Priority Claim

This application claims priority to co-pending U.S. Provisional Application No.

62/098,415, filed on December 31, 2014, the entire disclosure of which is incorporated herein by reference.

Background

The present disclosure relates to autonomous or robotic devices and particularly to devices operable to autonomously apply a coating to surfaces, such as floors and walls.

Painting walls, varnishing surfaces or applying surface coatings to floors are tedious tasks requiring manual application using paint brushes and rollers. Even in more "modern" approaches, a spray paint head must still be manually manipulated to apply the paint or other coating to the appropriate surface. The task becomes particularly onerous when painting walls, especially tall walls that require a step stool or ladder to reach the upper limits of the wall. More refined paint sprayers exist, such as HLVP (high volume low pressure) sprayers, that allow the spray head to be held closer to the surface to be painted or coated, but these devices still require a human to hold and guide the sprayer.

Robotic painting devices have been used for years to apply coatings, such as paint, to commercial products, such as automobiles. However, these robotic devices remain at a generally fixed location as the product traverses through a paint booth. More sophisticated robotic painters include a paint head at the end of a robotically controlled arm that can move around a product at the paint station. While these robotically controlled painting/coating devices are useful for applying paint/coatings to a product passing by in an assembly line fashion, these approaches are meaningless to a homeowner faced with the daunting task of painting a room or rooms.

Consequently, there is a need for an autonomous device capable of painting or applying coatings to any surface at any location.

Summary

An autonomous painting apparatus comprises a mobile base unit movable in relation to a surface to be painted, a reservoir for containing paint to be applied to the surface, and an applicator assembly supported on the mobile base unit. The applicator assembly includes an applicator configured to apply paint to the surface and a paint supply tube coupled between the applicator and the reservoir for drawing paint from the reservoir and supplying the paint to the applicator. The apparatus includes a control unit associated with the base unit operable to control the movement of the base unit and the applicator assembly for controlled application of paint to the surface.

In one aspect the reservoir can be in a unit separate from the base unit that does not need to be mobile. The mobile base unit includes a drive assembly that allows the unit to be propelled along the floor to move the apparatus along a surface to be painted. In one aspect, the applicator of the applicator assembly can be a spray nozzle, a roller or other device capable of applying paint to a surface. In one feature, the applicator can be in the form of a print head that allows for applying user-selected forms or decorations to the surface.

The applicator assembly includes components for maintaining and propelling the applicator along the surface being painted. In one feature, the applicator assembly includes an articulating arm assembly supported on the base unit with the applicator supported at an end of the articulating arm assembly. The articulating arm assembly is configured to extend and retract the applicator during application of paint to the surface. In another feature, the applicator assembly includes a bellows mechanism with the applicator supported at an upper end of the bellows mechanism. The bellows mechanism is configured to extend and retract the applicator during application of paint to the surface.

The control unit may incorporate a microprocessor or similar computing device that is capable of executing a stored program for directing the operation of the components of the autonomous painting apparatus. The control unit may be configured to communicate and receive instructions from a remote device, such as a smart phone.

In one aspect, the applicator assembly includes a Bernoulli device operable to generate a movable vacuum to hold the applicator on the surface. The Bernoulli device thus allows the applicator to move along a vertical wall or a horizontal ceiling. In another aspect, the applicator assembly includes a pair of spaced apart vertical arms, each supported at one end on the mobile base unit and including an anchor plate at an opposite end adapted to engage the ceiling of a room when the base unit is on the floor of the room. The applicator is slidably mounted between the vertical arms for vertical travel along the surface.

In a further aspect, the applicator assembly is configured to allow application of paint to a corner joint between two surfaces. The applicator assembly can include a pair of segments connected at a pivoting joint configured to allow the pair of segments to assume a planar position relative to each other to support the applicator on a planar surface, and to assume a right angle position relative to each other to support the applicator at a corner between surfaces. Description of the Figures

FIG. 1 is a series of diagrams illustrating the use of an autonomous painting device as described herein.

FIG. 2 is a further series of diagrams illustrating the use of an autonomous painting device as described herein.

FIG. 3 is a perspective view of a base unit for an autonomous painting device described herein.

FIG. 4 is a perspective view of an autonomous painting device described herein.

FIG. 5 is a perspective view of a further autonomous painting device described herein. FIG. 6 is a perspective view of another autonomous painting device described herein.

FIGS. 7a-7c are side and perspective views of another autonomous painting device in stages of operation.

FIG. 8 is a perspective view of yet another autonomous painting device described herein. FIG. 9 is a perspective view of a stationary unit for use with the autonomous painting devices described herein.

FIGS. 10a, 10b are perspective views of another autonomous painting device in stages of operation.

FIGS, lla-lld are views of a further autonomous painting device with detail views of the applicator of the device.

FIG. 12a-12b are perspective views of a still further autonomous painting device in stages of operation. FIGS. 13a-b are perspective views of another autonomous painting device in stages of operation.

FIGS. 14a-14c are views of a flying autonomous painting device according to a further aspect of the disclosure.

Detailed Description

For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein as would normally occur to one skilled in the art to which this disclosure pertains.

FIG. 1 illustrates one scenario for use of the autonomous painting/coating device disclosed herein. In this scenario a user desires to paint the walls W and ceiling C of a room using an autonomous device 10. The device is loaded with paint and then directed to paint the surface of a wall. The device is capable of navigating around the room, including around obstacles in the room, and capable of moving a paint head or applicator 11 in a pattern calibrated to paint the entire wall and/or ceiling. FIG. 2 depicts the steps in a painting process in which the first step involves defining the area to be painted/coated by the applicator 11. In one

embodiment, a hand-held device 100 may be provided that is configured to scan the surfaces to be painted/coated to provide the geometric constraints for movement of the paint head 11.

Alternatively, the hand-held device may be a smart-phone or similar device capable of executing an app operable to delineate the working area for the autonomous device 10 disclosed herein. The hand-held device is configured to communicate with the autonomous device 10, either by a direct interface or by a wireless interface. The device 10 includes software capable of reading the information generated and transmitted by the hand-held device 100 and directing the movement of the applicator 11 accordingly. Alternatively, the device itself may incorporate the user interface to program the movement of the applicator 11. In yet another alternative, the device and/or applicator may incorporate a recognition apparatus that is capable of visualizing the workspace and determining an appropriate movement pattern for the applicator to completely coat the workspace. The device 10 thus incorporates a controller and appropriate software operable to control the pattern of movement of the applicator 11 to completely and accurately coat the desired workspace area.

Referring again to FIG. 2, once the workspace has been determined, the user fills a reservoir in the autonomous device 10 with the desired paint or coating material. Alternatively, the device may carry its own quantity of material from which the user may select a desire paint color or coating composition. As needed, the device may incorporate a paint mixing device operable to mix different paints to obtain a desired hue. In step 3 shown in FIG. 2, the user then places the applicator 11 in position on a surface to be painted/coated. The device 10 may be configured to recognize the position and adjust the application pattern accordingly to ensure complete coverage of the work surface. The device executes software that robotically directs the movement of the applicator 11 and directs the flow of the paint/coating material to the applicator. The software is configured to move the applicator 11 in a pattern that avoids areas of the surface that have already been painted/coated. As shown in step 5 of FIG. 2, the applicator may be configured to move from one wall Wl to another wall W2, although in an alternative

embodiment the device is configured to paint/coat one surface at a time. The device may also be configured and programmed to clean the applicator as needed during or at the end of a process. In one embodiment, the autonomous device 10 may incorporate a mobile base unit 12 that includes a drive assembly 13 operable to propel the base unit about a workspace, as shown in FIGS. 3-4. The base unit 12 includes a removable and/or re-fillable reservoir for paint or other coating material. The base unit includes a pump (not shown) operable to draw the paint/coating material from the reservoir 14 and supply it to an applicator 11 through a flexible supply tube 17. The supply tube 17 is sufficiently long to reach the upper extent of a wall W or a ceiling C (FIG. 1) and to move through a desired swath length before the base unit must be moved to accommodate the applicator. In one embodiment, the supply tube can have a fully extended length of 10-15 ft, although other lengths are contemplated. The base unit 12 may be provided with a reel or other component to store, extend and retract the supply tube as the autonomous device 10 navigates through a workspace. The base unit 12 includes a controller or control unit that operates the functional components of the device 10 and includes a

microprocessor or computing unit operable to execute software instructions for controlling the drive assembly 13 and applicator 11. As depicted in FIG. 3, the base unit may plug into an electrical outlet in the workspace using the electrical cord 19 to supply electrical power to the control unit, drive assembly and applicator. Alternatively, the base unit may include an autonomous power supply, such as a rechargeable or replaceable battery to power the drive assembly 13 and pump.

In one embodiment, the applicator 11 includes a body 15 that provides openings (not shown) for dispensing the paint/coating material. Since the applicator is configured to travel along the surface being painted/coated the openings may incorporate nozzles for projecting or spraying the material onto the surface as the applicator moves away from the point of application. Alternatively the applicator may incorporate a roller, such as a typical paint roller, that is replenished with paint/coating material as it rolls across the work surface. In addition, the body 15 may house components for supporting and moving the applicator 11 on the work surface, regardless of the orientation of the surface. In one embodiment, the body 15 may incorporate air pressure grippers that use the Bernoulli principle to generate a movable vacuum to hold the applicator on the surface while allowing it to move along the surface. Other forms of vacuum generation may be utilized with appropriate tubing and/or cabling extending from the applicator 11 to the base unit 12. The applicator 11 may incorporate sensors 20 operable to survey the work surface to assist in the autonomous movement of the applicator. The sensor may communicate with the control unit in the base unit 12 and/or with another remote unit to send and/or receive information. For example, the sensors may receive information from the base unit or remote unit to assist in navigation of the work space.

The base unit and applicator may be provided in different configurations operable to perform the autonomous painting/coating operations contemplated herein. In one embodiment shown in FIG. 5, an articulating mechanism 20 may be incorporated with a base unit, such as the unit 12. The articulating mechanism includes a series of articulating links 22 with an applicator 11' at the end of the links. The links 22 are configured to move the applicator 11' vertically. The applicator 11' may include a material application roller 24 and a guide roller 25 configured to help the application roller 24 maintain proper pressure on the work surface. It is contemplated that the guide roller 25 is positioned relative to the application roller 24 so that the guide roller precedes the application roller on the surface being painted so that the guide roller does not travel through a freshly painted surface. The articulating mechanism 20 is thus operable to move the application roller 24 vertically along the surface. Each of the articulating links 22 may be individually controllable by the base unit 12 as necessary to provide a smooth vertical movement of the application roller. It is further contemplated that the uppermost link 26 may be separately controllable to permit horizontal movement of the application roller 24 along an elevated horizontal surface, such as a ceiling.

In lieu of the articulating link configuration shown in FIG. 5, an extendable bellows configuration may be used, as shown in FIG. 6. In this embodiment, the extendable mechanism 30 includes an expandable/extendable bellows 32 with the applicator 11" at the end of the bellows. As in the prior embodiment, the applicator 11" may include an application roller 34. The bellows 32 may be pneumatic or hydraulic and the bellows mechanism 30 may be associated with a base unit 12. In this embodiment, the application roller 34 is nominally limited to vertical application strokes applied by extending or retracting the bellows 32.

In an alternative embodiment, a robotic extendable unit 30' shown in FIGS. 7a-7c includes a bellows 32 mounted on a mobile base unit 31 that may be similar to the base unit 12. The applicator 11" includes an articulating arm 36 supported on an upper hub 35 affixed to the top of the bellows. The base 31 supports a paint/coating reservoir 37 that feeds paint to the roller 34 along the bellows and articulating arm 36. In this alternative embodiment, the movement of the roller 34 involves a combination of bellows extension and articulation of the arm 36. The arm 36 may pivot and translate in the direction of the arrows in FIG. 7b. The arm 36 may thus be provided with a separate motor to pivot the arm or to translate the arm relative to the upper hub 35. In another embodiment, a mobile base unit 40 is provided that may be similar to the unit 12 described above in that is supports a reservoir for the paint/coating material, control electronics and drive system 41. The unit includes a robotic articulating arm assembly 43 with a first arm 44 pivotably mounted to the base unit, a controllable joint 45 and a second arm 46 that carries an applicator 11"' that may be a roller or a spray head or other device operable to apply paint of other material to a surface. The robotic arm assembly 43 may be controlled to perform a painting motion akin to the motion of a human painting the surface. The base unit 40 is controllable to move along the surface being painted once the arm assembly completes a swath on the surface. It is understood that the arm assembly 43 may be sized to paint vertical and horizontal surfaces, including a ceiling surface.

The base units, such as units 12 and 40 described above, may be modified to connect to a generally stationary unit, such as unit 50 shown in FIG. 9. The stationary unit 50 includes a reservoir 51 for containing paint or other coating material, with a visible volume indicator 52 and a refill opening 53. The stationary unit 50 may include a detachable connection 55 for connecting to a source of compressed gas, such as compressed air, and for connecting to a supply tube that is connected to the robotic base unit 12 or 40, or to the applicator assembly 11, for instance. The detachable connection allows the stationary unit 50 to be disconnected from the robotic unit to be taken some place to be refilled, as desired by the user. The stationary base unit 50 can simplify the construction of the mobile units since the mobile unit no longer needs to carry the paint supply.

A self-contained mobile unit 60 is depicted in FIGS. 10a, 10b that incorporates a robotic base unit 61 with its own paint/coating reservoir 62. The unit includes an articulating arm assembly 63 that carries and moves an applicator 11 which may be a roller or spray head as described above. The articulating arm assembly 63 is configured to achieve a fully nested configuration as shown in FIG. 10b. In this nested configuration the entire mobile unit 60 fits in a small envelope for easy, non-obtrusive storage.

Another self-contained unit 70 is depicted in FIGS, lla-lld. The unit 70 includes a mobile robotic base unit 71 with a drive system 72 that may be configured for programmed or controlled operation as described above. The unit 70 includes a paint reservoir 73 that may be removably mounted on or within the base unit 71. The removable reservoir 73 may thus be removed from the current location of the self-contained unit 70, refilled and returned to the unit without disturbing the current position of the applicator 75. The applicator 75 is coupled to the base unit by an air hose 76 and a paint supply hose 77. The air hose 76 is used to power a Bernoulli suction device and can be used to power a drive mechanism. In one aspect, the air hose may also supply air flow to fan-driven traction wheels 78 used to propel the applicator 75 along the surface being painted. The paint supply hose 77 supplies paint or coating material to the applicator element 79 which may be a roller, sprayer, sponge applicator or other component capable of controlled feeding of paint to the surface. The applicator element 79 may define a pointed nose 79a to allow the element to reach into corners.

An applicator assembly 80 may be provided as shown in FIGS. 12a-12b that is specifically capable of painting at the junction between surfaces, such as between adjacent walls Wl, W2. The mobile base 81 of the applicator assembly 80 includes segments 81a, 81b joined at a pivoting joint 82 that is configured to allow the segments to pivot to a right angle position as shown in FIGS. 12b. In this position, the assembly supports the applicator 11 over the joint between the two walls Wl, W2. The applicator 11 is supported on each segment by a corresponding arm 86 so that the applicator 11 is always supported at an optimum position above the surface or wall joint to be painted. Thus, when the applicator assembly 80 is moving across a flat surface, as shown in FIG. 12a, the two segments are in the same plane and the arms 86 support the applicator 11 to apply paint or coating material to the surface.

The mobile base 81 may incorporate the Bernoulli nozzles described above to allow the base to be maneuvered along the surfaces and joints being painted. Between swaths the mobile base is configured to move transversely to the painted swath to paint a new adjacent swath. This movement may be assisted by rollers 87 at the sides of each segment and by central rollers 88. The rollers 87, 88 are configured to drive the mobile base along the planar surface while the central rollers are arranged to drive the unit across wall joints as the two segments are at an angle relative to each other.

An autonomous painting unit 90 shown in FIG. 13 is configured to be temporarily anchored at a painting location. The unit 90 includes a mobile base unit 91 that may be robotically controlled like the base units described above. The unit 90 includes telescoping arms 92 that project upward from the base unit 91 and terminate in an anchor plate 93. The telescoping arms 92 are sized to extend the anchor plate 93 to the ceiling where the plate engages the ceiling to hold the unit 90 in position. The unit includes an applicator assembly 95 that is slidably supported on the arms 92 by collars 96 that permit vertical movement of the applicator assembly 95. The applicator assembly may also be mounted to the collars 96 to permit a swivel movement as desired to assist in applying the paint/coating material. The applicator assembly includes a paint tube 98 that connects to a supply 97 that may be carried by or separate from the base unit 91. The base unit 91 may incorporate an array of sensor and/or cameras to help guide the movement of the base unit 91 during a painting procedure. It can be appreciated that the base unit 91 is associated with a controller that moves to a particular location, extends the telescoping arms 92 until the anchor plate 93 contacts the ceiling, and then drives the applicator 96 to apply the paint/coating to the wall surface.

In one embodiment, the applicator assembly 95 may be configured in the fashion of a printer with multiple print heads. In particular, the applicator assembly may be configured to generate patterns or images on the wall surface, as depicted in FIG. 13b. Thus, the applicator assembly 95 may incorporate multiple heads or nozzles that can be selectively controlled to apply paint/coating material. The applicator assembly may further be configured to permit application of multiple colors. The control system for the autonomous paint unit 90 or the applicator assembly 95 may be configured to upload artwork provided by the user. The artwork may be of the user's own creation using computer graphics software, or may be downloaded from a database of artwork.

The present disclosure contemplates an autonomous painting unit that is not limited to being ground-based. In particular, a flying unit 100 shown in FIGS. 14a-14c includes a body 100 with lift and flight elements 103. In the illustrated embodiment, the lift and flight elements 103 are in the form of helicopter rotors that are configured for controlled lift and flight. The rotors 103 are supported on arms 104 that may be controllable to determine the direction of flight of the unit 100. The body 101 may include a camera 107 or other sensor adapted to determine a suitable fight path for the unit. The unit may incorporate software capable of recognizing obstructions, determining proximity to the surface being painted and even determining whether the surface has already been painted/coated. The body 101 supports a container 105 for the paint/coating material and an applicator 106, which may be in the form of a spray head. The spray head may have a wide spray angle, such as 120° as depicted in FIG. 14c. The autonomous flying unit 100 may include a tether 108 to physically restrain the unit and/or to provide electrical power to the unit.

The present disclosure contemplates an autonomous device for applying paint or coating material to a surface, such as a wall, floor or ceiling. The device includes a mobile robotic self- propelled base unit that is operable to move an applicator to and from and along a surface to be painted/coated. In some embodiments the mobile base unit may carry its own paint/coating supply while in other embodiments the mobile base unit can be connected to a stationary reservoir. In a further aspect, the applicators are carried by applicator assemblies that are capable of traveling along vertical walls, such as by the use of Bernoulli nozzles or other devices configured to maintain suction between the applicator assembly and the wall surface sufficient to hold the assembly on the wall during movement and painting. The autonomous robotic unit may incorporate a controller operable to execute software instructions to direct the movement of the unit and the paint applicator. The instructions may be adapted to follow predetermined painting protocols or protocols developed by the user. The user may be provided with an interface to program the operation of the autonomous unit.

The autonomous robotic units disclosed herein can achieve highly accurate application of paint/coating material to any wall surface, thereby freeing the user from the tedium of preparing and painting the surfaces. For instance, the accuracy of the units disclosed herein eliminates the need to cover object and surfaces that are not intended to be painted. The control systems of the units described herein can execute software instructions to sense a surface, determine an optimum painting protocol and verify that the paint/coating has been properly applied, thereby removing the variability that comes with manual application of paint/coating materials.

The present disclosure should be considered as illustrative and not restrictive in character. It is understood that only certain embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.