movable between an open position and a closed position, and a door actuator coupled to the dust cup door; and a docking station comprising a ramp for receiving the robotic cleaner, wherein the door actuator is configured to maintain the dust cup door in an open position during a cleaning operation of the robotic cleaner to allow debris on a surface to be cleaned to be drawn into the dust cup through the debris inlet by the suction airflow, and wherein the door actuator is configured to maintain the dust cup door in a closed position when the robotic cleaner is on the ramp to substantially obstruct the suction airflow path to prevent debris in the dust cup from exiting the robotic cleaner through the air inlet.

18. The robotic cleaner of claim 17, wherein the door actuator is configured to move the dust cup door to the closed position when the robotic cleaner is rotated from a horizontal orientation by a pre-determined non-zero angle.

19. The robotic cleaner of claim 17, wherein the door actuator comprises a motor operatively coupled to the door and configured to move the dust cup door to the closed position or the open position.

20. The robotic cleaner of claim 17, wherein the door actuator comprises a pivoting member coupled to the dust cup door and the chassis for rotation about an axis under the force of gravity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Features of the present embodiments will be understood better by reading the following detailed description, taken together with the figures herein described. The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing.

[0004] FIG. 1 is a top schematic view of an example robotic cleaner consistent with embodiments of the present disclosure.

[0005] FIG. 2 is a side schematic view of a robotic cleaner consistent with the present disclosure in a horizontal orientation and a dust cup door in an open position.

[0006] FIG. 3 is a side schematic view of a robotic cleaner consistent with the present disclosure in a rotated orientation and a dust cup door in a closed position.

[0007] FIG. 4 is a side schematic view of a robotic cleaning system consistent with the present disclosure including a docking station and a robotic cleaner consistent with the present disclosure in a rotated orientation on a ramp of the docking station and a dust cup door in a closed position.

[0008] FIG. 5 is an illustrative block diagram of an example door actuator driven by a motor consistent with the present disclosure.

[0009] FIG. 6 is a front perspective view of one example of a cleaning system and a door actuator to move a dust cup door between open and closed positions consistent with the present disclosure.

[0010] FIG. 7 is a rear perspective of the cleaning system, the door actuator and a portion of the door shown in FIG. 6.

[0011] FIG. 8 is a side view of the cleaning system, the door actuator, and the door shown in FIG. 6.

[0012] FIG. 9 is a perspective, partially sectional view of a dust cup and cleaning fluid reservoir of a robotic cleaner consistent with the present disclosure showing a passive door actuator and a dust cup door in the open position consistent with the present disclosure FIG. 10 is detailed view of the door actuator and a portion of the door shown in FIG. 9.

[0013] FIG. 11 is a perspective, partially sectional view of the dust cup, the cleaning fluid reservoir, the a passive door actuator, and the dust cup door shown in FIG. 9 with the dust cup door in the closed position consistent with the present disclosure

[0014] FIG. 12 is detailed view of the door actuator and a portion of the door shown in FIG. 11.

DETAILED DESCRIPTION

[0015] The present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The examples described herein may be capable of other embodiments and of being practiced or being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting as such may be understood by one of skill in the art. Throughout the present description, like reference characters may indicate like structure throughout the several views, and such structure need not be separately discussed. Furthermore, any particular feature(s) of a particular exemplary embodiment may be equally applied to any other exemplary embodiment(s) of this specification as suitable. In other words, features between the various exemplary embodiments described herein are interchangeable, and not exclusive.

[0016] In general, a robotic cleaner consistent with the present disclosure may include a dust cup and a dust cup door movable between an open position and a closed position. When the robotic cleaner is positioned on a surface to be cleaned and performing a cleaning operation the dust cup door may be in an open position to allow suction airflow generated by the robotic cleaner to draw debris from a surface to be cleaned and into the dust cup. In some embodiments, when the dust cup door is in the open position it may act to restrict hair from entering the dust cup. When the robotic cleaner is disposed at an angle to the cleaning surface, the dust cup door may be automatically, i.e. without direct user manipulation of the door, moved to a closed position to block debris from falling out of the dust cup and landing in an undesired location. For example, the robotic cleaner may be configured to dock with a docking station. The docking station may, for example, electrically couple to the robotic cleaner to charge a battery in the robotic cleaner and/or may be configured to auto-empty the dust cup from the robotic cleaner into a collection bin in the docking station. The docking station may include a ramp on which the robotic cleaner is disposed when docked with the docking station. When the robotic cleaner is positioned on the ramp the robotic cleaner may be inclined or declined by the angle of the ramp and the dust cup door may be in the closed position to prevent debris in the dust cup from exiting the dust cup and landing on the top surface of the ramp.

[0017] The dust cup door may be moved between the open and closed positions by a door actuator. In some embodiments, the door actuator may be driven by a motor to automatically place the door in the open or closed position. In some embodiments, the door actuator may be driven by gravity to automatically place the door in the open or closed position.

[0018] FIG. 1 is a schematic view of one example of a robotic cleaner 100 consistent with the present disclosure. In the illustrated example embodiment, the robotic cleaner 100 includes a chassis 102, one or more wheels 104 coupled to the chassis 102, a suction motor 106, a dust cup 108, an air inlet 110, a dust cup door 112, a door actuator 114, a controller 116, and one or more sensors 118. The robotic cleaner 100 may perform wet and/or dry cleaning operations and may include a dry cleaning system 120 and/or a wet cleaning system 122.

[0019] In general, the motor 106 is configured to generate suction air flow to draw debris, which may include cleaning fluid, into the suction inlet 110 at the bottom of the chassis 112, through a suction air flow path 124 extending between the suction inlet 110 and the dust cup 108 and into the dust cup 108 through a debris inlet 126. The debris inlet 126 defines an opening to a cavity 128 configured to store debris drawn from the surface to be cleaned. The dust cup 108 may also include a debris outlet 130 for removing the debris from the cavity 128.

[0020] The dry cleaning system 120 may include a known system for directing debris on the surface to be cleaned into the air inlet 110. The dry cleaning system 120 may include a drive system, e.g., a motor, and an agitator, such as a rotating brush roll, rotating side brushes, an air jet, driven by the drive system. The wet cleaning system 122 may include a known system for performing wet cleaning. For example, the wet cleaning system 122 may include a drive system, e.g., including a motor, and an agitator, such as pad or cleaning cloth, that contacts the surface to be cleaned and is driven by the motor to cause vibration and/or rotation of the pad or cleaning cloth. In embodiments including a wet cleaning system 122, the robotic cleaner 100 may include a cleaning fluid reservoir 132 coupled, e.g. removably, to the chassis 102 for providing a source of cleaning fluid to be directly or indirectly deposited on the surface to be cleaned.

[0021] The robotic cleaner is configured to autonomously perform a wet and/or dry cleaning operation under control of the controller 116. In a dry cleaning operation, the robotic cleaner 100 traverses an area to be cleaned while the motor 106 generates suction airflow to draw debris, e.g. with the assistance of a dry cleaning system 120, into the air inlet 110 and into the dust cup 108 through the debris inlet 126. In a wet cleaning operation, the robotic cleaner 100 traverses an area to be cleaned while the wet cleaning system 122 applies cleaning fluid to directly or indirectly to the surface to be cleaned and agitates the cleaning fluid. The suction motor 106 generates suction air flow to draw the cleaning fluid and debris from the surface to be cleaned into the air inlet 110 and into the dust cup 108 through the debris inlet. A variety of configurations for performing autonomous wet and/or dry cleaning are well known.

[0022] One challenge with robotic cleaners configured to perform wet and or dry cleaning is that when the robotic cleaner is moved from a horizontal orientation the surface to be cleaned to an angle from the horizontal orientation, the debris, which may include cleaning fluid, can spill from the dust cup and exit the robot through the air inlet. In a system consistent with the present disclosure, the dust cup door 112 is controlled by the door actuator 114 to automatically move between an open position and a closed position. In the open position, the dust cup door 112 is positioned to allow debris to be drawn into the dust cup 108 through the debris inlet 126 by the suction airflow. The dust cup door 112 is moved to, or maintained in, the open position by the door actuator 114 during a cleaning operation. In some embodiments, when the dust cup door 112 is in the open position it may act to restrict hair from entering the dust cup 108.

[0023] In the closed position, the dust cup door 112 substantially obstructs the suction airflow path 124 between the debris inlet 126 and the air inlet 110 to substantially prevent debris in the cavity 128 of the dust cup 108 from exiting the robotic cleaner 100 through the air inlet 110. The dust cup door 112 may be moved to, or maintained in, the closed position whenever the robotic cleaner 100 is rotated from a horizontal orientation, e.g. by a predetermined angle, to prevent debris from spilling from the robotic cleaner 100. For example, the dust cup door 112 may be moved to, or maintained in, the closed position by the door actuator 114 when the robotic cleaner 100 is lifted from the floor by a user and rotated from the horizontal orientation. In addition, or alternatively, the dust cup door 112 may be moved to, or maintained in, the closed position by the door actuator 114 when the robotic cleaner 100 is disposed on a docking station to prevent debris in the dust cup 108 from exiting the robotic cleaner 100 and falling onto the docking station.

[0024] The dust cup door 112 may be provided in a variety of configurations and positions to move between the open position and the closed position. In some embodiments, the dust cup door 112 may be provided in the suction airflow path 124 and may be fixed to the chassis 102 to close against surfaces defining the suction airflow path 124. In some embodiments, the dust cup door 112 may be fixed to the dust cup 108 at the end of the suction airflow path 124 to close against the debris inlet 126 of the dust cup 112. In embodiments where the dust cup door 112 is fixed to the dust cup 108, the dust cup 108 may be removable from the robotic cleaner 100 and the dust cup door may be removable with the dust cup 108. Also, the door actuator 114 may be coupled to the chassis 102 or may be coupled to the dust cup 108. In some embodiments, the one or more components of the door actuator 114 may be coupled to the chassis 102 and one or more other components may be coupled to the dust cup 108.

[0025] FIGS. 2 and 3, diagrammatically illustrate an example configuration of the dust cup 108 and the dust cup door 112 in the open and closed positions, respectively. The dust cup door 112 may block the debris inlet 126 to the cavity 128 of the dust cup 108 at any point between the debris inlet 126 and the air inlet 110. In some embodiments, the dust cup door 112 may be a debris deflector configured to block hair when in the open position and configured to rotate to the closed position. In some embodiments, a removable dust cup 108 may be swapped with a different configuration of the dust cup 108. For example, a first configuration of the dust cup 108 may be used for dry cleaning operations and a second configuration of the dust cup 108 may be used for wet cleaning operations. A dust cup door 112 may be configured to block the debris inlet 126 in either or both configurations and may be coupled to the chassis 102 or to the dust cup 108.

[0026] FIG. 2 illustrates one example of the robotic cleaner 100, wherein the robotic cleaner 100 is positioned in a horizontal orientation. In the illustrated horizontal orientation, the robotic cleaner 100 has a central fore-aft axis 202 positioned substantially parallel, e.g. within about +/5 degrees, to a horizontal plane 204, such as a floor surface to be cleaned. The robotic cleaner 100 may be in a horizontal orientation when performing a normal cleaning operation. When the robotic cleaner 100 is in a horizontal orientation the dust cup door 112 may be in an open position, as shown, to allow debris to enter the dust cup 108.

[0027] FIG. 3 illustrates the robotic cleaner 100 in a rotated orientation. In the rotated orientation, the central fore-aft axis 202 of the robotic cleaner 100 is rotated by a non-zero angle A from the horizontal orientation. The rotated orientation may occur for example, when a user lifts the robotic cleaner 100 from a floor, or when the robotic cleaner 100 is positioned on a ramp of a docking station. When the robotic cleaner 100 is in a rotated orientation the dust cup door 112 may be in the closed position, as shown, to block debris in the dust cup 108 from exiting the robotic cleaner 100 through the air inlet 110.

[0028] The dust cup door 112 may be configured to automatically move to the closed position when the angle A reaches or exceeds a predetermined threshold angle. The threshold angle may be selected depending on the configuration of the robotic cleaner 100 to block debris from spilling out of through the air inlet 110. In some embodiments, the predetermined threshold angle may be 5 degrees or more.

[0029] FIG. 4, for example, diagrammatically illustrates a cleaning system 200 including the robotic cleaner 100 disposed on a docking station 400 and the dust cup door 112 in a closed position. As shown, the docking station 400 includes a ramp 402. A top surface 404 of the ramp 402 may be disposed at a non-zero angle A1 relative to the surface 406 on which the docking station 400 is disposed. In some embodiments, the robotic cleaner 100 may travel up the ramp 402 in a rearward direction to dock with the docking station 400. When the robotic cleaner 100 is positioned on the ramp 402, the robotic cleaner 100 is in a rotated orientation and the dust cup door 112 is in the closed position.

[0030] Before or during docking, suction airflow from the suction motor 106 may be stopped and the dust cup door 112 may be moved or maintained by the door actuator 114 in the closed position to prevent debris in the dust cup 108 from exiting robotic cleaner 100 through the air inlet 110 and landing on the top surface 404 of the ramp 402. The debris outlet 130 may be configured to couple with dock debris inlet 408 when the robotic cleaner 100 is disposed on the docking station 400 to perform an auto-emptying operation. In the auto-emptying operation contents of the dust cup 108 are transferred into the docking station 400 to empty the dust cup 108. During the auto-emptying operation, the dust cup door 112 may be in the closed position.

[0031] A door actuator 114 consistent with the present disclosure may be provided in a variety of configurations. In some embodiments, the door actuator 114 may be directly or indirectly driven to move between the open and closed positions by a motor. FIG. 5, for example, diagrammatically illustrates one example of a dry or wet cleaning system 120, 122 configured to drive a door actuator 114a of a robotic cleaner 100. The cleaning system 120,122 includes a motor 502 operatively coupled to a transmission 504. The transmission 504 is operatively coupled to an agitator 506, e.g. a brush roll, side brushes, cleaning pad, cleaning cloth, etc. The transmission 504 may be any configuration for coupling the rotational output of a the motor to the agitator 506, e.g., a gear train, a rod and/or a cam. With reference also to FIG. 1, during a cleaning operation, e.g., a vacuuming and/or wet mopping operation, the motor 502 drives the transmission 504 to drive the agitator 506, e.g. to cause rotation or vibration of the agitator 506, to urge debris from the surface to be cleaned whereby suction from the suction motor 106 may the draw debris into the dust cup 108 through the air inlet 110.

[0032] In the illustrated example embodiment, the motor 502 of the cleaning system 120,122 is also coupled through the transmission 504 to the door actuator 114a to move the dust cup door 112 between the open position and the closed position. For example, and with continued reference also to FIGS. 1 and 4, when the robotic cleaner 100 is positioned on the ramp 402 of the docking station 400, the transmission 504 may be configured to drive the door actuator 114a to cause to place dust cup door 112 in the closed position. In an embodiment, the controller 116 may be configured to control the motor 502. In some instances, the controller 116 may receive a signal from one or more sensors 118, e.g. a proximity sensor indicating proximity to a docking station 400, an accelerometer indicating rotational orientation of the robotic cleaner 100, etc., to determine whether the robotic cleaner 100 is in a horizontal orientation or a rotated orientation. In some instances, the controller 116 may determine that the robotic cleaner 100 has begun a docking operation with a docking station 400 that has an angled ramp 402, and the controller 116 may be configured to provide an output to the door actuator 114a to cause the door actuator 114a to close the dust cup door 112 as the robotic cleaner 100 approaches the docking station 400 and before it is on the ramp 402. The controller 116 may also be configured to open the dust cup door 112 once the robotic cleaner 100 has undocked from the docking station 400 or traversed a predetermined distance corresponding to the length of the ramp 402.

[0033] FIGS. 6-8 illustrate one example of a wet cleaning system 122a configured for driving a door actuator 114b consistent with the present disclosure. In the illustrated example embodiment, the wet cleaning system 122a includes a motor 502a having an output shaft 802 (FIG. 8), a transmission 504a configured as a gear train 602 coupled to the output shaft 802 of the motor 502a, and an agitator 506a, e.g. a cleaning pad or cleaning cloth, driven by the gear train 602. The gear train 602 is coupled to the door actuator 114b by an intermediate gear 604. The door actuator 114b includes an input gear 606, clutch 608, a pulley 610 coupled the input gear 606 through the clutch 608, a cable 612, a door trigger 614, and a door shaft 616 coupled to the dust cup door 112a.

[0034] In general, the gear train 602 includes an output member 618 coupled to the agitator 506a. During a cleaning operation of a robotic cleaner 100 including the wet cleaning system 122a, the robotic cleaner 100 may be in the horizontal orientation, e.g. a sensed by one or more sensors 118 (FIG. 1) of the robotic cleaner 100, and the controller 116a may provide a signal to the motor 502a to cause rotation of the output shaft 802 of the motor 502a in a first direction, e.g. counter-clock-wise. Rotation of the output shaft 802 of the motor 502a in the first direction the drives the gear train 602 to cause rotation of the output member 618 according to a gear ratio established by the gear train 602. The gear train 602 may be selected to achieve the desired gear ratio and may include one or more gears. Rotation of the output member 618, e.g. eccentric rotation, is coupled to the agitator 506a directly or indirectly to cause vibration, translation or rotation of the agitator 506a against a surface to be cleaned.

[0035] The input gear 606 of the door actuator 114b is coupled to the intermediate gear 604 for rotation therewith and the pulley 610 is coupled to the input gear 606 through the clutch 608. When the output shaft 802 of the motor 502a rotates in the first direction, the gear train 602 causes rotation of the intermediate gear 604 and the input gear 606 of the door actuator 114b. The clutch 608, however, is configured to decouple rotation of the input gear 606 from the pulley 610 whereby the pulley 610 does not rotate when the output shaft 802 of the motor 502a is rotating in the first direction. Rotation of the output shaft 802 of the motor 502a in the first direction thus drives the agitator 506a but does not rotate the pulley 610.

[0036] When the robotic cleaner 100 is moved from the horizontal orientation to a rotated orientation, e.g. as sensed by one or more sensors 118 (FIG. 1) of the robotic cleaner 100, the controller 116a may provide a signal to the motor 502a to cause rotation of the output shaft 802 of the motor 502a in a second direction opposite from the first direction, e.g. clock-wise. When the output shaft 802 of the motor 502a rotates in the second direction the gear train 602 causes rotation of the intermediate gear 604 and the input gear 606 of the door actuator 114b. The clutch 608 couples the rotation of the input gear 606 to the pulley 610 to cause corresponding rotation of the pulley 610 against the bias of a spring 620. Rotation of the output shaft 802 of the motor 502a in the second direction thus rotates the pulley 610.

[0037] The pulley 610 of the door actuator 114b is coupled to a dust cup door 112a by the cable 612. In the illustrated example embodiment, the cable 612 includes a wire 622 having a first end 804 fixed to the pulley 610, as shown in FIG. 7, and a second end 804 fixed to the door trigger 614, as shown in FIG. 8. The door trigger 614 is rotatably fixed to the chassis 102 and coupled to the door shaft 616 for rotation therewith about a longitudinal axis of the door shaft 616. The dust cup 112a is fixed to the door shaft 616. Rotation of the door trigger 614 causes corresponding rotation of the door shaft 616 and corresponding rotation of the dust cup door 112a. In the illustrated example embodiment, the door trigger 614 extends generally axially from the door shaft 616, as shown particularly in FIG. 8 and is biased to the position shown in FIGS. 6-8 by a torsion spring 624 wherein the dust cup door 112a is in the open position.

[0038] Rotation of the pulley 610 rotates the door trigger 614 against the bias of the torsion spring 624 to rotate the door shaft 616 and thereby rotate the door 112a, e.g. counter clock-wise in the from the position shown in FIG. 8, to the closed position. One or more sensors 118a, e.g. an optical sensor or Hall effect sensor, may sense the rotational position of the pulley 610 and provide a signal to the controller 118a to stop rotation of the output shaft 802 of the motor 502a when the pulley 610 reaches a rotational position corresponding to the closed position of the door 112a. When the motor 502a is energized by the controller 116a to drive the agitator 506a, the torsion spring 624 may return the door trigger 614 and the door 112a to the open position and the spring 620 may return the pulley 610 to the position corresponding to the open position.

[0039] Although the illustrated example embodiment includes a cleaning system motor 502a for driving the door actuator 114b, it is to be understood that the door actuator 114b may be driven by a dedicated motor or a motor for another system, e.g. a motor for driving the wheels. For example, the input gear 606 of the door actuator 114b may be coupled to a dedicated motor, e.g. through a gear train. The illustrated embodiment is thus provided by way of illustration, not of limitation.

[0040] In another example embodiment, the door actuator 114 may be configured to passively open and close the dust cup door 112 using, for example, gravity. In some embodiments, the door actuator 114 may use pivoting member coupled to the door actuator 114 wherein the pivoting member rotates around an axis under the force of gravity to move the dust cup 112 door between the open position and the closed position. When the robotic cleaner 100 is at a rotated angle, e.g., on the ramp 402 of a docking station 400, the pivoting member may be configured such that gravity causes rotation of the pivoting member in a first direction about the axis to move the dust cup door 112 into the closed position. When the robotic cleaner 100 is in a horizontal orientation, e.g., during a normal cleaning operation, the gravity causes the pivoting member to rotate in a second direction, opposite to the first direction, to move the dust cup door 112 into the open position.

[0041] The pivoting member may be provided in a variety of configurations. FIGS. 9-12, for example, illustrate one example embodiment consistent with the present disclosure wherein a door actuator 114c uses gravity to move a dust cup door 112b between open and closed positions. FIG. 9 is a partially sectional view of a dust cup 108a and cleaning fluid reservoir 132a of a robotic cleaner 100 showing the door actuator 114c and the dust cup door 112b in the open position. FIG. 10 is detailed view of the door actuator 114c shown in FIG. 9. FIG. 11 shows the dust cup 108a, the cleaning fluid reservoir 132a, the door actuator 114c, and the dust cup door 112b shown in FIG. 9 with the dust cup door 112b in the closed position. FIG. 12 is detailed view of the door actuator 114c and a portion of the dust cup door 112b shown in FIG. 11.

[0042] In the illustrated embodiment, the dust cup door 112b acts as a debris deflector when in the open position and blocks debris from exiting the robotic cleaner 100 when in the closed position. When operating as a debris deflector the dust cup door 112b is configured to deflect debris entering the dust cup 108a toward a bottom surface of the dust cup 108a and away from an exhaust vent filter of the robotic cleaner 100 to discourage the debris from clogging the exhaust vent filter.

[0043] The door actuator 114c includes a pivoting member 902 assembly and a weight 904. As shown particularly in FIGS. 10 and 12, the pivoting member 902 includes cam 1002 and a pivoting tray 1004. The pivoting member 902 may be pivotally coupled to chassis 102 of the robotic cleaner 100 for rotation about an axis AR parallel to a longitudinal axis of the pivoting member 902. The pivoting tray 1004 has a bottom 1006, first 1008 and second 1010 opposed sidewalls and first 1012 and second 1014 opposed ends defining a cavity 1016 for receiving the weight 904. The weight 904 shown in FIGS. 9-12 is configured as a ball, but the weight 904 may take any geometric shape or may be a liquid.

[0044] In the illustrated example embodiment, the cam 1002 is configured as a rectangular plate 1018 coupled to the second end 1014 of the pivoting tray 1004 adjacent dust cup door 112b for rotation with the pivoting tray 1004. A cam slot 1020 extends through the plate 1018 and extends diagonally in a direction away from the dust cup door 112b from a bottom 1022 to a top 1024 of the cam slot 1020. The dust cup door 112b includes a door shaft 1026 at a top thereof and a link arm 1028 extends radially outwardly from the door shaft 1026 toward the cam 1002. A distal end of the link arm 1028 opposite from the door shaft 1026 has an axially extending pin 1030 slidably disposed in the cam slot 1020.

[0045] As shown in FIGS. 9 and 10, when the robotic cleaner is a horizontal orientation, the weight 904 is forced by gravity toward the first end 1012 of the pivoting tray 1004, i.e. in the direction shown by arrow 906 in FIG. 9. Movement of the weight 904 toward the first end 1012 causes rotation of the pivoting tray 1004 about the axis AR in a first direction, e.g. clockwise as indicated by arrow 1032, and corresponding rotation of the cam 1002. As the cam 1002 rotates in the first direction the pin 1030 on the distal end of the link arm 1028 is forced downwardly toward the bottom 1022 of the cam slot 1020 to rotate the dust cup door 112b to the open position. In some embodiments, the pivoting tray 1004 may include a first indentation 1034 disposed in the bottom 1006 thereof adjacent the second end 1014. The first indentation 1034 may releasably retain the weight 904 adjacent the second end 1014 until the pivoting tray 1004 rotates by a predetermined angle from the horizontal orientation e.g. +5 degrees, to prevent excessive movement of the cam 1002 during operation of the robotic cleaner 100.

[0046] As shown in FIGS. 11 and 12, when the robotic cleaner is moved to a rotated orientation, the weight 904 is forced by gravity toward the second end 1014 of the pivoting tray 1004, as indicated by arrow 1102 in FIG. 11. Movement of the weight 904 toward the second end 1014 causes rotation of the pivoting tray 1004 about the axis AR in a second direction, e.g. counter-clockwise as indicated by arrow 1202, opposite to the first direction, and corresponding rotation of the cam 1002. As the cam 1002 rotates in the second direction the pin 1030 on the distal end of the link arm 1028 is forced upwardly toward the top 1024 of the cam slot 1020 to rotate the dust cup door 112b to the closed position. In some embodiments, the pivoting tray 1004 may include a second indentation 1204 disposed in the bottom 1006 thereof adjacent the first end 1012. The second indentation 1204 may releasably retain the weight 904 adjacent the first end 1012 until the pivoting tray 1004 rotates by a predetermined angle from the horizontal orientation e.g. more than +5 degrees, to prevent excessive movement of the cam 1002 during operation of the robotic cleaner 100.

[0047] According to one aspect of the disclosure there is thus provided a robotic cleaner including: a chassis defining an air inlet; a dust cup defining a debris inlet and a cavity for receiving debris through the debris inlet; a suction motor configured to generate suction airflow in a suction airflow path extending between the air inlet and the debris inlet; a dust cup door disposed in the suction airflow path and movable between an open position and a closed position; and a door actuator coupled to the dust cup door. The door actuator is configured to move the dust cup door to the open position when the robotic cleaner is in a horizontal orientation to allow debris on a surface to be cleaned to be drawn into the dust cup through the debris inlet by the suction airflow. The door actuator configured to move the dust cup door to the closed position when the robotic cleaner is rotated from the horizontal orientation to a rotated orientation to substantially obstruct the suction airflow path to prevent debris in the dust cup from exiting the robotic cleaner through the air inlet.

[0048] In some embodiments, the door actuator is configured to move the dust cup door to the closed position when the robotic cleaner is rotated from the horizontal orientation by a pre-determined non-zero angle.

[0049] In some embodiments, the predetermined non-zero angle is 5 degrees or more from the horizontal orientation.

[0050] In some embodiments, the door actuator includes a motor operatively coupled to the door and configured to move the dust cup door to the closed position or the open position.

[0051] In some embodiments, the door actuator includes: a door trigger coupled to a dust cup door shaft, the dust cup door being coupled to the dust cup door shaft, wherein the motor is coupled to the door trigger and configured to operate the door trigger to move the dust cup door to the closed position or the open position.

[0052] In some embodiments, the door actuator further includes a spring coupled to the door trigger to bias the dust cup door into the open position.

[0053] In some embodiments, the door actuator further includes: a pulley rotatably coupled to the motor; and a wire having a first end coupled to the pulley and a second end coupled to the door trigger.

[0054] In some embodiments, the door actuator further includes an input gear coupled to the motor and to the pulley.

[0055] In some embodiments, the input gear is coupled to the pulley through a clutch.

[0056] Is some embodiments the robotic cleaner further includes: a gear train coupled to an output shaft of the motor, the gear train having an output member; and an agitator coupled to the output member and configured to contact the surface to be cleaned, whereby rotation of the output shaft causes motion of the agitator against the surface to be cleaned.

[0057] In some embodiments, the robotic cleaner further includes an intermediate gear coupled to the gear train and wherein the door actuator further comprise an input gear coupled to the intermediate gear.

[0058] In some embodiments, the input gear is coupled to the pulley through a clutch.

[0059] In some embodiments, the door actuator includes a pivoting member coupled to the dust cup door and the chassis for rotation about an axis under the force of gravity.

[0060] In some embodiments, the door actuator is configured to move the dust cup door to the open position in response to rotation of the pivoting member under the force of gravity about the axis in a first direction and to move to the closed position in response to rotation of the pivoting member under the force of gravity about the axis in a second direction opposite from the first direction.

[0061] In some embodiments, the pivoting member includes: a pivoting tray defining a cavity for receiving a weight movable between a first end of the pivoting tray and a second end of the pivoting tray under the force of gravity; and cam coupled to the pivoting tray, the cam defining a cam slot, wherein the dust cup door is coupled to a link arm having a pin extending therefrom, the pin being slidably disposed in the cam slot, and wherein the dust cup door is configured to move to the open position when the weight moves to the first end of the pivoting tray and to move to the closed position when the weight moves to the second end of the pivoting tray.

[0062] In some embodiments, the cam is disposed between the pivoting tray and the dust cup door.

[0063] According to another aspect of the present disclosure, there is provided a robotic cleaning system including: a robotic cleaner including a dust cup defining a debris inlet and a cavity for receiving debris through the debris inlet, a suction motor configured to generate suction airflow in a suction airflow path extending between the air inlet and the debris inlet, a dust cup door disposed in the suction airflow path and movable between an open position and a closed position, and a door actuator coupled to the dust cup door; and a docking station including a ramp for receiving the robotic cleaner, wherein the door actuator is configured to maintain the dust cup door in an open position during a cleaning operation of the robotic cleaner to allow debris on a surface to be cleaned to be drawn into the dust cup through the debris inlet by the suction airflow, and wherein the door actuator is configured to maintain the dust cup door in a closed position when the robotic cleaner is on the ramp to substantially obstruct the suction airflow path to prevent debris in the dust cup from exiting the robotic cleaner through the air inlet.

[0064] In some embodiments, wherein the door actuator is configured to move the dust cup door to the closed position when the robotic cleaner is rotated from a horizontal orientation by a pre-determined non-zero angle.

[0065] In some embodiments, the door actuator includes a motor operatively coupled to the door and configured to move the dust cup door to the closed position or the open position.

[0066] In some embodiments, the door actuator includes a pivoting member coupled to the dust cup door and the chassis for rotation about an axis under the force of gravity.

[0067] The foregoing description of example embodiments has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto. Future-filed applications claiming priority to this application may claim the disclosed subject matter in a different manner and generally may include any set of one or more limitations as variously disclosed or otherwise demonstrated herein.

[0068] It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, aspect, embodiment, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, aspects, embodiments, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present invention.

[0069] The functions of the various elements shown in the figures, including any functional blocks labeled as a controller or processor, may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. The functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term controller or processor should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read-only memory (ROM) for storing software, random access memory (RAM), and non-volatile storage. Other hardware, conventional and/or custom, may also be included.

[0070] The phrase and/or, as used herein in the specification and in the claims, should be understood to mean either or both of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the and/or clause, whether related or unrelated to those elements specifically identified, unless clearly indicated to the contrary.

[0071] The term coupled as used herein refers to any connection, coupling, link or the like by which signals carried by one system element are imparted to the coupled element. Such coupled devices, or signals and devices, are not necessarily directly connected to one another and may be separated by intermediate components or devices that may manipulate or modify such signals. Likewise, the terms connected or coupled as used herein in regard to mechanical or physical connections or couplings is a relative term and does not require a direct physical connection.

[0072] Elements, components, modules, and/or parts thereof that are described and/or otherwise portrayed through the figures to communicate with, be associated with, and/or be based on, something else, may be understood to so communicate, be associated with, and/or be based on in a direct and/or indirect manner, unless otherwise stipulated herein.

[0073] Unless otherwise stated, use of the word substantially may be construed to include a precise relationship, condition, arrangement, orientation, and/or other characteristic, and deviations thereof as understood by one of ordinary skill in the art, to the extent that such deviations do not materially affect the disclosed methods and systems. Throughout the entirety of the present disclosure, use of the articles a and/or an and/or the to modify a noun may be understood to be used for convenience and to include one, or more than one, of the modified noun, unless otherwise specifically stated. The terms comprising, including and having are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0074] As used herein, use of the term nominal or nominally when referring to an amount means a designated or theoretical amount that may vary from the actual amount.

[0075] Spatially relative terms, such as beneath, below, upper, lower, above, left, right and the like may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. These spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation shown in the drawings. For example, if the device in the drawings is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the exemplary term below may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0076] Although the terms first, second, third etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections are not to be limited by these terms as they are used only to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section could be termed a second element, component, region, layer or section without departing from the scope and teachings of the present invention.

[0077] Although the methods and systems have been described relative to specific embodiments thereof, they are not so limited. Obviously, many modifications and variations may become apparent in light of the above teachings. Many additional changes in the details, materials, and arrangement of parts, herein described and illustrated, may be made by those skilled in the art.