AUTONOMOUS A/C DUCT CLEANING ROBOT FOR HVAC DUCT MAINTENANCE

Abstract

ABSTRACT The invention relates to an autonomous air conditioning (A/C) duct cleaning robot designed for cleaning HVAC ducts of varying shapes and sizes. The robot comprises a modular body with a primary rotating brush (1), an expandable umbrella brush (4), and a vacuum system (3) for debris collection. It employs AI-based navigation using ultrasonic sensor (13), pressure sensors (10), air quality sensors (11), and wheel encoders (9) for precise movement and cleaning. A NodeMCU microcontroller (12) with Wi-Fi and Bluetooth connectivity manages operations, enabling both autonomous and remote-controlled functions, while an ESP32-CAM (7) provides live video feedback. The system is powered by a rechargeable battery (8), offering flexibility and efficiency in duct maintenance. This robot provides a versatile, cost-effective solution for thorough HVAC cleaning, adapting to various duct conditions and eliminating the need for manual intervention. Figure 1.

Specification

Description:AUTONOMOUS A/C DUCT CLEANING ROBOT FOR HVAC DUCT MAINTENANCE

FIELD OF THE INVENTION
This invention relates to the field of robotics, specifically to an autonomous robot designed for cleaning and inspecting air conditioning (AC) ducts. The invention integrates advanced sensor technology, navigation systems, and cleaning mechanisms to provide a comprehensive solution for maintaining the cleanliness and efficiency of HVAC (Heating, Ventilation, and Air Conditioning) systems

BACKGROUND OF THE INVENTION
Maintaining the cleanliness of HVAC ducts is essential for ensuring efficient air circulation and preventing the spread of contaminants within indoor environments. Traditional methods for cleaning HVAC ducts often involve labor-intensive manual processes or the use of expensive specialized equipment. These approaches can be time-consuming, expose workers to health risks, and often fail to achieve thorough cleaning, especially in complex duct systems.
The accumulation of dust, debris, and biological contaminants within HVAC ducts can lead to reduced system efficiency, increased energy consumption, poor indoor air quality, and potential health hazards for building occupants. Additionally, inconsistent cleaning methods can result in incomplete removal of obstructions, further compromising the performance of HVAC systems.
To address these challenges, there is a need for an autonomous, efficient, and adaptable robot that can navigate and clean HVAC ducts of varying shapes, sizes, and configurations. Such a solution would enhance system performance, ensure comprehensive cleaning, and improve overall air quality, providing a safer and more effective alternative to existing methods.

SUMMARY OF THE INVENTION
The present invention relates to a novel A/C duct cleaning robot system comprising three main components: a monitoring device, a remote-controlled robot, and a dust removal device. The robot is designed to autonomously navigate through HVAC ducts, using an advanced guidance system to ensure precise movement and comprehensive cleaning. The robot's cleaning mechanism, which includes adjustable brushes and a vacuum system, is designed to adapt to various duct sizes and materials. The control system allows for both autonomous operation and remote control by an operator, with real-time data transmission facilitated through wireless communication. The invention also includes a detailed 3D model of the robot, developed using Pro/Engineer (Pro/E), and physical prototypes that have been rigorously tested to ensure optimal performance.
In one embodiment, the present invention relates to an autonomous robot designed for cleaning and maintaining AC ducts. The robot is equipped with rotating brushes, a vacuum system, and advanced sensors to dislodge and remove debris from duct surfaces. The robot's navigation is facilitated by a combination of AI algorithms and various sensors, including cameras, ultrasonic sensors, and air quality monitors. Powered by a rechargeable battery, the robot can operate remotely, transmitting real-time data to a user interface for monitoring and control. The system is designed to improve HVAC efficiency, ensure air quality, and reduce maintenance costs.

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 depicts the prototype of the A/C duct cleaning robot system, showing Brush (1), DC motor (2), Vacuum(3), Umbrella Brush (4), Storage (5), Motor Driver (6), ESP 32 CAM (7), Battery (8), Wheel Encoders (9), Pressure Sensors (10), Air Quality Sensors (11), Control Unit (12) and Ultrasonic Sensor (13).
Figure 2 illustrates the block diagram of the control unit, including the microcontroller, power supply, and input/output devices.
Figure 3 illustrates the line diagram representation of the A/C duct cleaning robot system
Figure 4 depicts the user interface for monitoring and control
Referring to the drawings, the embodiments of the present invention are further described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated or simplified for illustrative purposes only. One of ordinary skill in the art may appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an A/C duct cleaning robot system that automates the process of cleaning HVAC ducts, combining advanced robotics with intelligent sensor technology to ensure thorough and efficient operation.
In one embodiment, the present invention relates to an A/C duct cleaning robot system that autonomously navigate through HVAC ducts, using an advanced guidance system to ensure precise movement and comprehensive cleaning. The robot is equipped with several components that aid the operation, monitoring and control. The system is designed to improve HVAC efficiency, ensure air quality, and reduce maintenance costs. The robot features a modular and flexible body constructed from durable materials capable of withstanding various temperatures and debris commonly found within ducts. The flexible design allows the robot to navigate through ducts of different shapes and sizes while maintaining a compact form factor.

Components used in the A/C duct cleaning robot system
1. Cleaning Components:
Equipped with adjustable brushes and a vacuum system, the cleaning mechanism is designed to remove dust, dirt, and other contaminants from the duct surfaces. The brushes can be adjusted to accommodate ducts of varying diameters and materials, ensuring effective cleaning across different environments.
Brush (1): The primary cleaning tool is a rotating brush composed of durable bristles or fibers with partially rough edges, designed to effectively clean dust and debris from duct walls. The brush consists of round-shaped bristle strands bound together and is typically mounted in the lower section of the robot. It is attached to the robot's chassis via hydraulic holders positioned at the top of the robot, with the brush fixed at the ends of these holders. The brush assembly is powered by a DC motor and supported by lightweight steel frames, allowing it to rotate at variable speeds ranging from 30 RPM to 610 RPM. As the robot navigates through the ducts, the brush rotates at these adjustable speeds to dislodge and remove particles adhered to the duct walls, playing a critical role in breaking up stubborn buildup and ensuring comprehensive cleaning.
Umbrella Brush (4): This specialized brush is designed to expand and contract, allowing it to adapt to various duct diameters and maintain consistent contact with the entire surface area. It is particularly effective for cleaning ducts of different sizes. The umbrella brush consists of a shaft and a runner mechanism. The runner moves along the shaft, connecting the stretchers, which control the expansion and contraction of the brush. A spring mechanism provides the necessary tension to keep the umbrella brush in either the open or closed position. The shaft serves as the central rod, linking the handle to the top of the umbrella structure. The top surface of the umbrella is equipped with brush bristles, ensuring thorough contact cleaning of the duct walls and surfaces.
Vacuum System (3): Working in tandem with the brush, the vacuum system captures and stores dislodged debris. The system is equipped with an efficient suction mechanism that ensures all loosened contaminants are swiftly removed from the ducts.
Storage (5): The debris and dust collected by the vacuum are stored in a dedicated compartment within the robot. This compartment can be easily emptied after each cleaning cycle.

2. DC Motor (2):
A 12 Volt DC motor powers the rotating brush and other mechanical elements of the robot. It is designed for high efficiency and durability, enabling the robot to operate continuously during extended cleaning sessions.

3. Motor Driver (6):
This component manages the operation of the DC motor by adjusting its speed and torque according to the specific cleaning tasks. It consists of an L298 motor driver IC and a 78M05 5V regulator. The speed and torque of the motor are controlled manually via the NodeMCU controller, which interfaces with the motor driver. This setup allows precise regulation of the motor's performance through the operating interface connected to the driver control unit.

4. Sensor Suite:
The robot is outfitted with a sophisticated sensor suite, including camera module (ESP 32 CAM for better object detection. These sensors enable the robot to navigate autonomously, avoiding obstacles and mapping the ductwork layout. The robot employs several sensors and AI algorithms to navigate and clean the ducts:
Ultrasonic Sensor (13): Measure distances and detects obstacles within the ducts by emitting high-frequency sound waves and analyzing the echoes. The ultrasonic sensor is typically positioned on the front side of the robot's chassis, facing outward to detect obstacles or obstructions in the ductwork. It swivels to provide a wider range of coverage. As the robot traverses through the ductwork, the ultrasonic sensor continuously emits sound waves and detects reflections from the duct walls, bends, debris, or other obstacles. By analyzing the received signals, the robot adjust its path to avoid collisions and navigate safely through the duct system. The distance measurements obtained from the ultrasonic sensor are typically used as feedback for the robot's control system. Based on this feedback, the robot's actuators adjust speed, direction, or cleaning mechanisms to optimize performance and efficiency.
Pressure Sensors (10): Monitor air pressure within the ducts to detect leaks and assess airflow dynamics.
Air Quality Sensors (11): Monitor parameters such as temperature, humidity, and particulate matter, ensuring the air remains safe and clean.
Wheel Encoders (9): Track the movement of the robot's wheels, providing feedback for navigation and ensuring precise control over the robot's position.

5. Control Unit (NodeMCU) (12):
The NodeMCU serves as the central control unit, providing Wi-Fi and Bluetooth connectivity for wireless communication, allowing the device to receive commands and transmit data remotely. It is programmable using the Arduino IDE, simplifying the development of custom firmware. Equipped with digital GPIO pins, the NodeMCU supports the connection of various sensors, actuators, and other devices, and its built-in analog-to-digital converter (ADC) reads analog sensor data.
The control unit includes PWM outputs, configured in the programming to manage the speed of DC motors and the brightness of LEDs. NodeMCU integrates multiple sensors, such as ultrasonic, and GPS modules, enabling functions like obstacle detection, movement tracking, and navigation. It also controls DC motors, servos, and stepper motors, facilitating precise movement and manipulation.
The NodeMCU is programmed for autonomous operation or configured to respond to remote commands, enhancing the automation and control capabilities of the entire system. The predefined algorithms and codes stored in the NodeMCU execute specific tasks as per the embedded instructions. In autonomous operations, these predefined steps constitute the AI algorithms, which drive the system's responses based on sensor inputs and programmed logic.
The AI-based predefined algorithms and codes stored in the NodeMCU navigation system utilizes a combination of path planning algorithms and sensor fusion techniques to dynamically adjust the robot's cleaning path and speed in response to changes in duct topology, detected obstacles, or variations in air quality parameters, ensuring optimal cleaning efficiency and safety during operation.

6. ESP 32 CAM (7):
A key component for remote monitoring and control, the ESP 32 CAM provides live video feed and captures images of the duct interior. It is also essential for the robot's autonomous navigation capabilities. The ESP32-CAM is a versatile development board featuring the ESP32-S module, a powerful Wi-Fi and Bluetooth enabled system-on-chip (SoC) from Espressif Systems. The core of the ESP32-CAM is the ESP32-S module, which integrates a dual-core 32-bit microcontroller running at up to 240 MHz. This module provides Wi-Fi connectivity (802.11 b/g/n), Bluetooth (BLE), and various peripheral interfaces. The ESP32-CAM is equipped with the OV2640 camera module, capable of capturing still images in resolutions up to 2 megapixels (1600x1200 pixels). It supports various image formats including JPEG, BMP, and YUV.

7. Power Source (8):
The robot is powered by a rechargeable battery, ensuring it can operate independently within the ducts. The battery is designed for long-lasting performance and can be recharged using an external power supply.

8. Communication Module:
A wireless communication module enables the robot to transmit real-time data to a central control system or operator, using the NodeMCU for wireless communication in both operation and control. The robot continuously relays data on duct conditions, air quality, and its operational status. This module facilitates remote operation, allowing users to manually control the robot for specific tasks or troubleshooting purposes. It also supports ongoing monitoring, maintenance planning, and ensures the safety and effectiveness of the cleaning process by providing continuous feedback on the robot's performance and the environment within the ducts.

Working Mechanism
Remote Supervision and Management:
Operators monitor the robot's location and status in real-time through a user interface that offers live video feeds from onboard cameras and displays the robot's position on a digital map of the duct system. This user interface (UI) includes an embedded image stream utilizing the ESP32-CAM, an embedded module programmed via Arduino IDE to create a local server for streaming video data. The interface provides real-time visual feedback and allows operators to manually control and adjust the cleaning tools as needed, ensuring precise operation and adaptability during the cleaning process.

Remote Operation and Real-Time Data Transmission:
The robot facilitates remote operation through a user interface, which can be accessed via a handheld device. Operators can:
Live Video Feed: The ESP32-CAM is a crucial component for remote monitoring and control, providing real-time footage from the robot's cameras to track its progress and assess duct conditions. It delivers live video feeds and captures images of the duct interior, which are essential for the robot's autonomous navigation capabilities. The ESP32-CAM is a versatile development board built around the ESP32-S module, a powerful system-on-chip (SoC) from Espressif Systems, featuring Wi-Fi and Bluetooth capabilities. At its core is a dual-core 32-bit microcontroller operating at up to 240 MHz. The module supports Wi-Fi connectivity (802.11 b/g/n), Bluetooth Low Energy (BLE), and various peripheral interfaces, making it an integral part of the robot's communication and navigation systems.
Map and Positioning Display: Track the robot's location within the duct system using wheel encoders, which monitor the movement of the robot's wheels and provide critical feedback for navigation and precise control. This feedback includes data on position, speed, direction, and acceleration of the rotating wheels. Such information is essential for accurate tracking and navigation of the robot within the ducts, enabling efficient access to different locations and ensuring effective tracking. In emergency situations, the wheel encoders aid in accurately determining the robot's position, facilitating its recovery and return.
Manual Control: Direct the robot to specific locations for targeted cleaning using the manual control features of the interface. The NodeMCU transfers data to the UI, which operators can manage from either a mobile device or an operating platform. The controller connects to all equipment, including power sources, brushes, and motors, allowing for comprehensive control based on conditions and needs. The system supports continuous operation with video streaming for real-time direction. During automated operation, sensors provide data that guide the robot's actions based on real-time values and conditions.

The AC duct cleaning robot continuously collects information on the state of the ducts through sensors and monitoring systems through:
• Visual Inspection: The cameras in the robot captures high-resolution images or video footage of the interior of the ducts. These cameras provide real-time visuals to operators, allowing them to assess the condition of the ductwork, identify any signs of damage, debris buildup, or mold growth.
• Environmental Sensors: The environmental sensors measures the air quality parameters such as temperature, humidity, airborne particulate matter, and gas concentrations. By continuously monitoring these factors, the robot detects potential issues such as poor ventilation, excess moisture, or the presence of contaminants in the air.
• Pressure and Airflow Sensors: Pressure and airflow sensors monitors the performance of the HVAC system and airflow within the ducts. By measuring pressure differentials and airflow rates at various points in the ductwork, the robot identifies areas of obstruction, leaks, or inefficient airflow that may require attention.
• Ultrasonic Inspection: Ultrasonic sensor detect anomalies such as leaks or blockages by emitting high-frequency sound waves and analysing the echoes reflected off duct surfaces. The robot use this information to pinpoint the location and severity of any defects or obstructions in the ductwork.
• Data Logging and Analysis: The robot continuously logs and analyzes data collected by its sensors over time. This data is saved either on a web page or application generated by the NodeMCU or on a memory card attached to the ESP32-CAM. Historical data enables operators to track changes in duct conditions, identify trends or patterns that may indicate potential issues, and make informed decisions regarding maintenance or cleaning schedules.

Example/Experiments
Prototypes of the robot system were developed and tested in various duct environments. The prototypes demonstrated the robot's ability to autonomously navigate complex duct networks and effectively clean accumulated dust and debris. In a test environment, the AC duct cleaning robot was deployed in a standard commercial HVAC duct system. The robot successfully navigated the entire duct network, dislodged significant amounts of dust and debris using its rotating brush, and captured the contaminants with its vacuum system. Real-time data was transmitted to the operator, confirming the effectiveness of the cleaning process and the condition of the ducts. This test demonstrated the robot's capability to improve air quality and maintain HVAC efficiency.

Industrial Application
The AC duct cleaning robot is applicable in a wide range of industries, including commercial buildings, industrial facilities, shopping malls, and auditoriums. It provides a cost-effective, efficient, and autonomous solution for duct cleaning, reducing manual labor, improving system performance, and enhancing indoor air quality. The robot's ability to continuously monitor duct conditions also allows for proactive maintenance, preventing potential issues before they become critical.

It may be appreciated by those skilled in the art that the drawings, examples and detailed description herein are to be regarded in an illustrative rather than a restrictive manner. , Claims:We Claim:

1. An autonomous air conditioning (A/C) duct cleaning robot system, comprising:
a. a flexible, modular robot body designed to navigate HVAC ducts of varying shapes and sizes;
b. a primary rotating brush (1) with durable bristles and an umbrella brush (4) for dislodging dust, dirt, and other contaminants from duct surfaces, where the umbrella brush is capable of expanding and contracting to adapt to different duct diameters;
c. a vacuum system (3) operatively coupled to the brushes for capturing and storing dislodged debris in a storage compartment (5) within the robot;
d. a DC motor (2) for driving the brushes and other mechanical components of the robot, controlled by a motor driver (6) for adjusting the motor's speed and torque;
e. a sensor suite comprising ultrasonic sensor (13) for distance measurement and obstacle detection, pressure sensors (10) for monitoring air pressure, air quality sensors (11) for assessing air parameters, and wheel encoders (9) for tracking the movement of the robot's wheels;
f. a control unit (12) comprising a NodeMCU microcontroller with Wi-Fi and Bluetooth connectivity for wireless communication, interfacing with the robot's components to facilitate both autonomous and remote-controlled operation;
g. an ESP32-CAM (7) for providing live video feed and capturing images of the duct interior, facilitating navigation and monitoring;
h. a rechargeable battery (8) for powering the robot, allowing for independent operation within the ducts;
i. a communication module enabling real-time data transmission to a user interface for remote monitoring and control;
characterized in that the robot integrates an AI-based navigation system that autonomously guides the robot through HVAC ducts, adjusting cleaning mechanisms in real-time based on duct conditions, detected obstacles, and sensor feedback, thereby enabling precise navigation, efficient cleaning, and adaptability to various duct sizes and environments without manual intervention.
2. The A/C duct cleaning robot system as claimed in claim 1, wherein the primary rotating brush (1) is attached to the robot via hydraulic holders, allowing for adjustable positioning and variable speed rotation between 30 RPM and 610 RPM for effective cleaning of duct surfaces.
3. The A/C duct cleaning robot system as claimed in claim 1, wherein the umbrella brush (4) includes a shaft and runner mechanism with a spring mechanism for controlling the expansion and contraction of the brush to maintain consistent contact with duct walls of varying diameters.
4. The A/C duct cleaning robot system as claimed in claim 1, wherein the vacuum system (3) includes an efficient suction mechanism operatively coupled to the brushes, designed to capture loosened contaminants and transfer them to the storage compartment (5).
5. The A/C duct cleaning robot system as claimed in claim 1, wherein the motor driver (6) comprises an L298 motor driver IC and a 78M05 5V regulator, controlled via the NodeMCU for precise regulation of motor speed and torque in accordance with the specific cleaning tasks.
6. The A/C duct cleaning robot system as claimed in claim 1, wherein the NodeMCU is programmed using the Arduino IDE to provide custom firmware, facilitating the integration of various sensors, actuators, and navigation algorithms for autonomous operation.
7. The A/C duct cleaning robot system as claimed in claim 1, wherein the ESP32-CAM (7) provides real-time video streaming and still images to a user interface, allowing operators to monitor the robot's progress and assess duct conditions remotely.
8. The A/C duct cleaning robot system as claimed in claim 1, wherein the communication module allows for manual control via a handheld device, providing operators the ability to direct the robot to specific locations for targeted cleaning or troubleshooting.
9. The A/C duct cleaning robot system as claimed in claim 1, wherein the power source (8) comprises a rechargeable lithium-ion battery capable of sustaining prolonged operational periods, with an external power supply for recharging.
10. The A/C duct cleaning robot system as claimed in claim 1, wherein the AI-based navigation system utilizes a combination of path planning algorithms and sensor fusion techniques to dynamically adjust the robot's cleaning path and speed in response to changes in duct topology, detected obstacles, or variations in air quality parameters, ensuring optimal cleaning efficiency and safety during operation.

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