阅读说明：本技术 用于机器人清洁器的对接站 (Docking station for robot cleaner ) 是由 特雷弗·霍夫曼 安德烈·D·布朗 安德洛莫达·哈夫曼 于 2019-10-22 设计创作，主要内容包括：用于机器人清洁器的对接站可包括壳体、联接到壳体的至少一个充电触点以及设置在壳体内的至少三个光学发射器。所述至少三个光学发射器可包括：第一光学发射器,所述第一光学发射器被配置成在第一发射场内生成第一光学信号；第二光学发射器,所述第二光学发射器被配置成在第二发射场内生成第二光学信号；以及第三光学发射器,所述第三光学发射器被配置成在第三发射场内生成第三光学信号。第三光学发射器可设置于第一光学发射器与第二光学发射器之间。第一光学信号、第二光学信号和第三光学信号可以彼此不同。第三光学信号可以被配置成在壳体的方向上引导机器人清洁器。(A docking station for a robotic cleaner may include a housing, at least one charging contact coupled to the housing, and at least three optical emitters disposed within the housing. The at least three optical emitters may include: a first optical emitter configured to generate a first optical signal within a first field of emission; a second optical emitter configured to generate a second optical signal within a second emission field; and a third optical emitter configured to generate a third optical signal within a third emission field. The third optical emitter may be disposed between the first optical emitter and the second optical emitter. The first optical signal, the second optical signal, and the third optical signal may be different from each other. The third optical signal may be configured to guide the robot cleaner in a direction of the housing.)

1. A docking station for a robotic cleaner, comprising:

a housing;

at least one charging contact coupled to the housing; and

at least three optical emitters disposed within the housing, the at least three optical emitters comprising:

a first optical emitter configured to generate a first optical signal within a first field of emission;

a second optical emitter configured to generate a second optical signal within a second emission field; and

a third optical emitter configured to generate a third optical signal within a third emission field, the third optical emitter disposed between the first optical emitter and the second optical emitter, and the first, second, and third optical signals being different from one another, wherein the third optical signal is configured to direct a robotic cleaner in a direction of the housing.

2. The docking station of claim 1, wherein the first transmission field and the second transmission field do not have substantial overlap within a detection zone.

3. The docking station of claim 2, wherein at least a portion of the third transmitted field extends in an area between the first transmitted field and the second transmitted field, the area corresponding to a location where the robot cleaner detects the third optical signal without the first and second optical signals.

4. The docking station of claim 1, wherein the first transmission field, the second transmission field, and the third transmission field overlap one another for at least a portion of a detection zone.

5. The docking station of claim 1, further comprising at least three shadow boxes disposed within the housing, each shadow box corresponding to a respective one of the first, second, and third optical emitters.

6. The docking station of claim 1, wherein the first optical emitter and the second optical emitter are angled relative to the third optical emitter.

7. The docking station of claim 1, wherein the first optical emitter, the second optical emitter, and the third optical emitter are aligned along a common horizontal plane.

8. The docking station of claim 1, wherein the third optical emitter is vertically offset from the first and second optical emitters.

9. The docking station of claim 8, wherein the first optical emitter and the second optical emitter are aligned along a common horizontal plane.

10. A robotic cleaning system, comprising:

a robotic cleaner having at least one optical receiver; and

a docking station having at least one charging contact and at least three optical emitters, the at least three optical emitters comprising:

a first optical emitter configured to generate a first optical signal within a first field of emission;

a second optical emitter configured to generate a second optical signal within a second emission field; and

a third optical emitter configured to generate a third optical signal within a third emission field, the third optical emitter disposed between the first optical emitter and the second optical emitter, and the first, second, and third optical signals being different from one another, wherein the third optical signal is configured to guide the robotic cleaner in a direction of the docking station.

11. The robotic cleaning system according to claim 10, wherein the first optical emission field and the second optical emission field do not have substantial overlap within a detection zone.

12. The robotic cleaning system according to claim 11, wherein at least a portion of the third transmitted field extends in a region between the first transmitted field and the second transmitted field, the region corresponding to a location where the robotic cleaner detects the third optical signal without the first and second optical signals.

13. The robotic cleaning system according to claim 10, wherein the first, second, and third transmission fields overlap one another for at least a portion of a detection zone.

14. The robotic cleaning system according to claim 10, further comprising at least three shadow boxes disposed within the docking station, each shadow box corresponding to a respective one of the first, second, and third optical emitters.

15. The robotic cleaning system according to claim 10, wherein the first and second optical emitters are angled relative to the third optical emitter.

16. The robotic cleaning system according to claim 10, wherein the first optical emitter, the second optical emitter, and the third optical emitter are aligned along a common horizontal plane.

17. The robotic cleaning system according to claim 10, wherein the third optical emitter is vertically offset from the first and second optical emitters.

18. The robotic cleaning system according to claim 17, wherein the first optical emitter and the second optical emitter are aligned along a common horizontal plane.

19. The robotic cleaning system according to claim 10, wherein the robotic cleaner is moved toward the third optical signal when the at least one optical receiver detects one of the first optical signal or the second optical signal.

20. The robotic cleaning system according to claim 19, wherein when the at least one optical receiver detects the third optical signal, the robotic cleaner is caused to follow the third optical signal until the robotic cleaner engages the docking station such that the robotic cleaner is electrically coupled to the at least one charging contact.

Technical Field

The present disclosure relates generally to a docking station for a robot cleaner, and more particularly, to a docking station for a robot cleaner configured to generate a signal for guiding the robot cleaner to the docking station.

Background

The robotic cleaner may include a chassis having one or more drive wheels coupled thereto for moving the robotic cleaner over a surface to be cleaned. The one or more drive wheels may be powered by one or more batteries electrically coupled thereto. Over time, the power stored by the one or more batteries may fall below a threshold amount, indicating that the robotic cleaner should be moved to a location to have the one or more batteries recharged. For example, the robotic cleaner may be moved to a docking station configured to have one or more batteries recharged.

The docking station may be configured to emit one or more signals (e.g., optical signals) that are detectable by the robotic cleaner. The robotic cleaner may navigate to the docking station using the transmitted signal. For example, the docking station may transmit a first navigation signal and a second navigation signal configured to overlap, and the robotic cleaner may be configured to determine whether the first signal, the second signal, or both the first signal and the second signal are detected. Based on this determination, the robot cleaner may adjust its moving direction so that the robot cleaner may dock with the docking station. However, the robot cleaner may not consistently achieve proper alignment with the docking station when docked based on detecting the overlap of the two signals. Thus, adjustments to the robotic cleaner (e.g., by movement) may be required in order to obtain proper alignment (e.g., to align the docking station sufficiently so that the battery or batteries can be recharged).

Drawings

These and other features and advantages will be better understood from a reading of the following detailed description taken in conjunction with the drawings in which:

fig. 1A is a schematic example of a docking station and a robotic cleaner consistent with embodiments of the present disclosure.

Fig. 1B is another schematic example of a docking station and a robotic cleaner consistent with embodiments of the present disclosure.

Fig. 1C is another schematic example of a docking station and a robotic cleaner consistent with embodiments of the present disclosure.

Fig. 2 is a perspective view of a docking station consistent with embodiments of the present disclosure, which may be an example of the docking station of fig. 1B.

FIG. 3 is a perspective view of a transmitter shadow box housing that can be used with the docking station of FIG. 2 consistent with embodiments of the present disclosure.

Fig. 4 is a circuit diagram of a circuit that may be used with the docking station of fig. 2 that is configured to combine the first modulated signal and the second modulated signal to generate a third modulated signal consistent with embodiments of the present disclosure.

FIG. 5 is a schematic view of a transmitter shadow box housing that can be used with, for example, the docking station of FIG. 1B, consistent with embodiments of the present disclosure.

FIG. 6 is a schematic view of a transmitter shadow box that can be used with, for example, the docking station of FIG. 1B, consistent with embodiments of the present disclosure.

FIG. 7 illustrates an example of the transmit field of the transmitter shadow box housing of FIG. 6 consistent with embodiments of the present disclosure.

FIG. 8 illustrates a perspective view of a cylindrical transmitter shadow box that can be used with, for example, the docking station of FIG. 1B, consistent with embodiments of the present disclosure.

Fig. 9 illustrates a cross-sectional view of the cylindrical transmitter shadow box of fig. 8 taken along line IX-IX consistent with an embodiment of the present disclosure.

FIG. 10 illustrates an example of the transmit field of the transmitter shadow box of FIG. 8 consistent with embodiments of the present disclosure.

Fig. 11 illustrates an example of the transmit fields of three emitters, each emitter disposed within a respective transmitter shadow box of fig. 8, consistent with an embodiment of the present disclosure.

Fig. 12 illustrates an orientation of the emitter of fig. 11 consistent with an embodiment of the present disclosure.

Fig. 13 illustrates another example of the transmit fields of three emitters, each emitter disposed within a respective transmitter shadow box of fig. 8, consistent with an embodiment of the present disclosure.

Fig. 14 illustrates an orientation of the emitter of fig. 13 consistent with an embodiment of the present disclosure.

FIG. 15 illustrates a cross-sectional view of a cylindrical transmitter shadow box that can be used with, for example, the docking station of FIG. 1B, consistent with embodiments of the present disclosure.

FIG. 16 illustrates an example of the transmit field of the transmitter shadow box of FIG. 15 consistent with an embodiment of the present disclosure.

Fig. 17 illustrates an example of the transmit fields of three emitters, each emitter disposed within a respective transmitter shadow box of fig. 15, consistent with an embodiment of the present disclosure.

Fig. 18 illustrates an orientation of the emitter of fig. 17 consistent with an embodiment of the present disclosure.

Fig. 19 shows an example of the transmit fields of three emitters, each emitter disposed within a respective transmitter shadow box of fig. 15, consistent with an embodiment of the present disclosure.

Fig. 20 illustrates an orientation of the emitter of fig. 19 consistent with an embodiment of the present disclosure.

FIG. 21 shows a schematic view of a transmitter shadow box housing that can be used with, for example, the docking station of FIG. 1C, consistent with embodiments of the present disclosure.

FIG. 22 shows a schematic example of the transmitter shadow box housing of FIG. 21 and a schematic example of a receiver shadow box housing configured to be coupled to, for example, a robotic cleaner, consistent with embodiments of the present disclosure.

Fig. 23 shows a schematic example of the transmitter shadow box housing of fig. 21 and a schematic example of the receiver box of fig. 22 in a non-aligned state, consistent with an embodiment of the present disclosure.

Fig. 24 shows a schematic example of a docking station configured to transmit a single docking signal consistent with embodiments of the present disclosure.

FIG. 25 illustrates a perspective view of a sender shadow box housing having first, second, and third sender shadow boxes, consistent with an embodiment of the present disclosure.

FIG. 26 illustrates a top view of an exemplary arrangement of the first, second, and third sender shadow boxes of FIG. 25, consistent with an embodiment of the present disclosure.

Fig. 27 illustrates an example of an emitted field of the shadow box housing of fig. 26 consistent with embodiments of the present disclosure.

FIG. 28 illustrates a cross-sectional perspective view of a sender shadow box, which may be an example of the first, second, and/or third sender shadow boxes of FIG. 25, consistent with an embodiment of the present disclosure.

FIG. 29 illustrates a cross-sectional side view of the transmitter shadow box of FIG. 28 consistent with an embodiment of the present disclosure.

FIG. 30 is a perspective view of a transmitter shadow box housing consistent with embodiments of the present disclosure.

FIG. 31 is a perspective view of a transmitter shadow box housing, which may be an example of the transmitter shadow box housing of FIG. 30, consistent with an embodiment of the present disclosure.

FIG. 32 is a cross-sectional perspective view of the transmitter shadow box housing of FIG. 31 taken along line XXXII-XXXII consistent with embodiments of the present disclosure.

FIG. 33 is a cross-sectional view of the transmitter shadow box housing of FIG. 31 taken along line XXXIII-XXXIII consistent with embodiments of the present disclosure.

FIG. 34 is an example of an emission pattern corresponding to the transmitter shadow box housing of FIG. 31 consistent with embodiments of the present disclosure.

Fig. 35 is an enlarged view of a portion of the emission pattern of fig. 34 consistent with an embodiment of the present disclosure.

FIG. 36 is a perspective view of a transmitter shadow box housing, which may be an example of the transmitter shadow box housing of FIG. 30, consistent with an embodiment of the present disclosure.

FIG. 37 is a perspective cross-sectional view of the transmitter shadow box housing of FIG. 36 taken along line XXXVII-XXXVII consistent with embodiments of the present disclosure.

FIG. 38 is an example of an emission pattern corresponding to the transmitter shadow box housing of FIG. 36 consistent with embodiments of the present disclosure.

Fig. 39 is an enlarged view of the emission pattern of fig. 38 consistent with an embodiment of the present disclosure.

Fig. 40 is a schematic example of a docking station and a robotic cleaner consistent with embodiments of the present disclosure.

Fig. 41 is an example of a receiver shadow box housing configured for use with the robotic cleaner of fig. 40 consistent with embodiments of the present disclosure.

FIG. 42 is a perspective cross-sectional view of a transmitter shadow box housing consistent with an embodiment of the present disclosure.

Detailed Description

The present disclosure generally relates to docking stations for robotic cleaners (e.g., robotic vacuum cleaners). The docking station includes a housing, at least three signal transmitters, and charging contacts configured to supply power to the robotic cleaner. The at least three signal transmitters are configured to transmit signals within a detection zone extending at least partially around the housing. The first and second signal emitters may be disposed within the housing and configured to emit first and second signals, respectively. The signals emitted from the first signal emitter and the second signal emitter may not have substantial overlap within the detection zone (e.g., the robotic cleaner is not detectable). The third signal transmitter may be configured to transmit a third signal extending between the first signal and the second signal within the detection zone. The first, second and third signals may be optical, acoustic, radio frequency and/or any other type of signal. The first, second, and third signals may each have different characteristics (e.g., pulse at different rates).

The robotic cleaner may be configured to adjust its path of movement based at least in part on the detection of the first, second, or third signal. The detection of the first signal or the second signal may turn the robot cleaner in the direction of the third signal. Detecting the third signal (e.g., in the absence of the first and second signals) may cause the robotic cleaner to follow the third signal until the robotic cleaner engages (e.g., touches) the dock.

In some cases, the docking station may be configured to enable detection of a third signal without the first signal and the second signal at least within the detection zone. A portion of the detection zone where the third signal is detectable without the first and second signals may be configured to be narrow relative to the transmission fields of the first and second transmitters. For example, the third transmitter may be configured to generate a narrow transmission field and/or the transmission field of the third transmitter may be configured to overlap a portion of the transmission fields of the first and second transmitters such that the third signal may be detected without a portion of the detection zone of the first and second signals having a desired width. A measure of a width of the detection zone at which the third signal is detectable without the first and second signals may be based at least in part on an expected alignment tolerance between the robot cleaner and the docking station when the robot cleaner engages (e.g., contacts) the docking station.

Improving the alignment of the robot cleaner with the docking station may result in a more consistent docking. Accordingly, operations such as charging the robot cleaner and/or discharging debris from a dust cup of the robot cleaner may be more easily accomplished. For example, when debris is ejected from a dirt cup of the robotic cleaner, one or more evacuation ports may be required to achieve a predetermined alignment for the dirt cup to be fluidly coupled to the docking station.

Fig. 1A shows a schematic example of a docking station 10 and a robotic cleaner 12. As shown, the docking station 10 is configured to generate at least one docking signal 14 (e.g., an optical signal, such as an infrared signal generated by a light emitting diode, an acoustic signal, such as an ultrasonic signal generated by an acoustic transducer, and/or any other type of signal). The docking signal 14 is configured to direct the robotic cleaner 12 to the docking station 10. For example, when the robotic cleaner 12 detects the docking signal 14, the robotic cleaner 12 may be configured to follow the docking signal 14 until the robotic cleaner 12 engages (e.g., contacts) the docking station 10 such that, for example, the robotic cleaner 12 is electrically coupled to the one or more charging contacts 11 of the docking station 10. The alignment of the robotic cleaner 12 with the docking station 10 (e.g., the orientation of the robotic cleaner 12 relative to the docking station 10) may be based at least in part on the width 16 of the docking signal 14. For example, the narrow width 16 may cause an axis 18 of the robotic cleaner 12 extending parallel to a forward direction of travel of the robotic cleaner 12 to be substantially aligned with the central axis 13 of the docking signal 14, for example.

In some cases, the docking station 10 may be configured to generate a proximity signal 20 extending from both sides of the docking station 10. The proximity signal 20 may indicate to the robotic cleaner 12 that the robotic cleaner 12 is proximate to the docking station 10. This may cause, for example, the robotic cleaner 12 to enter a search routine in which the robotic cleaner 12 searches for at least one docking signal 14. In some cases, the proximity signal 20 may be generated by at least two transmitters, each transmitter disposed on an opposite side of the docking station 10.

In some cases, the docking station 10 may be configured to move (e.g., slide or pivot) relative to the robotic cleaner 12 when the robotic cleaner 12 is engaged (e.g., contacted) with the docking station 10. Thus, if the robotic cleaner 12 is approaching the docking station 10 in a misaligned orientation (e.g., an orientation in which the robotic cleaner 12 is not electrically coupled to the docking station 10), the docking station 10 may be configured to move such that the robotic cleaner 12 may still be aligned with the docking station 10. In these cases, for example, only a single docking signal 14 may be used. When only a single docking signal 14 is used, the width 16 of the docking signal 14 may be based on the degree of movement (e.g., sliding or pivoting) through which the docking station 10 may move. Accordingly, the width 16 of the docking signal 14 may be increased so that the robotic cleaner 12 may more easily locate the docking signal 14 without substantially compromising the ability of the robotic cleaner 12 to electrically couple to the docking station 10.

Fig. 1B shows an illustrative example of a docking station 100 and a robotic cleaner 102, which may be examples of the docking station 10 and the robotic cleaner 12 of fig. 1A. As shown, the docking station 100 includes a housing 104 having a first optical emitter 106 (shown in phantom), a second optical emitter 108 (shown in phantom), and a third optical emitter 110 (shown in phantom) coupled thereto. As shown, the third optical emitter 110 is disposed between the first optical emitter 106 and the second optical emitter 108. The first optical emitter 106 is configured to emit a first optical signal 112 within a first emitted field 114, the second optical emitter 108 is configured to emit a second optical signal 116 within a second emitted field 118, and the third optical emitter 110 is configured to emit a third optical signal 120 within a third emitted field 122. As shown, the first and second transmit fields 114, 118 do not substantially overlap with each other within the detection zone 124 of the docking station 100 (e.g., no overlap is detectable by the robotic cleaner 102). Also as shown, third transmit field 122 extends between first transmit field 114 and second transmit field 118. The third transmitted field 122 may overlap at least a portion of one or more of the first transmitted field 114 and the second transmitted field 118 within the detection zone 124. The detection zone 124 may be generally described as an area where the signal strength of one or more of the optical signals 112, 116, and 120 is sufficient to be detected by the robotic cleaner 102 and/or above a predetermined threshold.

The robotic cleaner 102 may have one or more sensors 126 configured to detect one or more of the optical signals 112, 116, and/or 120. For example, when the sensor 126 detects the second optical signal 116, the robotic cleaner 102 may be configured to turn toward the third transmission field 122 (e.g., turn left). When the robotic cleaner 102 detects the third optical signal 120, the robotic cleaner 102 may be configured to move such that the sensor 126 remains detecting (e.g., following) the third optical signal 120 while moving toward the docking station 100. Thus, the third optical signal 120 may be used to direct the robotic cleaner 102 to the docking station 100. Similarly, for example, when the sensor 126 detects the first optical signal 112, the robotic cleaner 102 may be configured to turn toward the third transmission field 122 (e.g., turn right) such that the robotic cleaner 102 may follow the third optical signal 120 to the docking station 100. For example, the third optical signal 120 may be used to direct the robotic cleaner to one or more charging contacts 121 of the docking station 100 so that the robotic cleaner 102 may be electrically coupled to the one or more charging contacts 121.

The alignment of the robotic cleaner 102 with the docking station 100 may be based at least in part on the width 128 of the third transmission field 122. The width 128 may be based at least in part on the emission angle α of the third emitter 110. Thus, the area of the detection zone 124 where the third optical signal 120 can be detected without the first optical signal 112 and the second optical signal 116 can be reduced by, for example, reducing the emission angle α. As the area of the detection zone 124, where the third optical signal 120 may be detected, decreases, the alignment of the robotic cleaner 102 with the docking station 100 may be improved. For example, when the third transmission field 122 is narrowed, the deviation of the robot cleaner 102 from the center line 123 of the third transmission field may be reduced.

In some cases, and as shown, first transmitted field 114 and second transmitted field 118 can overlap at least a portion of third transmitted field 122. In these cases, for example, when the robotic cleaner 102 detects a first overlap region 130 formed by the overlap of the first field of emission 114 and the third field of emission 122, the robotic cleaner 102 may turn toward a center portion (e.g., right) of the third field of emission 122. As a further example, when the robot cleaner 102 detects a second overlap region 132 formed by the overlap of the second and third transmitted fields 118, 122, the robot cleaner may turn toward a center portion (e.g., left) of the transmitted field 122. When the robotic cleaner 102 is no longer within the first and second overlapping regions 130, 132 and still detects the third optical signal 120, the robotic cleaner 102 may be moved toward the docking station 100 by maintaining detection of the third optical signal 120 in the absence of the first and second signals 112, 116. Accordingly, improved alignment with the docking station 100 may be obtained by reducing the area within the detection zone 124 where the robot cleaner 102 does not detect the first optical signal 112 and/or the second optical signal 116 at the same time as the third optical signal 120. Accordingly, the deviation of the robot cleaner 102 from the center line 123 may be reduced.

Fig. 1C shows an illustrative example of a docking station 134 and a robotic cleaner 136, which may be examples of the docking station 10 and the robotic cleaner 12 of fig. 1A. As shown, the docking station 100 includes a housing 138 having a first optical emitter 140 (shown in phantom), a second optical emitter 142 (shown in phantom), and a third optical emitter 144 (shown in phantom). The first optical emitter 140 is configured to emit a first optical signal 146 within a first emission field 148, the second optical emitter 142 is configured to emit a second optical signal 150 within a second emission field 152, and the third optical emitter 144 is configured to emit a third optical signal 154 within a third emission field 156. As shown, at least a portion of the first transmitted field 148, the second transmitted field 152, and the third transmitted field 156 overlap one another for at least a portion of the detection zone 157. The detection zone 157 may be generally described as an area where the signal strength of one or more of the optical signals 146, 150, and 154 is sufficient to be detected by the robotic cleaner 136 and/or above a predetermined threshold.

When the robotic cleaner 136 detects the first optical signal 146 or the second optical signal 150 without the third optical signal 154, the robotic cleaner 136 is configured to turn toward the third emitted field 156. When the robot cleaner 136 detects the third optical signal 154, the robot cleaner follows the third optical signal 154 until the robot cleaner engages (e.g., contacts) the docking station 134. In other words, when the robot cleaner 136 detects the third optical signal 154, the robot cleaner 136 does not navigate using the first optical signal 146 and the second optical signal 150. Alignment of the robotic cleaner 136 relative to the docking station 134 may be improved by making the width 158 of the third transmitted field 156 measure less than the width 160 of the first transmitted field 148 and/or the width 162 of the second transmitted field 152.

Fig. 2 shows a perspective view of a docking station 200 (which may be an example of docking station 100 of fig. 1B) and a robotic vacuum cleaner 202 (which may be an example of robotic cleaner 102 of fig. 1B). As shown, the docking station 200 is configured to generate a left signal 204, a right signal 206, and an intermediate (e.g., homing) signal 208. Each of the left signal 204, the right signal 206 and the mid signal 208 may be modulated according to a respective modulation pattern such that the robotic vacuum cleaner 202 may distinguish between each of the generated signals. In some cases, for example, the intermediate signal 208 may be configured to resemble a signal generated by the left signal 204 and the right signal 206 overlapping within the detection zone 210 (fig. 4 shows an example of circuitry configured to generate the intermediate signal 208 using the modulation pattern of the left signal 204 and the right signal 206).

As shown, the left signal 204 and the right signal 206 do not overlap within a detection zone 210 that extends around the docking station 200. As also shown, the left signal 204 and the right signal 206 may overlap the middle signal 208 within the detection zone 210. Thus, navigation of the robotic cleaner 202 to the docking station 200 may be based at least in part on the signals it detects.

For example, when attempting to position the docking station 200, the robotic vacuum cleaner 202 may be configured to move in the direction of the mid signal 208 in response to detecting one of the left signal 204 or the right signal 206. The robotic vacuum cleaner 202 may determine that it is moving towards the mid signal 208 by detecting a respective overlap region 209 or 211 corresponding to an overlap between the mid signal 208 and a respective one of the left signal 204 or the right signal 206. When the respective one of the overlapping areas 209 or 211 is detected, the robotic vacuum cleaner 202 may continue to move according to its current orientation until the middle signal 208 is detected without the left and right signals 204 and 206. The robotic vacuum cleaner 202 may then orient itself to move in a direction toward the docking station 200. If, after detecting the middle signal 208 and the absence of the left signal 204 and the right signal 206, the robotic vacuum cleaner 202 encounters the respective overlap area 209 or 211, the robotic vacuum cleaner 202 may be configured to turn in a direction away from the overlap area 209 or 211. In other words, robotic vacuum cleaner 202 may be moved back and forth between overlapping regions 209 and 211 until robotic vacuum cleaner 202 engages (e.g., contacts) docking station 200 and/or obtains a desired orientation that is substantially aligned with docking station 200.

The separation distance 212 extending between the left signal 204 and the right signal 206 may measure in the range of 25.4 centimeters (cm) and 66 cm, as measured at 2.13 meters (m) from the docking station 200. As another example, the separation distance 212 as measured at 2.13m from the docking station 200 may measure approximately 45.7 cm. The angle β between the left 204 and right 206 signals may measure about 12.2 ° when the separation distance 212 is about 45.7cm, as measured at 2.13m from the docking station.

The overlap angle μ extending between the left edge of the mid signal 208 and the right edge of the left signal 204 may be measured, for example, in the range of 3 ° and 7 °. As another example, the overlap angle μmay measure about 4.7 °. Similarly, the overlap angle θ extending between the right edge of the mid signal 208 and the left edge of the right signal 206 may be measured, for example, in the range of 3 ° and 7 °. As another example, the overlap angle θ may measure approximately 4.7. In some cases, at least two of the angle β, the overlap angle μ, and/or the overlap angle θ may be measured to be substantially the same.

FIG. 3 shows a perspective view of an example of a transmitter shadow box housing 300 disposed within the docking station 200. As shown, the transmitter shadow box housing 300 may include a left shadow box 303 defining a left transmitter compartment 302, a right shadow box 305 defining a right transmitter compartment 304, and a middle shadow box 307 defining a middle transmitter compartment 306. Each compartment 302, 304, and 306 is configured to receive a respective transmitter. As shown, at least a portion of the left and right emitter compartments 302, 304 may be blocked by a light shield 308. The light shield 308 is configured to block a portion of the light generated by the respective emitters within the left and right emitter compartments 302, 304. By blocking a portion of the generated light, the left signal 204 and the right signal 206 may be prevented from overlapping within the detection zone 210.

In some cases, the left and right emitters may be configured to be vertically offset from the middle emitter. For example, the middle emitter may be disposed below the left and right emitters, and the left and right emitters may be disposed on a common horizontal plane. In some cases, the left emitter, the right emitter, and the middle emitter may each be arranged on a common horizontal plane. For example, the horizontal plane may be substantially aligned with one or more corresponding receivers on the robotic vacuum cleaner 202.

The interior sidewalls 310 of the left compartment 302, right compartment 304, and middle compartment 306 may or may not reflect the emitted light. When the inner side walls 310 do not reflect light, internal reflections within the compartments 302, 304, and 306 may be reduced. However, such a configuration may result in at least a portion of the light being diffused, some of which may escape the respective compartment 302, 304, or 306. Changing the geometry and/or size of the compartments 302, 304, and 306 and/or the light shield 308 may change the size and/or shape of the left signal 204, the right signal 206, and the middle signal 208.

Fig. 4 shows a circuit diagram 400 of a circuit configured to generate the intermediate signal 208 using the modulation pattern of the transmitter corresponding to the left signal 204 and the right signal 206. As shown, the circuit includes: a plurality of NOR gates 402, each NOR gate configured to receive a respective modulation pattern corresponding to one of the left signal 204 or the right signal 206; an OR gate 404 configured to combine the modulation patterns, and an NPN transistor 406 for inverting the combined signal, which is used to generate the intermediate signal 208.

Fig. 5 shows a schematic view of a transmitter shadow box housing 500 configured for use with, for example, docking station 100 of fig. 1B. As shown, the transmitter shadow box housing 500 may include a first optical emitter 502, a second optical emitter 504, and a third optical emitter 506, wherein the third optical emitter 506 is disposed between the first optical emitter 502 and the second optical emitter 504. The first central axis 501 of the first optical emitter 502 may be offset from the second central axis 503 of the second optical emitter 504 as the distance from the sender shadow box housing 500 in the direction of emission of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506 increases. In other words, the first optical emitter 502 and the second optical emitter 504 may emit light in divergent directions.

The transmitter shadow box housing 500 may include a plurality of shadow boxes 507, 509, and 511 defining transmitter compartments 508, 510, and 512 configured to receive a respective one of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506. Each of compartments 508, 510, and 512 may be configured to shape and/or direct emitted light. For example, the first compartment 508 and the second compartment 510 may be configured to shape and/or direct light emitted by the first optical emitter 502 and the second optical emitter 504, respectively, such that the light emitted by the first optical emitter 502 and the second optical emitter 504 do not substantially overlap within the detection zone 514 of the docking station (e.g., the robotic cleaner does not detect any overlap). The third compartment 512 may be configured to shape and/or direct light emitted by the third optical emitter 506 such that at least a portion of the light emitted by the third optical emitter 506 overlaps with at least a portion of the light emitted by the first and second optical emitters 502, 504.

As shown, the transmitter shadow box housing 500 may be configured such that when light is emitted from each of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506, there is a docking area 516 within the detection zone 514 that extends between the light emitted by the first optical emitter 502 and the second optical emitter 504. In other words, when in this area, the robot cleaner detects light emitted by the third optical emitter 506 without light emitted by the first and second optical emitters 502 and 504. The width 518 of the docking area 516 may be narrowed by increasing the overlap of light generated by one or more of the first optical emitter 502 and the second optical emitter 504 with light generated by the third optical emitter 506. As the robot cleaner follows the light generated by third optical emitter 506, the alignment of the robot cleaner relative to the docking station may be improved by reducing the width 518 of docking zone 516. In some cases, the width 518 may be measured to be substantially constant for a majority (e.g., at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99%) of the detection zone 514.

Fig. 6 shows an example of a transmitter shadow box 600 (shown transparent for clarity) that may be configured for use with, for example, docking station 100 of fig. 1B. As shown, the transmitter shadow box 600 defines at least one cylindrical transmitter compartment 602. The cylindrical compartments 602 are configured to receive a respective optical emitter (e.g., one of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506). The diameter 604 of the cylindrical compartment 602 may measure, for example, about 6 millimeters (mm), and the height 606 of the cylindrical compartment 602 may measure, for example, about 10 mm. As also shown, a cylindrical compartment 602 may be centered within the transmitter shadow box 600. In some cases, when multiple transmitter shadow boxes 600 are included within a shadow box housing, the separation distance between the centers of two adjacent cylindrical compartments 602 can measure, for example, about 20 mm.

Fig. 7 shows an example of the emission field (or light propagation) of the emitter disposed within the sender shadow box 600 when the sender shadow box 600 is formed of foam. The diffusion is shown as extending over a range of up to 182.88 centimeters (cm).

Fig. 8 shows a perspective view of a cylindrical transmitter shadow box 800, which may be configured for use with, for example, docking station 100 of fig. 1B. Sender shadow box 800 includes a cylindrical sender compartment 802, wherein at least a portion of cylindrical compartment 802 is configured to receive a respective emitter (e.g., one of first optical emitter 502, second optical emitter 504, and third optical emitter 506). In some cases, a plurality of cylindrical transmitter shadow boxes 800 can be included within the transmitter shadow box housing.

As shown, the cylindrical transmitter shadow box 800 includes a first cylindrical portion 804 and a second cylindrical portion 806 extending from the first cylindrical portion 804, wherein the diameter of the second cylindrical portion 806 measures less than the diameter of the first cylindrical portion 804. As shown, the first cylindrical portion 804 and the second cylindrical portion 806 may be concentrically arranged.

FIG. 9 shows a cross-sectional view of the cylindrical transmitter shadow box 800 taken along line IX-IX of FIG. 8. As shown, the cylindrical compartment 802 may define a first cavity 900 and a second cavity 902. The first cavity 900 may be defined in the first cylindrical portion 804 and may be configured to receive a respective emitter (e.g., one of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506), and the second cavity 902 may be defined in the second cylindrical portion 806 and may have a diameter 904 that measures less than a diameter 906 of the first cavity 900, which diameter 906 of the first cavity 900 may correspond to the diameter of the emitter received therein. The second cavity 902 may be configured to at least partially collimate light generated by the emitter.

As shown, the diameter 906 of the first lumen 900 may measure about 5mm, and the diameter 904 of the second lumen 902 may measure about 4 mm. Also as shown, the first cylindrical portion diameter 908 may measure about 25mm, the second cylindrical portion diameter 910 may measure about 16mm, the first cylindrical portion height 912 may measure about 8mm, and the second cylindrical portion height 914 may measure about 10 mm.

FIG. 10 shows an example of the transmit field (or light spreading) of an emitter disposed within sender shadow box 800 when sender shadow box 800 is formed of polyoxymethylene (e.g., as sold by DuPont under the trade name DELRIN). The diffusion shows a range up to 182.88 cm.

Fig. 11 shows an example of the transmitted fields of three emitters, each emitter being disposed within a respective transmitter shadow box 800 in an orientation corresponding to that shown in fig. 12. As shown, in fig. 12, each of the emitters 1200, 1202, and 1204 are spaced apart from each other, and the first emitter 1200 and the second emitter 1202 are angled with respect to the third emitter 1204. For example, each of the emitters 1200, 1202, and 1204 may be spaced about 15mm apart from each other and oriented such that adjacent emitters are angled about 37 ° with respect to each other. As shown in fig. 11, such a configuration may create gaps 1100 and/or 1102 between the transmit field of the third transmitter 1204 and the respective transmit fields of the first transmitter 1200 and the second transmitter 1202.

Fig. 13 shows an example of the transmitted fields of three emitters, each emitter being disposed within a respective transmitter shadow box 800 in an orientation corresponding to that shown in fig. 14. As shown in fig. 14, each of the emitters 1400, 1402, and 1404 are spaced apart from each other, and the first emitter 1400 and the second emitter 1402 are angled with respect to the third emitter 1404. For example, the first emitter 1400, the second emitter 1402, and the third emitter 1404 may be spaced apart by about 50mm and oriented such that adjacent emitters are angled at about 18 ° with respect to each other. As shown in fig. 13, such a configuration may create overlap regions 1300 and/or 1302 between the transmit field of the third transmitter 1404 and the respective transmit fields of the first and second transmitters 1400 and 1402. A narrowest width 1304 extending between the transmit fields of the first transmitter 1400 and the second transmitter 1402 may indicate that the robotic cleaner is about to engage (e.g., contact) the docking station.

Fig. 15 shows a cross-sectional view of a cylindrical transmitter shadow box 1500, which may be configured for use with, for example, docking station 100 of fig. 1B. The transmitter shadow box 1500 includes a cylindrical transmitter compartment 1502, wherein at least a portion of the cylindrical compartment 1502 is configured to receive a respective emitter (e.g., one of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506). In some cases, a plurality of cylindrical transmitter shadow boxes 1500 can be included within the transmitter shadow box housing.

As shown, the cylindrical transmitter shadow box 1500 includes a first cylindrical portion 1504 and a second cylindrical portion 1506 extending from the first cylindrical portion 1504, wherein the second cylindrical portion 1506 has a diameter greater than the measured diameter of the first cylindrical portion 1504. As shown, the first cylindrical portion 1504 and the second cylindrical portion 1506 may be concentrically arranged.

As also shown, the cylindrical compartment 1502 may define a first cavity 1508 and a second cavity 1510. A first cavity 1508 may be defined in the first cylindrical portion 1504 and may be configured to receive a respective emitter (e.g., one of the first optical emitter 502, the second optical emitter 504, and the third optical emitter 506), and a second cavity 1510 may be defined in the second cylindrical portion 1506 and may have a diameter 1512 that measures less than a diameter 1514 of the first cavity 1508, the diameter 1514 of the first cavity 1508 may correspond to the diameter of the emitter received therein. The second cavity 1510 may be configured to at least partially collimate light generated by the emitter.

As shown, the diameter 1514 of the first lumen 1508 may measure about 5mm, and the diameter 1512 of the second lumen 1510 may measure about 4 mm. Also as shown, the first cylindrical portion diameter 1516 may measure about 25mm, the second cylindrical portion diameter 1518 may measure about 16mm, the first cylindrical portion height 1520 may measure about 8mm, and the second cylindrical portion height 1522 may measure about 5 mm.

FIG. 16 shows an example of the transmit field (or light spreading) of an emitter disposed within transmitter shadow box 1500 when transmitter shadow box 1500 is formed of polyoxymethylene (as sold by DuPont under the trade name DELRIN). The diffusion shows a range up to 182.88 cm.

Fig. 17 shows an example of the transmitted fields of three emitters, each emitter being disposed within a respective transmitter shadow box 1500 in an orientation corresponding to that shown in fig. 18. As shown in fig. 18, each of the transmitters 1800, 1802, and 1804 are spaced apart from one another, and the first transmitter 1800 and the second transmitter 1802 may be angled with respect to the third transmitter 1804. For example, the first emitter 1800, the second emitter 1802, and the third emitter 1804 may be spaced apart from each other by about 25mm and oriented such that adjacent emitters are angled at about 45 ° with respect to each other. As shown in fig. 17, this configuration may create gaps 1700 and/or 1702 between the transmit field of the third transmitter 1804 and the respective transmit fields of the first transmitter 1800 and the second transmitter 1802.

Fig. 19 shows an example of the transmitted fields of three emitters, each emitter being disposed within a respective transmitter shadow box 1500 in an orientation corresponding to that shown in fig. 20. As shown, in fig. 20, each of the emitters 2000, 2002, and 2004 are spaced apart from one another, and the first emitter 2000 and the second emitter 2002 may be angled relative to the third emitter 2004. For example, the first launcher 2000, the second launcher 2002, and the third launcher 2004 may be spaced about 12mm apart from each other and oriented such that adjacent launchers are at an angle of about 43 ° with respect to each other. As shown in fig. 19, such a configuration may create overlap regions 1900 and/or 1902 between the transmit field of the third emitter 2004 and the respective transmit fields of the first emitter 2000 and the second emitter 2002.

FIG. 21 shows a schematic example of a transmitter shadow box housing 2100 that can be used with, for example, the docking station 134 of FIG. 1C. As shown, the transmitter shadow box housing 2100: includes a first shadow box 2101 defining a first transmitter compartment 2102 having a first optical transmitter 2104; a second shadow box 2103 defining a second transmitter compartment 2106 having a second optical transmitter 2108; and a third shadow box 2105 defining a third transmitter compartment 2110 having a third optical transmitter 2112, wherein the third optical transmitter 2112 is disposed between the first optical transmitter and the second optical transmitter 2104. In some cases, first optical emitter 2104, second optical emitter 2108, and third optical emitter 2112 can be arranged along a common horizontal plane (e.g., a plane substantially parallel to the surface to be cleaned).

As shown, the third compartment 2110 substantially surrounds the third optical emitter 2112 such that light emitted from the third optical emitter 2112 passes through an aperture 2114 defined in the third compartment 2110. Thus, the light emitted from the third compartment 2110 may generally be described as collimated. The apertures 2114 may have a circular, rectangular, square, and/or any other shape. Thus, the shape of the aperture may be configured such that the aperture 2114 obscures at least one side of the third optical emitter 2112. For example, the shape of the aperture 2114 may be configured such that the aperture 2114 obscures only two sides (e.g., left and right sides or top and bottom) of the third optical emitter 2112. The blockage of the top and bottom sides of the third optical emitter 2112 may determine, at least in part, the detection distance of the third optical emitter 2112, and the blockage of the left and right sides of the third optical emitter may determine, at least in part, the width of the signal emitted by the third optical emitter 2112.

As also shown, the first and second compartments 2102, 2106 are at least partially defined by first and second shields 2116, 2118, respectively, extending in a direction away from the third compartment 2110. The first and second shields 2116, 2118 include portions of the first and second optical emitters 2104, 2108 such that light emitted by the first and second optical emitters 2104, 2108 can have a desired shape (e.g., to control an amount of overlap between emissions generated by the first, second, and/or third emitters 2104, 2108, 2112). In some cases, the sides of the first and second compartments 2102, 2106 opposite the first and second shields 2116, 2118 may be open. The first 2116 and second 2118 shields may be configured to block one or more sides of the first 2104 and second 2108 optical emitters. For example, the first and second shields 2116 and 2118 may be configured to block only two sides (e.g., left and right sides or top and bottom) of the first and second optical emitters 2104 and 2108, respectively. The obstructions on the top and bottom sides of the first optical emitter 2104 and the second optical emitter 2108 may at least partially determine the detection distance of the first optical emitter 2104 and the second optical emitter 2108, and the obstructions on the left and right sides of the first optical emitter 2104 and the second optical emitter 2108 may at least partially determine the width of the emitted signal of the first optical emitter 2104 and the second optical emitter 2108.

Fig. 22 shows a schematic example of the transmitter shadow cartridge housing 2100 of fig. 21 and a schematic example of a receiver shadow cartridge housing 2200 configured to be coupled to, for example, a robotic cleaner. As shown, the receiver shadow cartridge housing 2200 includes a first optical receiver 2202 and a second optical receiver 2204 that are each configured to receive one or more of a first optical signal 2206, a second optical signal 2208, and/or a third optical signal 2210 generated by a first optical emitter 2104, a second optical emitter 2108, and/or a third optical emitter 2112, respectively.

As shown, each of the first optical receiver 2202 and the second optical receiver 2204 can detect the third optical signal 2210 when the receiver shadow cartridge housing 2200 is aligned with the transmitter shadow cartridge housing 2100. In other words, when the first optical receiver 2202 and the second optical receiver 2204 both detect the third optical signal 2210, the robotic cleaner can be properly aligned with the docking station by maintaining detection (e.g., following) of the third optical signal 2210. Accordingly, when the third optical signal 2210 is detected, the robot cleaner does not need to determine whether the first optical signal 2206 and the second optical signal 2208 are detected.

Fig. 23 shows a schematic example of the transmitter shadow cartridge housing 2100 of fig. 21 and a schematic example of the receiver shadow cartridge housing 2200 of fig. 22 in a misaligned condition. As shown, when misaligned, only one of the optical receivers 2202 and 2204 may detect the third optical signal 2210. In this case, for example, the robotic cleaner having the receiver shadow cartridge housing 2200 coupled thereto may be moved in a direction such that the other of the optical receivers 2202 or 2204 detects the third optical signal. When the other of the optical receivers 2202 or 2204 detects the third optical signal 2210, the robotic cleaner may move to an orientation to attempt to achieve or maintain the third optical signal 2210 in detection by both of the optical receivers 2202 and 2204. Thus, the robotic cleaner can oscillate the receptor shadow cartridge housing 2200 about the third optical signal 2210 at least prior to obtaining the robotic cleaner engagement docking station and/or a desired orientation (e.g., aligned with a central axis of the third optical signal 2210). As the width 2300 of the third optical signal 2210 increases (e.g., by increasing the size of the aperture 2114), the robotic cleaner may more easily acquire an orientation in which the optical receivers 2202 and 2204 simultaneously detect the third optical signal 2210. However, as the width 2300 increases, the alignment of the robotic cleaner relative to the docking station may decrease as the robotic cleaner engages (e.g., contacts) the docking station.

Fig. 24 shows a schematic view of a docking station 2400, which may be an example of the docking station 10 of fig. 1A. The docking station 2400 is configured to transmit a single docking signal 2404 and at least one proximity signal 2406. The robotic cleaner 2408 with the forward signal receiver 2410 and the first and second rearward signal receivers 2412, 2414 is configured to follow the docking signal 2404 until the robotic cleaner 2408 engages the docking station 2400. When following the docking signal 2404, the robotic cleaner 2408 may approach the docking station 2400 in a misaligned orientation (e.g., an orientation relative to the docking station 2400 in which the robotic cleaner 2408 will not be electrically coupled to the docking station 2400). In these cases, the docking station 2400 may be configured to move (e.g., pivot or slide) in response to the robotic cleaner 2408 engaging the docking station 2400. The movement of the docking station 2400 may be configured to correct misalignment of the robotic cleaner 2408 relative to the docking station 2400.

The rearward receivers 2412, 2414 may be used to determine the pose of the robotic cleaner 2408. For example, the determination of the pose of the robotic cleaner 2408 may be based on whether one or both of the rearward receivers 2412 and 2414 are detecting the proximity signal 2406.

Fig. 25 illustrates a perspective view of a shadow box housing 2501 having a first transmitter shadow box 2500, a second transmitter shadow box 2502, and a third transmitter shadow box 2504, which can be configured for use with, for example, the docking station 100 of fig. 1B. As shown, each of the sender shadow boxes 2500, 2502, and 2504 is disposed (or defined) within the shadow box housing 2501 such that the third sender shadow box 2504 is disposed between the first shadow box 2500 and the second shadow box 2502. In other words, the sender shadow cartridges 2500, 2502, and 2504 can generally be described as being defined within a housing coupled to or formed by the robotic cleaner. Each of the sender shadow boxes 2500, 2502, and 2504 is configured to receive a respective optical emitter, each optical emitter configured to emit a different optical signal.

As shown in fig. 26, the first and second sender shadow boxes 2500, 2502 can be spaced apart from each other and angled relative to the third sender shadow box 2504. For example, and as shown, the first and second shadow boxes 2500, 2502 can be positioned such that the optical emitters corresponding to the first and second shadow boxes 2500, 2502 are spaced about 35mm apart from each other and are angled about 23 ° relative to the optical emitters corresponding to the third shadow box 2504. FIG. 27 shows an example of the transmit fields of three emitters, each emitter disposed in a respective one of the sender shadow boxes 2500, 2502, and 2504 in an orientation corresponding to that shown in FIG. 26.

As shown in fig. 27, a channel 2700 can extend between a first field of emission 2702 corresponding to a first optical emitter and a second field of emission 2704 corresponding to a second optical emitter. The channel 2700 can correspond to a portion of the third transmitted field 2706 corresponding to the third optical transmitter, wherein a signal transmitted by the third optical transmitter can be detected without signals transmitted by the first and second optical transmitters. The width 2708 of the channel 2700 may be substantially constant for a majority of the length 2710 of the channel 2700. As shown, the channel 2700 may extend only a portion of the length of the detection zone 2712.

Fig. 28 shows a cross-sectional perspective view of an example of a transmitter shadow box 2800, which can be an example of one or more of a first transmitter shadow box 2500, a second transmitter shadow box 2502, or a third transmitter shadow box 2504. As shown, the transmitter shadow box 2800 includes a base portion 2801 and a quasi-straight portion 2803. The collimating portion 2803 includes a cylindrical portion 2802 and a frustoconical portion 2804 extending around the cylindrical portion 2802. A cavity 2806 is defined within the collimating portion 2803 having a shape generally corresponding to the cylindrical portion 2802 and the frustoconical portion 2804 of the collimating portion 2803. An orifice 2808 extends from an outer surface 2810 of the frustoconical portion 2804 and into the cavity 2806. For example, the aperture 2808 may extend from a top planar surface of the frustoconical portion 2804 and into the cavity 2806. In some cases, the aperture 2808 may be a circular aperture, where the aperture 2808 is concentric with the optical emitter 2812. In these cases, the cylindrical collimator 2814 may extend from the aperture 2808 in the direction of the optical emitter 2812.

As shown, the base portion 2801 and the collimating portion 2803 are configured to couple to one another. In some cases, transmitter shadow box 2800 may be formed from a single unitary piece.

As also shown, the base portion 2801 is configured to receive an optical emitter 2812. For example, the base portion 2801 can define a socket 2816 for receiving at least a portion of the optical emitter 2812, and the socket is configured to align the optical emitter 2812 relative to, for example, the aperture 2808. In some cases, the socket 2816 is configured to align a central axis 2818 of the optical emitter 2812 with a central axis 2820 of the aperture 2808. For example, socket 2816 may be configured to align optical emitter 2812 such that optical emitter 2812 is concentric with aperture 2808. The alignment of the optical emitter 2812 can affect the shape and/or size of the emission field of the optical emitter 2812.

Fig. 29 illustrates a cross-sectional view of a transmitter shadow box 2800 showing an example reflection pattern of an optical emission 2900 generated by an optical emitter 2812.

Fig. 30 shows a perspective view of an example of a transmitter shadow box housing 3000 that includes a first transmitter shadow box 3002 defining a first transmitter compartment 3004, a second transmitter shadow box 3006 defining a second transmitter compartment 3008, and a third transmitter shadow box 3010 defining a third transmitter compartment 3012. The third shadow box 3010 is disposed between the first shadow box 3002 and the second shadow box 3006. The first and second shadow boxes 3002, 3006 include respective output apertures 3014, 3016 through which light within the respective compartment 3004 or 3006 can be emitted. The output apertures 3014, 3016 include at least one dimension that is smaller than a respective dimension of the respective compartment 3004 or 3006. Thus, the output apertures 3014, 3016 can generally be described as being configured to shape light emitted therefrom.

As shown, the third shadow box 3010 includes an optical shaper 3018. The optical shaper 3018 is configured to shape the light such that at least two illumination zones are formed using light emitted from the third compartment 3012. Each illumination zone may have, for example, a different intensity such that the robotic cleaner may detect only one illumination zone at a predetermined distance away from the transmitter shadow box housing 3000.

The optical shaper 3018 may include one or more optical barriers 3020. For example, the optical shaper 3018 may include a plurality of optical barriers 3020 defining optical shaping channels 3022 and a plurality of optical dispersion channels 3024 on opposite sides of the optical shaping channels 3022. The optically dispersive channel 3024 can be generally described as being configured to increase the width of the optical signal at a location near the optical shadow box housing 3000 (when compared to the width of light emitted from the optically shaped channel 3022 at a location near the shadow box housing 3000). The optically dispersive channel 3024 may be configured such that the intensity of light emitted therefrom is measured to be less than the intensity of light emitted from the optically shaped channel 3022. Thus, the light emitted from the optical dispersion channel 3024 may be configured such that it is detected only by a portion of the detection distance of the robot cleaner for the light emitted from the optical shaping channel 3022. In other words, the optical shaper 3018 may be configured to increase the propagation of detectable light emitted from the third shadow box 3010 at a location proximate to the shadow box housing 3000. The increase in detectable light may be used, for example, by a robotic cleaner to determine its proximity to the docking station. For example, in some cases, detectable light emitted from the third shadow box 3010 proximate the shadow box housing 3000 and/or docking station may extend up to 180 ° around the shadow box housing 3000 and/or docking station.

Fig. 31 shows a top perspective view of a shadow box housing 3100, which can be an example of the transmitter shadow box housing 3000 of fig. 30. For clarity, a portion of the shadow box housing 3100 is shown as transparent. As shown, the shadow box housing 3100 includes a first transmitter shadow box 3102 defining a first transmitter compartment 3104, a second transmitter shadow box 3106 defining a second transmitter compartment 3108, and a third transmitter shadow box 3110 defining a third transmitter compartment 3112. The first compartment 3104 and the second compartment 3108 each include a first divider 3114, a second divider 3116, and a third divider 3118. The first, second, and third separators 3114, 3116, 3118 are configured such that light can pass through a portion of each of the separators 3114, 3116, 3118. Thus, the first, second, and third dividers 3114, 3116, 3118 can be configured to shape light passing therethrough, e.g., to have a predetermined size and/or shape, when emitted from the respective shadow box 3102 or 3106.

The partitions 3114, 3116, and 3118 define a first dispersion zone 3120, a second dispersion zone 3122, and a third dispersion zone 3124. The discrete zones 3120, 3122, and 3124 are configured to reflect light that does not pass through the respective partitions 3114, 3116, and 3118 within the respective discrete zone 3120, 3122, or 3124. The reflection of light within the respective dispersion zone 3120, 3122, or 3124 reduces the intensity of the light such that a majority of the light emitted from the respective shadow box 3102 or 3106 generally conforms to the shape defined by the portion of the divider 3114, 3116, and 3118 through which the light can pass.

As shown, the third compartment 3112 includes an optical shaper 3126. The optical shaper 3126 may include one or more optical barriers 3128. As shown, the optical shaper 3126 includes a plurality of optical barriers 3128 such that optical shaping passages 3130 are defined between the optical barriers 3128. Optical shaping channel 3130 is configured to shape light emitted from third compartment 3112. In some cases, optical shaping channels 3130 may increase in width along emission direction 3134. A plurality of optically dispersive channels 3129 are disposed on opposite sides of the optically shaped channel 3130. The optical dispersion channel 3129 is configured to reduce the intensity of light emitted therefrom. The optical dispersion channels 3129 are at least partially defined by the guide surfaces 3132 of the respective optical barriers 3128. The guiding surface 3132 is configured to reflect light incident thereon within the third compartment 3112. As the number of reflections increases, the intensity of the light decreases. For example, the guide surface 3132 may comprise an arcuate surface configured to reflect light in a direction opposite to the emission direction 3134, such that light is reflected from a surface of the third compartment 3112 and at least a portion of the reflected light may be emitted from the third compartment 3112.

Fig. 32 is a perspective cross-sectional view of the shadow box housing 3100 taken along line XXXII-XXXII of fig. 31. As shown, the first, second, and third dividers 3114, 3116, 3118 each include respective apertures 3200, 3202, 3204 through which light generated by the optical emitter 3206 (e.g., a light emitting diode) passes. For example, and as shown, the orifices 3200, 3202, and 3204 may each have a circular shape. A measure of the diameter of each aperture 3200, 3202 and 3204 may increase in a direction of emission along an emission axis 3208 of light emitter 3206. In other words, the diameter of the first aperture 3200 may measure less than the diameter of the second aperture 3202, and the diameter of the second aperture 3202 may measure less than the diameter of the third aperture 3204. By including multiple apertures 3200, 3202, and 3204, each having a different diameter, the light emitted from the third aperture 3204 may have an emission cone 3203 of a predetermined shape and/or size. For example, the first aperture 3200, the second aperture 3202, and the third aperture 3204 may be configured such that the launch cone 3203 has a spread angle Φ in a range extending between 0 ° and 180 °. As a further example, the spread angle φ may be measured in a range of 15 to 55. Accordingly, light emitted from at least the first and second shadow boxes 3102 and 3106 may be prevented from overlapping within a detection zone extending around the shadow box housing 3100.

The partitions 3114, 3116, and 3118 may be spaced apart from one another by a spacing distance measured in a range of, for example, 2 millimeters (mm) to 5 mm. As a further example, the partitions 3114, 3116, and 3118 may be spaced apart from each other by a spacing distance of about 3.5 mm.

Fig. 33 is a cross-sectional top view of the shadow box housing 3100 taken along line XXXIII-XXXIII of fig. 31. As shown, each of the orifices 3200, 3202, 3204 may include a respective tapered zone 3300, 3302, 3304. Each tapered region 3300, 3302, and 3304 tapers in a direction opposite the direction of light emission (e.g., such that the diameter of each of the apertures 3200, 3202, and 3204 increases with increasing distance from the optical emitter). Tapered regions 3300, 3302, and 3304 are configured to cause light incident thereon to be reflected within the respective dispersion region 3120, 3122, or 3124, which may reduce the amount of back reflection. The reflection of the light within the dispersion areas 3120, 3122, and 3124 reduces the intensity of the reflected light so that the robot cleaner does not detect the reflected light. Thus, the detectable portion of light emitted from a respective one of the shadow boxes 3102 or 3106 corresponds to a predetermined size and/or shape.

In some cases, the surfaces defining the dispersion regions 3120, 3122, and 3124 can be configured to be reflective (e.g., to reflect at least 10%, 20%, 30%, or 40% of the light incident thereon). In other cases, the surfaces defining the dispersing areas 3120, 3122, and 3124 can be configured to be matte (e.g., reflect less than 10% of the light incident thereon). Using reflective surfaces instead of matte surfaces may allow greater control over the shape of light emitted from the respective shadow boxes 3102 and 3106.

The shadow boxes 3102, 3106 and 3110 are arranged such that light emitted from the first and second shadow boxes 3102, 3106 diverges in the direction of light emitted from the shadow box housing 3100, and light emitted from the third shadow box 3110 extends therebetween. As also shown, each of the shadow boxes 3102, 3106 and 3110 defines an optical emitter socket 3306, 3308 and 3310. Each photo-emitter socket 3306, 3308, 3310 is configured to receive at least a portion of a respective photo-emitter.

The shape and/or size of the emission cone 3203 may be based at least in part on a minimum diameter of each of the apertures 3200, 3202 and 3204, a taper angle γ measured between the emission axis 3208 and the tapered surfaces 3305, 3307, 3309 of the tapered zones 3300, 3302, 3304, and/or a size of the light emitter (e.g., the diameter of the emitted light measures greater than the diameter of at least the first aperture 3200). For example, the minimum diameter of each of the apertures 3200, 3202 and 3204, the taper angle γ, and/or the size of the optical emitter 3206 may affect the intensity of the emitted light within the predetermined area. Thus, adjusting the minimum diameter, the taper angle γ, and/or the size of the optical emitter 3206 of each of the apertures 3200, 3202, and 3204 may allow for adjusting the intensity distribution of the transmitted signal.

The taper angle γ may be measured in a range between, for example, 0 ° and 180 °. As another example, the taper angle γ may be measured in the range of 40 ° to 80 °. As yet another example, the taper angle γ may measure in the range of 50 ° to 70 °. As yet another example, the taper angle γ may measure 60 °.

The minimum diameter of the first orifice 3200 may measure, for example, in the range of 4mm to 8mm, the minimum diameter of the second orifice 3202 may measure, for example, in the range of 5.5mm to 9.5mm, and the minimum diameter of the third orifice 3204 may measure, for example, in the range of 7mm to 10.5 mm. In some cases, the minimum diameter of the orifices 3200, 3202 and/or 3204 may be dynamically adjustable (e.g., using adjustable gates).

Although apertures 3200, 3202, and 3204 are shown in a generally circular shape, apertures 3200, 3202, and 3204 are not limited to circles. For example, the apertures 3200, 3202 and/or 3204 may be square, oval, octagonal, and/or any other shape. Although the tapered surfaces 3305, 3307, and 3307 are generally shown as diverging in a direction moving away from the optical emitter 3206, in some cases, the tapered surfaces 3305, 3307, and 3307 may converge in a direction moving away from the optical emitter 3206.

Fig. 34 shows an example of an emission pattern corresponding to the shadow cartridge housing 3100. The illustrated emission pattern is shown as extending 1.8288m (or 6 feet) from the shadow box housing 3100. As shown, the gap 3400 extends between a first signal 3402 and a second signal 3404. The first signal 3402 corresponds to light emitted from the first shadow box 3102 and the second signal 3404 corresponds to light emitted from the second shadow box 3106. At least a portion of the third signal 3406 may extend within the gap 3400 between the first signal 3402 and the second signal 3404. Fig. 35 shows an enlarged view of the emission pattern of fig. 34, such that the width of the gap 3400 at various distances from the shadow cartridge housing 3100 may be shown.

FIG. 36 shows a top perspective view of a transmitter shadow box housing 3600, which can be an example of the transmitter shadow box housing 3000 of FIG. 30. For clarity, a portion of the transmitter shadow box housing 3600 is shown as transparent. As shown, the transmitter shadow box housing 3600 includes: a first transmitter shadow box 3602 defining a first transmitter compartment 3604; a second sender shadow box 3606 defining a second sender compartment 3608; and a third transmitter shadow box 3610 defining a third transmitter compartment 3612.

The first compartment 3604 and the second compartment 3608 each include a first divider 3614 and a second divider 3616. The first and second separators 3614 and 3616 are configured such that light can pass through a portion of each of the separators 3614 and 3616. Accordingly, the first and second dividers 3614, 3616 can be configured to shape the light passing therethrough, e.g., to have a predetermined shape and/or size, when emitted from the respective shadow box 3602 or 3606.

The third compartment 3612 can include an optical shaper 3618. As shown, the optical shaper includes a plurality of optical barriers 3620 such that optical channels 3622 are defined between the plurality of barriers 3620. The optical channel 3622 is configured to shape light emitted from the third compartment 3612. A plurality of dispersion channels 3623 are disposed on opposite sides of optical channel 3622 and are at least partially defined by guide surfaces 3624 of a respective one of barriers 3620. Optical dispersion channel 3623 is configured to reduce the intensity of light emitted therefrom.

FIG. 37 is a perspective cross-sectional view of transmitter shadow box housing 3600 taken along line XXXVII-XXXVII of FIG. 36. As shown, the first and second dividers 3614 and 3616 each include respective apertures 3700 and 3702 through which light generated by an optical emitter 3704 (e.g., a light emitting diode) passes. For example, and as shown, the apertures 3700, 3702 may each have a circular shape, with a measure of the diameter of each of the apertures 3700, 3702 increasing with increasing distance from the optical emitter 3704. As also shown, each orifice 3700, 3702 can include a respective tapered region 3706, 3708.

The minimum diameter of the first orifice 3700 may measure, for example, in the range of 2.0mm to 10.0mm, and the minimum diameter of the second orifice 3702 may measure, for example, in the range of 2.5mm to 10.5 mm. In some cases, the minimum diameter of the orifices 3700 and/or 3702 may be dynamically adjustable (e.g., using an adjustable gate).

Although the orifices 3700, 3702 are shown in a generally circular shape, the orifices 3700, 3702 are not limited to circles. For example, the apertures 3700 and/or 3702 may be square, oval, octagonal, and/or any other shape. Although the tapered surfaces defining the tapered regions 3706, 3708 are generally shown as diverging in a direction moving away from the optical emitter 3704, in some cases they may converge in a direction moving away from the optical emitter 3704.

FIG. 38 shows an example of a shot pattern corresponding to a sender shadow box housing 3600. The emission pattern shown extends six feet from the transmitter shadow box housing 3600. As shown, the first gap 3800 and the second gap 3802 extend between the first signal 3804 and the second signal 3806, the second gap 3802 being spaced apart from the first gap 3800. The overlap region 3808 may extend between the first gap 3800 and the second gap 3802. At least a portion of the third signal 3810 extends within the first and second gaps 3800, 3802 and through the overlap region 3808 such that the robotic cleaner may follow the third signal 3810. Fig. 39 shows an enlarged view of the emission pattern of fig. 38, so that the width of the overlapping region 3808 at different positions can be shown.

Fig. 40 shows illustrative examples of docking station 4000 and robot cleaner 4002, which may be examples of docking station 10 and robot cleaner 12 of fig. 1A, respectively. As shown, the robotic cleaner 4002 includes a receiver shadow box housing 4004 (shown in phantom) configured to have one or more receivers 4006 (shown in phantom) disposed therein. The receiver 4006 is configured to detect an intermediate signal 4010 emitted by the docking station 4000 and extending within a gap 4011 between side signals 4013 and 4015 (e.g., left and right signals). A measure of receiver shadow box housing opening width 4012 can generally correspond to a measure of gap width 4014 corresponding to gap 4011. For example, a measure of receiver shadow box housing opening width 4012 can be measured to be substantially equal to the narrowest measure of gap width 4014. Such a configuration may allow robot cleaner 4002 to more accurately follow intermediate signal 4010 by, for example, limiting (e.g., preventing) interference caused by side signals 4013, 4015.

In some cases, robotic cleaner 4002 can include a plurality of receiver shadow box housings 4004, each having one or more of receivers 4006. Receiver shadow box housing 4004 can be disposed on an opposite side of robotic cleaner 4002. For example, each receiver shadow box housing 4004 can be disposed along a central axis that extends substantially parallel to the forward direction of movement of the robotic cleaner 4002. When multiple receptor shadow cartridge housings 4004 are used, the robot cleaner 4002 can approach the docking station 4000 in a first direction using one or more receptors 4006 disposed within one of the receptor shadow cartridge housings 4004, and, upon reaching a predetermined distance from the docking station 4000, the robot cleaner 4002 can be configured to rotate (e.g., substantially 180 °) and move in a second direction (which is substantially opposite the first direction) and align with the docking station 4000 using the one or more receptors 4006 of another one of the receptor shadow cartridge housings 4004 so as to move into engagement (e.g., contact) with the docking station 4000.

In some cases, robotic cleaner 4002 can include a plurality of side sensors 4016 (shown in phantom) disposed on opposite sides of receiver shadow box housing 4004. The side sensor 4016 may be configured to determine the attitude of the robotic cleaner 4002 relative to the docking station 4000 based on the sensor 4016 detecting, for example, the intermediate signal 4010 and/or the side signals 4013, 4015.

Fig. 41 illustrates a cross-sectional view of a receiver shadow box housing 4100, which may be an example of the receiver shadow box housing 4004 of fig. 40. As shown, the receiver shadow box housing 4100 includes a first receiver shadow box 4102 defining a first receiver compartment 4104 and a second receiver shadow box 4106 defining a second receiver compartment 4108. The first compartment 4104 is configured to receive at least a portion of the first optical receiver 4110 and the second compartment 4108 is configured to receive at least a portion of the second optical receiver 4112. The first compartment 4104 and the second compartment 4108 may each be at least partially defined by a respective guide surface 4105, 4109. The guide surfaces 4105, 4109 may extend transverse to the receiving axes 4111, 4113 of a respective one of the first and second optical receptacles 4110, 4112.

As shown, the guiding surfaces 4105 and 4109 diverge in a direction away from the first optical receiver 4110 and the second optical receiver 4112. In other words, a measure of the separation distance 4114 extending between the guide surfaces 4105, 4109 increases as the distance from the first optical receiver 4110 and the second optical receiver 4112 increases. For example, separation distance 4114, measured at its maximum, may be substantially equal to the narrowest width of the detectable signal generated by docking station 4000 of fig. 40.

As shown, an optical barrier 4116 separates the first compartment 4104 from the second compartment 4108. The optical barrier 4116 includes an optical shield 4118 that is spaced apart from and extends at least partially over a respective one of the first optical receptacle 4110 and/or the second optical receptacle 4112. Accordingly, the optical shield 4118 extends at least partially within respective ones of the first and second compartments 4104, 4108.

Fig. 42 shows a perspective cross-sectional view of an example of a transmitter shadow box housing 4200. As shown, the transmitter shadow box housing 4200 includes a first transmitter shadow box 4202 defining a first transmitter compartment 4204, a second transmitter shadow box 4206 defining a second transmitter compartment 4208, and a third transmitter shadow box 4210 defining a third transmitter compartment 4212. As shown, the third transmitter shadow box 4210 is disposed between the first transmitter shadow box 4202 and the second transmitter shadow box 4206. The first and second transmitter shadow boxes 4202 and 4206 each include a first spacer 4214, a second spacer 4216, and a third spacer 4218. Each of the first, second, and third spacers 4214, 4216, 4218 comprises an aperture 4220, 4222, and 4224 through which light can pass. The orifices 4220, 4222, and 4224 may be configured to shape light passing therethrough.

As also shown, the third transmitter shadow box 4206 includes first and second optical shields 4226, 4228, each extending from opposite sides of the third transmitter compartment 4212. The first optical shield 4226 and the second optical shield 4228 extend into the third transmitter compartment to define an optical passage 4230 through which light is emitted. As shown, the optical passage 4230 may be aligned with a central axis 4232 of a corresponding optical emitter 4234. The optical passage 4230 may be configured to shape light passing therethrough.

An example of a docking station for a robotic cleaner consistent with the present disclosure may include a housing, at least one charging contact coupled to the housing, and at least three optical emitters disposed within the housing. The at least three optical emitters may include: a first optical emitter configured to generate a first optical signal within a first field of emission; a second optical emitter configured to generate a second optical signal within a second emission field; and a third optical emitter configured to generate a third optical signal within a third emission field. The third optical transmitter may be disposed between the first optical transmitter and the second optical transmitter, and the first optical signal, the second optical signal, and a third optical signal may be different from each other, wherein the third optical signal is configured to guide the robot cleaner in a direction of the housing.

In some cases, the first and second transmission fields may not have substantial overlap within the detection zone. In some cases, at least a portion of the third transmitted field may extend in a region between the first transmitted field and the second transmitted field, the region corresponding to a location where the robotic cleaner detected the third optical signal without the first optical signal and the second optical signal. In some cases, at least a portion of the first, second, and third transmit fields may overlap one another for at least a portion of the detection zone. In some cases, the docking station may further include at least three shadow boxes disposed within the housing, each shadow box corresponding to a respective one of the first, second, and third optical emitters. In some cases, the first optical emitter and the second optical emitter may be angled relative to the third optical emitter. In some cases, the first optical emitter, the second optical emitter, and the third optical emitter may be aligned along a common horizontal plane. In some cases, the third optical emitter may be vertically offset from the first optical emitter and the second optical emitter. In some cases, the first optical emitter and the second optical emitter may be aligned along a common horizontal plane.

An example of a robotic cleaning system consistent with the present disclosure may include a robotic cleaner having at least one optical receiver and a docking station having at least one charging contact and at least three optical emitters. The at least three optical emitters may include: a first optical emitter configured to generate a first optical signal within a first field of emission; a second optical emitter configured to generate a second optical signal within a second emission field; and a third optical emitter configured to generate a third optical signal within a third emission field. The third optical emitter may be disposed between the first optical emitter and the second optical emitter, and the first optical signal, the second optical signal, and the third optical signal may be different from each other, wherein the third optical signal is configured to guide the robot cleaner in a direction of the docking station.

In some cases, the first optical emission field and the second optical emission field may not have substantial overlap within the detection zone. In some cases, at least a portion of the third transmitted field may extend in a region between the first transmitted field and the second transmitted field, the region corresponding to a location where the robotic cleaner detected the third optical signal without the first optical signal and the second optical signal. In some cases, the first, second, and third transmission fields may overlap one another within at least a portion of the detection zone. In some cases, the robotic cleaning system may include at least three shadow boxes disposed within the docking station, each shadow box corresponding to a respective one of the first, second, and third optical emitters. In some cases, the first optical emitter and the second optical emitter may be angled relative to the third optical emitter. In some cases, the first optical emitter, the second optical emitter, and the third optical emitter may be aligned along a common horizontal plane. In some cases, the third optical emitter may be vertically offset from the first optical emitter and the second optical emitter. In some cases, the first optical emitter and the second optical emitter may be aligned along a common horizontal plane. In some cases, the robot cleaner may be moved toward the third optical signal when the at least one optical receiver detects one of the first or second optical signals. In some cases, when the at least one optical receiver detects the third optical signal, the robotic cleaner may be caused to follow the third optical signal until the robotic cleaner engages the docking station such that the robotic cleaner is electrically coupled to the at least one charging contact.

Although the disclosure herein generally discloses the signal emitter being disposed on the docking station and the signal receiver being disposed on the robotic cleaner, in some cases the signal emitter may be disposed on the robotic cleaner and the signal receiver may be disposed on the docking station. In these cases, the docking station may be configured to transmit a movement signal based on a signal transmitted from the robot cleaner to the robot cleaner so that the robot cleaner can adjust its position relative to the docking station. Accordingly, the robot cleaner can be navigated to the docking station based on the communication received from the docking station.

While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. In addition to the exemplary embodiments shown and described herein, other embodiments are also encompassed within the scope of the present invention. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.