Appendix O: Roomba Engineering Changes - iRobot Roomba Scheduler Service Manual

Appendix O: Roomba Engineering Changes

Gearbox Housing
Serial Port
Housing
Side Brush
Vacuum Impeller
Flapper Rod
Vacuum Bin
Contacts
Wheel Encoder
Tab
Ziptie
IR Blocker
Bearing hole
Main brush motor
Rewiring
Brush Gearbox
Wheel Housing
bowed
Change outboard housing from POM to GF NYLON which has a
2004-11-07
higher melting temperature.
Bevel the metal housing to reduce shorting between the hot tab of
2004-11-15
the charging jack and the ground casing of the serial port.
2004-12-03 Change black bristles to white bristles which are transparent to IR
Better balance impeller by increasing gates in mold and thereby
2004-12-12
improve the flow of plastic.
To strengthen rod and reduce bouncing internal shaft changed to
2005-01-17
stronger steel.
Corrosion and pitting of the vacuum bin contacts due to
2005-01-22 contamination and vibration cause the contacts to fail. Change the
vacuum bin contacts to Nickel plated Beryllium.
Add a tab to the hub behind the encoder that seals area from external
2005-02-22
dirt.
Secure anti tassel halves of main brush with a ziptie. This stiffens
2005-04-11
main brush and reduces bouncing.
The plastic formulation of the bumper in 41xx is transparent to IR.
2005-04-11
Add black plastic part which is impermeable to IR.
Hair and dust builds up in the yellow bearing can lead to bearing
2005-04-28 pushing out and melting and even cracking cleaning frame. Extend
axial bore through bushing for hair extrusion.
2005-05-07 Change motor wire to one with higher temperature winding.
Use less hot glue and improve wire routing on bumper, chassis and
2005-05-09
cleaning frame
Reduce housing / output shaft clearance on main brush gear box by :
• Deepen hole in output gear to accommodate shaft an extra
2005-05-24 1.5 mm
• Lengthen pin in gearbox tat holds output gear
• Shorten Shaft
Bowed housings allow more clearance between the o-ring and
2005-05-29 cover. This prevents the o-ring from chaffing against the cover and
allowing the o-ring dust to contaminate the wheel encoder.
84