US20170000305A1 - Vacuum cleaner with brushroll control - Google Patents
Vacuum cleaner with brushroll control Download PDFInfo
- Publication number
- US20170000305A1 US20170000305A1 US15/196,412 US201615196412A US2017000305A1 US 20170000305 A1 US20170000305 A1 US 20170000305A1 US 201615196412 A US201615196412 A US 201615196412A US 2017000305 A1 US2017000305 A1 US 2017000305A1
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- United States
- Prior art keywords
- brushroll
- motor
- vacuum cleaner
- pressure
- sensed
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Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
- A47L9/2836—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means characterised by the parts which are controlled
- A47L9/2847—Surface treating elements
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L5/00—Structural features of suction cleaners
- A47L5/12—Structural features of suction cleaners with power-driven air-pumps or air-compressors, e.g. driven by motor vehicle engine vacuum
- A47L5/22—Structural features of suction cleaners with power-driven air-pumps or air-compressors, e.g. driven by motor vehicle engine vacuum with rotary fans
- A47L5/24—Hand-supported suction cleaners
- A47L5/26—Hand-supported suction cleaners with driven dust-loosening tools
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L5/00—Structural features of suction cleaners
- A47L5/12—Structural features of suction cleaners with power-driven air-pumps or air-compressors, e.g. driven by motor vehicle engine vacuum
- A47L5/22—Structural features of suction cleaners with power-driven air-pumps or air-compressors, e.g. driven by motor vehicle engine vacuum with rotary fans
- A47L5/28—Suction cleaners with handles and nozzles fixed on the casings, e.g. wheeled suction cleaners with steering handle
- A47L5/30—Suction cleaners with handles and nozzles fixed on the casings, e.g. wheeled suction cleaners with steering handle with driven dust-loosening tools, e.g. rotating brushes
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L5/00—Structural features of suction cleaners
- A47L5/12—Structural features of suction cleaners with power-driven air-pumps or air-compressors, e.g. driven by motor vehicle engine vacuum
- A47L5/22—Structural features of suction cleaners with power-driven air-pumps or air-compressors, e.g. driven by motor vehicle engine vacuum with rotary fans
- A47L5/36—Suction cleaners with hose between nozzle and casing; Suction cleaners for fixing on staircases; Suction cleaners for carrying on the back
- A47L5/362—Suction cleaners with hose between nozzle and casing; Suction cleaners for fixing on staircases; Suction cleaners for carrying on the back of the horizontal type, e.g. canister or sledge type
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/02—Nozzles
- A47L9/04—Nozzles with driven brushes or agitators
- A47L9/0405—Driving means for the brushes or agitators
- A47L9/0411—Driving means for the brushes or agitators driven by electric motor
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/02—Nozzles
- A47L9/04—Nozzles with driven brushes or agitators
- A47L9/0461—Dust-loosening tools, e.g. agitators, brushes
- A47L9/0466—Rotating tools
- A47L9/0477—Rolls
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/10—Filters; Dust separators; Dust removal; Automatic exchange of filters
- A47L9/16—Arrangement or disposition of cyclones or other devices with centrifugal action
- A47L9/1683—Dust collecting chambers; Dust collecting receptacles
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/24—Hoses or pipes; Hose or pipe couplings
- A47L9/248—Parts, details or accessories of hoses or pipes
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
- A47L9/2805—Parameters or conditions being sensed
- A47L9/2821—Pressure, vacuum level or airflow
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
- A47L9/2805—Parameters or conditions being sensed
- A47L9/2831—Motor parameters, e.g. motor load or speed
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L9/00—Details or accessories of suction cleaners, e.g. mechanical means for controlling the suction or for effecting pulsating action; Storing devices specially adapted to suction cleaners or parts thereof; Carrying-vehicles specially adapted for suction cleaners
- A47L9/28—Installation of the electric equipment, e.g. adaptation or attachment to the suction cleaner; Controlling suction cleaners by electric means
- A47L9/30—Arrangement of illuminating devices
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B40/00—Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
Definitions
- the present invention relates to vacuum cleaners, and more particularly to vacuum cleaners with a brushroll.
- the invention provides a vacuum cleaner including a base having a floor nozzle that defines a suction chamber, a brushroll driven by a brushroll motor, and a brushroll motor sensor configured to measure an electrical current used by the brushroll motor.
- the vacuum cleaner further includes a pressure sensor configured to measure an internal pressure within the vacuum cleaner, and a controller in communication with the brushroll motor sensor and the pressure sensor. The controller is operable to control an operating speed of the brushroll motor based on feedback received from the pressure sensor and the brushroll motor sensor.
- the invention provides a method of controlling a brushroll motor in a vacuum cleaner.
- the method includes sensing a pressure within the vacuum cleaner, sensing a motor current of the brushroll motor used to drive the brushroll, comparing the sensed pressure with one or more reference pressure values, comparing the motor current with one or more reference current values, and controlling operation of the brushroll motor based on the sensed pressure and motor current.
- Controlling operation of the brushroll motor includes turning the brushroll motor on based on the sensed pressure.
- the invention provides a method of controlling a brushroll motor in a vacuum cleaner.
- the method includes sensing an electrical current used by the brushroll motor to drive the brushroll at a first speed, sensing the speed of the brushroll motor or the brushroll, varying the electrical current to maintain the first speed of the brushroll, and determining a change in current drawn by the brushroll motor to maintain the first speed of the brushroll.
- the method also includes comparing the change in current to a threshold current change value, maintaining the first brushroll speed when the change in current is less than the threshold current change value, and maintaining a second brushroll speed different than the first brushroll speed when the change in current is greater than the threshold current change value.
- FIG. 1 is a perspective view of a vacuum cleaner according to an embodiment of the invention.
- FIG. 2 is a perspective view of a base of the vacuum cleaner of FIG. 1 , with a portion removed.
- FIG. 3 is a bottom view of the base of FIG. 2 .
- FIG. 4 is a top view of the base of FIG. 2 , with a portion removed.
- FIG. 5 is a perspective view of the base of FIG. 2 , with a portion removed.
- FIG. 6 is a perspective view of a portion of a pressure sensor used in the base of FIG. 2 .
- FIG. 7 is a perspective view of a portion of the pressure sensor used in the base of FIG. 2 .
- FIG. 8 is a perspective view of a portion of the pressure sensor used in the base of FIG. 2 .
- FIG. 9 is a cross-sectional view of a portion of the base of FIG. 2 .
- FIG. 10 is a graph illustrating suction and brushroll motor data for a vacuum cleaner passing from carpet to hard floor.
- FIG. 11 is a block diagram illustrating the interaction between various sensors, a controller, and brushroll elements.
- FIG. 12 is a perspective view of a pressure sensor according to another embodiment.
- FIG. 13 is a cross-sectional view of the pressure sensor of FIG. 12 .
- FIG. 14 is an exploded view of a portion of the pressure sensor of FIG. 12 .
- FIG. 15 is a graph illustrating pressure and voltage correlation data for the pressure sensor of FIG. 11 in a variety of operating conditions.
- FIG. 1 illustrates an exemplary vacuum cleaner 10 .
- the illustrated vacuum cleaner 10 is an upright vacuum cleaner and includes a base assembly 14 and a handle assembly 18 pivotally coupled to the base assembly 14 .
- other types and styles of vacuum cleaners can be utilized (e.g., canister, handheld, utility, etc.).
- the base assembly 14 is movable along a surface to be cleaned, such as a carpeted or hard-surface floor.
- the handle assembly 18 extends from the base assembly 14 and allows a user to move and manipulate the base assembly 14 along the surface.
- the handle assembly 18 is also movable relative to the base assembly 14 between an upright position ( FIG. 1 ) and an inclined position (not shown).
- the handle assembly 18 includes a maneuvering handle 22 having a grip 26 for a user to grasp and maneuver the vacuum cleaner 10 .
- the vacuum cleaner 10 also includes a detachable wand 30 .
- the wand 30 may be used to clean above-floor surfaces (e.g., stairs, drapes, corners, furniture, etc.).
- An accessory tool 34 e.g., a crevice tool, an upholstery tool, a pet tool, etc.
- a canister 38 is supported on the handle assembly 18 and includes a separator 42 and a dirt cup 46 .
- the separator 42 removes dirt particles from an airflow drawn into the vacuum cleaner 10 which are then collected by the dirt cup 46 .
- the separator 42 may be a cyclonic separator, filter bag, or other separator as desired.
- the canister 38 including the dirt cup 46 is removable from the handle assembly 18 to facilitate emptying the dirt particles from the dirt cup 46 .
- the vacuum cleaner 10 further includes a suction motor (not shown) contained within a motor housing 54 ( FIG. 1 ) and a suction source (not shown), such as an impeller fan assembly, driven by the suction motor.
- the suction motor selectively receives power from a power source (e.g., a cord for plugging into a source of utility power, a battery, etc.) to generate the suction airflow through the vacuum cleaner 10 .
- a power source e.g., a cord for plugging into a source of utility power, a battery, etc.
- the base assembly 14 includes a suction nozzle or floor nozzle 58 having a suction chamber 70 ( FIG. 3 ).
- the suction chamber 70 is formed between an upper portion 62 and a lower portion 66 of the floor nozzle 58 ( FIG. 2 ). Air and debris may be drawn into the suction chamber 70 through an elongate inlet opening 74 in the lower portion 66 ( FIG. 3 ).
- a plurality of cross bars 78 are positioned across the opening 74 inhibiting ingress of electrical cords and other objects into the opening 74 . In other embodiments, the cross bars 78 may be omitted. After entering the suction chamber 70 , air and debris pass through a nozzle outlet 82 that fluidly communicates with the separator 42 .
- the base assembly 14 includes a pair of rear wheels 86 and a pair of forward supporting elements or wheels 90 spaced from the rear wheels 86 and located generally adjacent the inlet opening 74 .
- the wheels 86 , 90 facilitate movement of the base assembly 14 along the surface to be cleaned.
- the forward wheels 90 may assist in positioning the inlet 74 of the floor nozzle 58 at a desired height above the surface to be cleaned.
- an agitator or brushroll 94 is rotatably supported at its ends within the nozzle suction chamber 70 .
- the brushroll 94 includes an array of bristle tufts 98 or other protrusions that may extend through the opening 74 to agitate the surface to be cleaned.
- the agitator 94 is rotatably driven by a drive belt 106 ( FIG. 4 ) that receives power from a brushroll motor 108 .
- the brushroll motor 108 drives the brushroll 94
- the suction motor drives the suction source.
- a single motor may be provided to drive the suction source and the brushroll 94 .
- the floor nozzle 58 also includes a pressure sensor 110 .
- the illustrated pressure sensor 110 is in communication with the suction chamber 70 ( FIG. 3 ) for determining a nozzle suction pressure within the floor nozzle 58 .
- the pressure sensor 110 can be used to determine a nozzle suction pressure in any other type of nozzle, such as an accessory wand or other above-floor cleaning attachment.
- the illustrated pressure sensor 110 is disposed proximate the suction chamber 70 ; however, in other embodiments, the pressure sensor 110 can be located remote from the suction chamber 70 . In such embodiments, the pressure sensor 110 can monitor the nozzle suction pressure via a tube or other suitable means having an end exposed to the suction chamber 70 .
- the illustrated pressure sensor 110 includes a pressure sensor housing 114 ( FIG. 5 ) defining a chamber that is at least partially enclosed by a pressure sensor cap portion 118 .
- the upper portion 62 of the floor nozzle 58 includes an aperture between the pressure sensor housing 114 and the suction chamber 70 forming a pressure sensor inlet 122 ( FIGS. 8 and 9 ) to allow for fluid communication between the pressure sensor 110 and the suction chamber 70 .
- the housing includes an internal wall 126 dividing the inner chamber of the pressure sensor 110 such that the inlet 122 is at least partially isolated from the remainder of the pressure sensor 110 .
- the internal wall 126 includes an aperture that allows for fluid communication between the inlet 122 and the remainder of the pressure sensor 110 while providing a barrier to inhibit the intake of dust particles and debris flowing through the suction chamber 70 .
- the aperture is a U-shaped opening in the internal wall 126 .
- the pressure sensor 110 also includes an inlet guard 130 positioned adjacent to the inlet 122 to further limit the intake of dust particles and debris into the pressure sensor 110 .
- the inlet guard 130 may attach to the inlet 122 .
- the inlet guard 130 may be shaped in various ways to provide desirable flow characteristics within the suction chamber 70 and/or the chamber of the pressure sensor 110 .
- the illustrated inlet guard 130 provides a sloped surface 134 such that the area of the inlet 122 decreases in a direction toward the interior of the pressure sensor 110 , allowing fewer particles to enter the pressure sensor chamber.
- the pressure sensor housing 114 may be integrally formed in the floor nozzle 58 .
- the pressure sensor housing 114 may be integrally formed in the upper portion 62 .
- the pressure sensor housing 114 may be a separate component assembled to the vacuum cleaner 10 .
- the air inlet 122 of the pressure sensor 110 may be configured as a fitting, optionally with a barb feature at an end of the fitting, or a threaded fitting, or compression fitting, or other fitting, to be in fluid communication with the suction chamber 70 using a duct or a tube connected to the fitting.
- the illustrated pressure sensor 110 also includes a piston block 138 holding a magnet 142 that is movable with respect to a hall-effect sensor 150 .
- the hall-effect sensor 150 is mounted to a circuit board 146 .
- the piston block 138 is forced toward the hall-effect sensor 150 by a spring (not shown), which may be positioned between the internal wall 126 and the piston block 138 , while negative pressure within the suction chamber 70 generated by the suction source pulls on the piston block 138 , tending to overcome the force of the spring and move the piston block 138 and magnet 142 away from the sensor 150 .
- the relative distance of the piston block 138 from the hall-effect sensor 150 can be correlated to the suction pressure within the chamber 70 .
- the higher the suction (i.e., the lower the pressure) within the suction chamber 70 the further the piston block 138 moves away from the sensor 150 against the force of the spring, and vice versa.
- the hall-effect sensor 150 and magnet 142 are used to determine the relative distance between the piston block 138 and the sensor 150 to compute a sensed pressure. It should be understood that in other embodiments, other types of pressure sensors may be used, such as optical, piezoresistive, and the like.
- the vacuum cleaner 10 further includes a brushroll motor sensor 133 and a controller 116 in communication with the sensors 110 , 133 .
- the brushroll motor sensor 133 can be configured to sense a torque output or current draw of the brushroll motor 108 .
- the controller 116 can receive and analyze data from the pressure sensor 110 and the brushroll motor sensor 133 and use some or all of that data as feedback to control the rotational speed of the brushroll motor 108 .
- the suction motor drives the fan assembly or suction source to generate airflow through the vacuum cleaner 10 .
- the airflow enters the floor nozzle 58 through the inlet opening 74 and flows into the suction chamber 70 ( FIG. 3 ).
- the airflow and any debris entrained therein then travel through the nozzle outlet 82 and into the separator 42 .
- the separator 42 filters or otherwise cleans the airflow
- the cleaned airflow is directed out of the canister 38 and into the motor housing 54 , (e.g., through an airflow channel extending through the handle assembly 18 ) ( FIG. 1 ).
- the cleaned airflow is ultimately exhausted back into the environment through air outlet openings.
- the controller 116 receives the data from the sensors 110 , 133 and compares the sensed pressure from the pressure sensor 110 and the sensed current and/or torque values from the brushroll motor sensor 133 with one or more corresponding predetermined thresholds.
- the predetermined thresholds i.e., pressure, torque, and/or current
- the controller 116 determines the floor surface by comparing the sensed pressure and the sensed motor current and/or torque values with the predetermined thresholds, and automatically operates the brushroll motor 108 , and optionally the suction motor, in a manner optimized for the type of floor surface.
- high-pile carpet will generally cause high suction (i.e., low pressure) within the suction chamber 70 and force the brushroll motor 108 to work harder (i.e., generate higher torque and draw more current), while a hard floor surface will lead to lower suction (i.e., higher pressure that is closer to atmospheric pressure) within the suction chamber 70 and will allow the brushroll motor 108 to work more easily (i.e., generate lower torque and draw less current).
- high suction i.e., low pressure
- a hard floor surface will lead to lower suction (i.e., higher pressure that is closer to atmospheric pressure) within the suction chamber 70 and will allow the brushroll motor 108 to work more easily (i.e., generate lower torque and draw less current).
- FIG. 10 illustrates exemplary suction and brushroll motor data for a vacuum cleaner passing from carpet to hard floor.
- the controller 116 operates the brushroll motor 108 in a desired state to drive the brushroll motor 108 at a desired speed.
- the controller 116 may operate the brushroll motor 108 at a slow rotational speed when the floor nozzle 58 is located on a hard floor surface to reduce scattering of debris and reduce energy consumed by the brushroll motor 108 .
- the controller 116 may operate the brushroll motor 108 at a high rotational speed while the floor nozzle 58 is on carpet to better agitate dust particles out of the carpet fibers.
- the controller 116 may shut off the brushroll motor 108 when the floor nozzle 58 is located on certain surfaces (e.g., hard floor), to conserve energy, reduce scattering of debris, and/or reduce wear on delicate surfaces.
- the controller 116 may also or alternatively operate the suction motor based on floor type. For example, the controller 116 may operate the suction motor at a lower power on a hard floor surface to conserve energy or a higher power on a hard floor surface to increase debris pick-up. In some embodiments, the suction motor may be operated at a lower power on certain height carpets to reduce the clamp-down of the nozzle 58 to the carpet so that the vacuum cleaner 10 is easier to push.
- the controller 116 determines when the vacuum 10 passes from one surface type to another surface type and alters the brushroll speed, and optionally suction, to provide a pre-programmed vacuum cleaner operation in response to the different conditions created by different floor types. Either or both of the pressure sensor 110 and the brushroll motor sensor 133 may be continually used to alter the rotational speed of the brushroll motor 108 in response to the sensed data. If the brushroll motor 108 is off, however, only the pressure sensor 110 is used to determine a change in floor type.
- a switch 112 may be provided to allow a user to selectively switch between different modes of operation, such as to put the vacuum cleaner 10 in a “speed control mode.” in which the controller 116 changes the rotational speed of the brushroll motor 108 (and the brushroll 94 ) in response to the sensed data, or in an “on/off mode”, in which controller 116 turns the brushroll motor 108 on or off in response to the sensed data.
- a switch may be positioned for easy access by a user for changing the operational mode of the vacuum cleaner 10 .
- either the speed control mode or the on/off mode may be preferred by the manufacturer, and the switch 112 may be positioned in a less accessible location to a user, such as behind a cover so that the switch 112 may be accessible to a user only if the cover or other portion of the floor nozzle 58 is removed.
- the switch 112 is provided on the circuit board 146 .
- the pressure sensor 110 and the brushroll motor sensor 133 continuously or intermittently provide sensed data representative of the suction pressure and the motor current and/or torque, as described above.
- the controller 116 operates the brushroll motor 108 at a first rotational speed, for example, between about 1000 and 5000 revolutions per minute (RPM), or between about 2000 and 4000 RPM.
- the controller 116 operates the brushroll motor 108 at a second rotational speed that is lower than the first rotational speed, for example, between about 100 and 1000 RPM, or between about 300 and 600 RPM.
- the pressure sensor 110 and the brushroll motor sensor 133 may be continually or intermittently used to alter the rotational speed of the brushroll motor 108 in response to the sensed data.
- either the pressure sensor 110 or the brushroll motor sensor 133 may be omitted so that only the other of the pressure sensor 110 or the brushroll motor sensor 133 provides feedback used to alter the rotational speed of the brushroll motor 108 .
- the pressure sensor 110 While the vacuum cleaner 10 is in the “on/off mode,” the pressure sensor 110 continually monitors the nozzle suction pressure; however, the brushroll motor sensor 133 may monitor the motor current and/or torque when the brushroll motor 108 is on. When the brushroll motor 108 is off, the motor current and/or torque will not provide data useful in determining the type of floor surface the floor nozzle 58 is on.
- the controller 116 operates the brushroll motor 108 (and the brushroll 94 ) at a first rotational speed.
- the controller 116 turns the brushroll motor 108 off. While the floor nozzle 58 is operating on the hard floor surface and the brushroll motor 108 is off, the controller 116 relies on the pressure sensor 110 alone to determine whether to turn the brushroll motor 108 on. The controller 116 may use either or both of the sensors 110 , 133 , to determine whether to turn the brushroll motor 108 off.
- the vacuum cleaner 10 further includes a tachometer 155 that measures a rotational speed of the brushroll motor 108 or the brushroll 94 during operation ( FIG. 11 ).
- the tachometer 155 can include one or more hall-effect sensors, optical encoders, or any other type of sensor suitable for measuring rotational speed.
- the sensed brushroll speed data from the tachometer 155 can be used by the controller 116 in conjunction with data from the brushroll motor sensor 133 to maintain a relatively constant rotational speed of the brushroll 94 .
- the controller 116 may increase the current supplied to the brushroll motor 108 to increase the torque output by the brushroll motor 108 .
- the controller 116 may decrease the current supplied to the brushroll motor 108 to decrease the torque output by the brushroll motor 108 .
- the controller 116 compares the amount of current increase or decrease needed to maintain the speed of the brushroll 94 and compares the amount to a threshold current change value. If the current increase or decrease exceeds the threshold current value, then the controller 116 operates the brushroll 94 at a second speed instead of the first speed.
- the controller 116 uses the amount of current change needed to maintain a constant brushroll speed, as well as whether the current change is an increase or decrease to determine the kind of floor type the vacuum cleaner 10 is operating on, and the controller 116 adjusts the current supplied to the brushroll motor 108 to maintain the speed of the brushroll 94 at a speed desired for the particular floor type. In this way, the controller 116 determines the type of floor surface using the change in brushroll motor current needed to maintain a speed compared to predetermined thresholds and automatically operates the brushroll motor 108 , and optionally the suction motor, in a manner corresponding to the type of floor surface. In some cases, the controller 116 may turn off the brushroll motor 108 if the current exceeds the threshold current value.
- the controller 116 may include overload protection programming.
- FIGS. 12-14 illustrate a pressure sensor 110 ′ according to another embodiment that can be used in conjunction with the vacuum cleaner 10 (e.g., instead of the pressure sensor 110 or in addition to the pressure sensor 110 ).
- the pressure sensor 110 ′ includes a base portion 120 ′ and a cap portion 118 ′ that cooperate to define a pressure sensor housing 114 ′.
- the base portion 120 ′ is integrally formed with a wall bounding the airflow path of the vacuum cleaner 10 .
- the housing 114 ′ contains a diaphragm 123 ′ holding a magnet 142 ′ that is movable with respect to the housing 114 ′ when the diaphragm 123 ′ flexes ( FIG. 13 ).
- the diaphragm 123 ′ is sandwiched between the base portion 120 ′ and the cap portion 118 ′ such that the diaphragm 123 ′ creates a substantially airtight seal between the base portion 120 ′ and the cap portion 118 ′. Accordingly, the diaphragm 123 ′ is subject to pressure forces resulting from any pressure imbalance between air contained within the base portion 120 ′ and air contained within the cap portion 118 ′.
- the air inlet of the pressure sensor 110 ′ is configured as a fitting 125 ′, such as a hose barb or nipple, a threaded fitting, compression fitting, or other fitting.
- the fitting 125 ′ extends from the base portion 120 ′.
- the fitting 125 ′ can be integrally formed with the base portion 120 ′ as a single piece, or alternatively, the fitting 125 ′ can be formed separately and attached to the base portion 120 ′ by threads or another type of suitable airtight connection.
- the fitting 125 ′ i.e. the air inlet for the pressure sensor 110 ′
- the fitting 125 ′ receives one end of a tube (not shown) that extends to the suction chamber 70 (e.g., to the pressure sensor inlet 122 ( FIGS. 8 and 9 ) on the upper portion 62 of the floor nozzle 58 ) to allow for fluid communication between the pressure sensor 110 ′ and the suction chamber 70 .
- the pressure sensor 110 ′ can be directly connected to the suction chamber 70 .
- a hall-effect sensor 150 ′ is located on the cap portion 118 ′ ( FIG. 13 ).
- the hall-effect sensor 150 ′ may be incorporated onto a circuit board 146 ′.
- all or a portion of the hall-effect sensor may be positioned on or adjacent the cap portion 118 ′ and electrically connected to a circuit board positioned in a separate location.
- the cap portion 118 ′ may include attachments for securing the circuit board 146 ′ or the hall-effect sensor 150 ′ to the cap portion 118 ′.
- the hall-effect sensor 150 ′ can be located on the base portion 120 ′.
- the diaphragm 123 ′ is a first diaphragm 123 ′ that is interchangeable with a second diaphragm (not shown) having different deflection characteristics under pressure.
- the first and second diaphragms can be interchanged in order to vary the responsiveness or operating pressure range of the pressure sensor 110 ′.
- the first diaphragm 123 ′ has a first attribute selected from a group consisting of thickness, durometer, shape, and material, and where the first diaphragm is replaceable with a second diaphragm having a second attribute selected from a group consisting of thickness, durometer, shape, and material.
- the first diaphragm 123 ′ may be made from a polyurethane material and the second diaphragm may be made from butyl rubber providing different response characteristics.
- the first diaphragm 123 ′ may have a flat shape or uniform thickness and the second diaphragm may have a concave shape that is thicker near its perimeter, or alternatively thinner near its perimeter, providing different response characteristics, or in yet another alternative, the second diaphragm may have a shape having ribs, apertures, protrusions, grooves, or other shapes.
- first diaphragm 123 ′ may have a durometer of 25 Shore A and the second diaphragm may have a durometer of 40 Shore A, providing different response characteristics.
- the second diaphragm may be thinner than the first diaphragm 123 ′ and therefore experience greater deflection than the first diaphragm 123 ′ at a particular pressure difference between the base portion 120 ′ and the cap portion 118 ′.
- the diaphragm 123 ′ may be made from materials such as butyl rubber, polyurethane, silicone rubber, and other synthetic rubbers, thermoplastic elastomer (TPE), rubber, thermoplastic vulcanizates (TPV), thermoplastics, and other materials to provide response characteristics under pressure as desired for the application.
- TPE thermoplastic elastomer
- TPV thermoplastic vulcanizates
- the diaphragm 123 ′ may have a durometer between about 15 and 80 Shore A, or for particular embodiments between about 20 and 40 Shore A, or other hardnesses as desired to provide response characteristics under pressure as desired for the application.
- the diaphragm 123 ′ is a thermoplastic elastomer having a durometer between 20 and 30 Shore A.
- the pressure sensor 110 , 110 ′ positioned in the air flow path of the vacuum cleaner 10 can be used indicate more than one system condition, as shown in FIG. 15 .
- a filter e.g., a pre-motor filter or a post-motor filter in some embodiments
- the controller 116 may illuminate a signal to the user indicating that the filter is missing, and/or may turn off the suction motor to prevent damage to the vacuum cleaner 10 .
- the pressure reading at the sensor 110 , 110 ′ decreases as the dirt cup 46 fills, and when the pressure reaches a predetermined value, the controller 116 may illuminate a signal to the user indicating that the dirt cup 46 is full, and/or may turn off the suction motor.
- the controller 116 may provide a signal, such as a light or other display, to the user to indicate that the vacuum 10 is operating normally.
- the vacuum cleaner 10 may pick up a large object or enough debris to form a blockage in the air path, or a filter or filter bag in the vacuum may become clogged (i.e. may contain enough debris that vacuum cleaner performance is reduced).
- a clog occurs, the system pressure, as measured by the sensor 110 , 110 ′, drops.
- the controller 116 may provide a signal such as a light or other display to the user indicating that a clog has developed, and/or may turn off the suction motor.
- one pressure sensor 110 , 110 ′ may be positioned in fluid communication with the air path of the vacuum cleaner 10 to provide system information for a variety of operating conditions.
- one pressure sensor 110 , 110 ′ may be positioned in fluid communication with the air path of the vacuum cleaner 10 to provide two or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation.
- one pressure sensor 110 , 110 ′ may be positioned in fluid communication with the air path of the vacuum cleaner 10 to provide three or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation.
- one pressure sensor 110 , 110 ′ may be positioned in fluid communication with the air path of the vacuum cleaner 10 to provide four or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation.
- the controller 116 continuously or periodically monitors the pressure sensor and provides a signal such as a light or other display to the user indicating a system condition, and/or may turn off the suction motor.
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- Engineering & Computer Science (AREA)
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- Electric Vacuum Cleaner (AREA)
- Nozzles For Electric Vacuum Cleaners (AREA)
Abstract
Description
- This application claims priority to U.S. Provisional Patent Application No. 62/186,998, filed Jun. 30, 2015 and claims priority to U.S. Provisional Patent Application No. 62/187,001, filed Jun. 30, 2015, the entire contents all of which are hereby incorporated by reference herein.
- The present invention relates to vacuum cleaners, and more particularly to vacuum cleaners with a brushroll.
- In one aspect, the invention provides a vacuum cleaner including a base having a floor nozzle that defines a suction chamber, a brushroll driven by a brushroll motor, and a brushroll motor sensor configured to measure an electrical current used by the brushroll motor. The vacuum cleaner further includes a pressure sensor configured to measure an internal pressure within the vacuum cleaner, and a controller in communication with the brushroll motor sensor and the pressure sensor. The controller is operable to control an operating speed of the brushroll motor based on feedback received from the pressure sensor and the brushroll motor sensor.
- In another aspect, the invention provides a method of controlling a brushroll motor in a vacuum cleaner. The method includes sensing a pressure within the vacuum cleaner, sensing a motor current of the brushroll motor used to drive the brushroll, comparing the sensed pressure with one or more reference pressure values, comparing the motor current with one or more reference current values, and controlling operation of the brushroll motor based on the sensed pressure and motor current. Controlling operation of the brushroll motor includes turning the brushroll motor on based on the sensed pressure.
- In another aspect, the invention provides a method of controlling a brushroll motor in a vacuum cleaner. The method includes sensing an electrical current used by the brushroll motor to drive the brushroll at a first speed, sensing the speed of the brushroll motor or the brushroll, varying the electrical current to maintain the first speed of the brushroll, and determining a change in current drawn by the brushroll motor to maintain the first speed of the brushroll. The method also includes comparing the change in current to a threshold current change value, maintaining the first brushroll speed when the change in current is less than the threshold current change value, and maintaining a second brushroll speed different than the first brushroll speed when the change in current is greater than the threshold current change value.
- Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
-
FIG. 1 is a perspective view of a vacuum cleaner according to an embodiment of the invention. -
FIG. 2 is a perspective view of a base of the vacuum cleaner ofFIG. 1 , with a portion removed. -
FIG. 3 is a bottom view of the base ofFIG. 2 . -
FIG. 4 is a top view of the base ofFIG. 2 , with a portion removed. -
FIG. 5 is a perspective view of the base ofFIG. 2 , with a portion removed. -
FIG. 6 is a perspective view of a portion of a pressure sensor used in the base ofFIG. 2 . -
FIG. 7 is a perspective view of a portion of the pressure sensor used in the base ofFIG. 2 . -
FIG. 8 is a perspective view of a portion of the pressure sensor used in the base ofFIG. 2 . -
FIG. 9 is a cross-sectional view of a portion of the base ofFIG. 2 . -
FIG. 10 is a graph illustrating suction and brushroll motor data for a vacuum cleaner passing from carpet to hard floor. -
FIG. 11 is a block diagram illustrating the interaction between various sensors, a controller, and brushroll elements. -
FIG. 12 is a perspective view of a pressure sensor according to another embodiment. -
FIG. 13 is a cross-sectional view of the pressure sensor ofFIG. 12 . -
FIG. 14 is an exploded view of a portion of the pressure sensor ofFIG. 12 . -
FIG. 15 is a graph illustrating pressure and voltage correlation data for the pressure sensor ofFIG. 11 in a variety of operating conditions. - Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
-
FIG. 1 illustrates anexemplary vacuum cleaner 10. The illustratedvacuum cleaner 10 is an upright vacuum cleaner and includes abase assembly 14 and ahandle assembly 18 pivotally coupled to thebase assembly 14. In other embodiments, other types and styles of vacuum cleaners can be utilized (e.g., canister, handheld, utility, etc.). - In the illustrated embodiment of the
vacuum cleaner 10, thebase assembly 14 is movable along a surface to be cleaned, such as a carpeted or hard-surface floor. Thehandle assembly 18 extends from thebase assembly 14 and allows a user to move and manipulate thebase assembly 14 along the surface. Thehandle assembly 18 is also movable relative to thebase assembly 14 between an upright position (FIG. 1 ) and an inclined position (not shown). - The
handle assembly 18 includes amaneuvering handle 22 having agrip 26 for a user to grasp and maneuver thevacuum cleaner 10. In the illustrated embodiment, thevacuum cleaner 10 also includes adetachable wand 30. Thewand 30 may be used to clean above-floor surfaces (e.g., stairs, drapes, corners, furniture, etc.). An accessory tool 34 (e.g., a crevice tool, an upholstery tool, a pet tool, etc.) is detachably coupled to thehandle assembly 18 for storage and may be used with thewand 30 for specialized cleaning. - With continued reference to
FIG. 1 , acanister 38 is supported on thehandle assembly 18 and includes aseparator 42 and adirt cup 46. Theseparator 42 removes dirt particles from an airflow drawn into thevacuum cleaner 10 which are then collected by thedirt cup 46. Theseparator 42 may be a cyclonic separator, filter bag, or other separator as desired. In the illustrated embodiment, thecanister 38 including thedirt cup 46 is removable from thehandle assembly 18 to facilitate emptying the dirt particles from thedirt cup 46. - The
vacuum cleaner 10 further includes a suction motor (not shown) contained within a motor housing 54 (FIG. 1 ) and a suction source (not shown), such as an impeller fan assembly, driven by the suction motor. The suction motor selectively receives power from a power source (e.g., a cord for plugging into a source of utility power, a battery, etc.) to generate the suction airflow through thevacuum cleaner 10. - Now referring to
FIGS. 2-4 , thebase assembly 14 includes a suction nozzle orfloor nozzle 58 having a suction chamber 70 (FIG. 3 ). In the illustrated embodiment, thesuction chamber 70 is formed between anupper portion 62 and alower portion 66 of the floor nozzle 58 (FIG. 2 ). Air and debris may be drawn into thesuction chamber 70 through an elongate inlet opening 74 in the lower portion 66 (FIG. 3 ). In the illustrated embodiment, a plurality ofcross bars 78 are positioned across the opening 74 inhibiting ingress of electrical cords and other objects into theopening 74. In other embodiments, thecross bars 78 may be omitted. After entering thesuction chamber 70, air and debris pass through anozzle outlet 82 that fluidly communicates with theseparator 42. - Optionally, the
base assembly 14 includes a pair ofrear wheels 86 and a pair of forward supporting elements orwheels 90 spaced from therear wheels 86 and located generally adjacent theinlet opening 74. Thewheels base assembly 14 along the surface to be cleaned. In addition, theforward wheels 90 may assist in positioning theinlet 74 of thefloor nozzle 58 at a desired height above the surface to be cleaned. - With reference to
FIG. 3 , an agitator orbrushroll 94 is rotatably supported at its ends within thenozzle suction chamber 70. Thebrushroll 94 includes an array ofbristle tufts 98 or other protrusions that may extend through theopening 74 to agitate the surface to be cleaned. Theagitator 94 is rotatably driven by a drive belt 106 (FIG. 4 ) that receives power from abrushroll motor 108. In the illustrated embodiment, thebrushroll motor 108 drives thebrushroll 94, while the suction motor drives the suction source. In other embodiments, a single motor may be provided to drive the suction source and thebrushroll 94. - With reference to
FIG. 4 , thefloor nozzle 58 also includes apressure sensor 110. The illustratedpressure sensor 110 is in communication with the suction chamber 70 (FIG. 3 ) for determining a nozzle suction pressure within thefloor nozzle 58. Alternatively, thepressure sensor 110 can be used to determine a nozzle suction pressure in any other type of nozzle, such as an accessory wand or other above-floor cleaning attachment. The illustratedpressure sensor 110 is disposed proximate thesuction chamber 70; however, in other embodiments, thepressure sensor 110 can be located remote from thesuction chamber 70. In such embodiments, thepressure sensor 110 can monitor the nozzle suction pressure via a tube or other suitable means having an end exposed to thesuction chamber 70. - The illustrated
pressure sensor 110 includes a pressure sensor housing 114 (FIG. 5 ) defining a chamber that is at least partially enclosed by a pressuresensor cap portion 118. Theupper portion 62 of thefloor nozzle 58 includes an aperture between thepressure sensor housing 114 and thesuction chamber 70 forming a pressure sensor inlet 122 (FIGS. 8 and 9 ) to allow for fluid communication between thepressure sensor 110 and thesuction chamber 70. With reference toFIG. 5 , the housing includes aninternal wall 126 dividing the inner chamber of thepressure sensor 110 such that theinlet 122 is at least partially isolated from the remainder of thepressure sensor 110. Theinternal wall 126 includes an aperture that allows for fluid communication between theinlet 122 and the remainder of thepressure sensor 110 while providing a barrier to inhibit the intake of dust particles and debris flowing through thesuction chamber 70. In the illustrated embodiment, the aperture is a U-shaped opening in theinternal wall 126. - Referring to
FIGS. 8 and 9 , thepressure sensor 110 also includes aninlet guard 130 positioned adjacent to theinlet 122 to further limit the intake of dust particles and debris into thepressure sensor 110. Theinlet guard 130 may attach to theinlet 122. Further, theinlet guard 130 may be shaped in various ways to provide desirable flow characteristics within thesuction chamber 70 and/or the chamber of thepressure sensor 110. For example, the illustratedinlet guard 130 provides asloped surface 134 such that the area of theinlet 122 decreases in a direction toward the interior of thepressure sensor 110, allowing fewer particles to enter the pressure sensor chamber. - The
pressure sensor housing 114 may be integrally formed in thefloor nozzle 58. Thepressure sensor housing 114 may be integrally formed in theupper portion 62. Alternatively, thepressure sensor housing 114 may be a separate component assembled to thevacuum cleaner 10. Alternatively or additionally, theair inlet 122 of thepressure sensor 110 may be configured as a fitting, optionally with a barb feature at an end of the fitting, or a threaded fitting, or compression fitting, or other fitting, to be in fluid communication with thesuction chamber 70 using a duct or a tube connected to the fitting. - With reference to
FIGS. 6 and 7 , the illustratedpressure sensor 110 also includes apiston block 138 holding amagnet 142 that is movable with respect to a hall-effect sensor 150. In the illustrated embodiment, the hall-effect sensor 150 is mounted to acircuit board 146. Thepiston block 138 is forced toward the hall-effect sensor 150 by a spring (not shown), which may be positioned between theinternal wall 126 and thepiston block 138, while negative pressure within thesuction chamber 70 generated by the suction source pulls on thepiston block 138, tending to overcome the force of the spring and move thepiston block 138 andmagnet 142 away from thesensor 150. Therefore, the relative distance of the piston block 138 from the hall-effect sensor 150 can be correlated to the suction pressure within thechamber 70. Specifically, the higher the suction (i.e., the lower the pressure) within thesuction chamber 70, the further thepiston block 138 moves away from thesensor 150 against the force of the spring, and vice versa. The hall-effect sensor 150 andmagnet 142 are used to determine the relative distance between thepiston block 138 and thesensor 150 to compute a sensed pressure. It should be understood that in other embodiments, other types of pressure sensors may be used, such as optical, piezoresistive, and the like. - With reference to
FIG. 11 , thevacuum cleaner 10 further includes abrushroll motor sensor 133 and acontroller 116 in communication with thesensors brushroll motor sensor 133 can be configured to sense a torque output or current draw of thebrushroll motor 108. Thecontroller 116 can receive and analyze data from thepressure sensor 110 and thebrushroll motor sensor 133 and use some or all of that data as feedback to control the rotational speed of thebrushroll motor 108. - In general operation, the suction motor drives the fan assembly or suction source to generate airflow through the
vacuum cleaner 10. The airflow enters thefloor nozzle 58 through theinlet opening 74 and flows into the suction chamber 70 (FIG. 3 ). The airflow and any debris entrained therein then travel through thenozzle outlet 82 and into theseparator 42. After theseparator 42 filters or otherwise cleans the airflow, the cleaned airflow is directed out of thecanister 38 and into themotor housing 54, (e.g., through an airflow channel extending through the handle assembly 18) (FIG. 1 ). The cleaned airflow is ultimately exhausted back into the environment through air outlet openings. - With reference to
FIG. 11 , during operation, thecontroller 116 receives the data from thesensors pressure sensor 110 and the sensed current and/or torque values from thebrushroll motor sensor 133 with one or more corresponding predetermined thresholds. The predetermined thresholds (i.e., pressure, torque, and/or current) are associated with different floor types to represent a distinction between floor surfaces (e.g., carpet and hard floor). Thecontroller 116 determines the floor surface by comparing the sensed pressure and the sensed motor current and/or torque values with the predetermined thresholds, and automatically operates thebrushroll motor 108, and optionally the suction motor, in a manner optimized for the type of floor surface. For example, high-pile carpet will generally cause high suction (i.e., low pressure) within thesuction chamber 70 and force thebrushroll motor 108 to work harder (i.e., generate higher torque and draw more current), while a hard floor surface will lead to lower suction (i.e., higher pressure that is closer to atmospheric pressure) within thesuction chamber 70 and will allow thebrushroll motor 108 to work more easily (i.e., generate lower torque and draw less current). -
FIG. 10 illustrates exemplary suction and brushroll motor data for a vacuum cleaner passing from carpet to hard floor. Depending on the comparison of the sensed pressure, torque, and/or current with their corresponding threshold values, thecontroller 116 operates thebrushroll motor 108 in a desired state to drive thebrushroll motor 108 at a desired speed. For example, thecontroller 116 may operate thebrushroll motor 108 at a slow rotational speed when thefloor nozzle 58 is located on a hard floor surface to reduce scattering of debris and reduce energy consumed by thebrushroll motor 108. Further, thecontroller 116 may operate thebrushroll motor 108 at a high rotational speed while thefloor nozzle 58 is on carpet to better agitate dust particles out of the carpet fibers. Alternatively, thecontroller 116 may shut off thebrushroll motor 108 when thefloor nozzle 58 is located on certain surfaces (e.g., hard floor), to conserve energy, reduce scattering of debris, and/or reduce wear on delicate surfaces. - The
controller 116 may also or alternatively operate the suction motor based on floor type. For example, thecontroller 116 may operate the suction motor at a lower power on a hard floor surface to conserve energy or a higher power on a hard floor surface to increase debris pick-up. In some embodiments, the suction motor may be operated at a lower power on certain height carpets to reduce the clamp-down of thenozzle 58 to the carpet so that thevacuum cleaner 10 is easier to push. - By continuously or intermittently monitoring pressure and motor current and/or torque using data from the
sensors controller 116 determines when thevacuum 10 passes from one surface type to another surface type and alters the brushroll speed, and optionally suction, to provide a pre-programmed vacuum cleaner operation in response to the different conditions created by different floor types. Either or both of thepressure sensor 110 and thebrushroll motor sensor 133 may be continually used to alter the rotational speed of thebrushroll motor 108 in response to the sensed data. If thebrushroll motor 108 is off, however, only thepressure sensor 110 is used to determine a change in floor type. - Referring to
FIG. 11 , aswitch 112 may be provided to allow a user to selectively switch between different modes of operation, such as to put thevacuum cleaner 10 in a “speed control mode.” in which thecontroller 116 changes the rotational speed of the brushroll motor 108 (and the brushroll 94) in response to the sensed data, or in an “on/off mode”, in whichcontroller 116 turns thebrushroll motor 108 on or off in response to the sensed data. Such a switch may be positioned for easy access by a user for changing the operational mode of thevacuum cleaner 10. In certain applications, either the speed control mode or the on/off mode may be preferred by the manufacturer, and theswitch 112 may be positioned in a less accessible location to a user, such as behind a cover so that theswitch 112 may be accessible to a user only if the cover or other portion of thefloor nozzle 58 is removed. In some embodiments, theswitch 112 is provided on thecircuit board 146. - While the
vacuum cleaner 10 is operated in the “speed control mode,” thepressure sensor 110 and thebrushroll motor sensor 133 continuously or intermittently provide sensed data representative of the suction pressure and the motor current and/or torque, as described above. When the sensed data of thepressure sensor 110 and thebrushroll motor sensor 133 correspond to the values associated with thevacuum cleaner 10 operating on a carpet surface, or the like, thecontroller 116 operates thebrushroll motor 108 at a first rotational speed, for example, between about 1000 and 5000 revolutions per minute (RPM), or between about 2000 and 4000 RPM. When the sensed data of thepressure sensor 110 and thebrushroll motor sensor 133 correspond to the values associated with thevacuum cleaner 10 operating on a hard floor surface, or the like, thecontroller 116 operates thebrushroll motor 108 at a second rotational speed that is lower than the first rotational speed, for example, between about 100 and 1000 RPM, or between about 300 and 600 RPM. Either or both of thepressure sensor 110 and thebrushroll motor sensor 133 may be continually or intermittently used to alter the rotational speed of thebrushroll motor 108 in response to the sensed data. In alternative embodiments, either thepressure sensor 110 or thebrushroll motor sensor 133 may be omitted so that only the other of thepressure sensor 110 or thebrushroll motor sensor 133 provides feedback used to alter the rotational speed of thebrushroll motor 108. - While the
vacuum cleaner 10 is in the “on/off mode,” thepressure sensor 110 continually monitors the nozzle suction pressure; however, thebrushroll motor sensor 133 may monitor the motor current and/or torque when thebrushroll motor 108 is on. When thebrushroll motor 108 is off, the motor current and/or torque will not provide data useful in determining the type of floor surface thefloor nozzle 58 is on. When the sensed data of thepressure sensor 110 and thebrushroll motor sensor 133 correspond to the values associated with thevacuum cleaner 10 operating on a carpet surface, thecontroller 116 operates the brushroll motor 108 (and the brushroll 94) at a first rotational speed. When the sensed data of thepressure sensor 110 and thebrushroll motor sensor 133 correspond to the values associated with thevacuum cleaner 10 operating on a hard floor surface, or the like, thecontroller 116 turns thebrushroll motor 108 off. While thefloor nozzle 58 is operating on the hard floor surface and thebrushroll motor 108 is off, thecontroller 116 relies on thepressure sensor 110 alone to determine whether to turn thebrushroll motor 108 on. Thecontroller 116 may use either or both of thesensors brushroll motor 108 off. - In some embodiments, the
vacuum cleaner 10 further includes atachometer 155 that measures a rotational speed of thebrushroll motor 108 or thebrushroll 94 during operation (FIG. 11 ). Thetachometer 155 can include one or more hall-effect sensors, optical encoders, or any other type of sensor suitable for measuring rotational speed. - The sensed brushroll speed data from the
tachometer 155 can be used by thecontroller 116 in conjunction with data from thebrushroll motor sensor 133 to maintain a relatively constant rotational speed of thebrushroll 94. For example, when thebrushroll 94 encounters increased resistance, such as when transitioning from a hard floor surface to a carpeted floor surface, thecontroller 116 may increase the current supplied to thebrushroll motor 108 to increase the torque output by thebrushroll motor 108. When the brushroll 94 encounters decreased resistance, such as when transitioning from a carpeted floor surface to a hard floor surface, thecontroller 116 may decrease the current supplied to thebrushroll motor 108 to decrease the torque output by thebrushroll motor 108. In such embodiments, thecontroller 116 compares the amount of current increase or decrease needed to maintain the speed of thebrushroll 94 and compares the amount to a threshold current change value. If the current increase or decrease exceeds the threshold current value, then thecontroller 116 operates thebrushroll 94 at a second speed instead of the first speed. - As the
vacuum cleaner 10 passes from one surface type to another, thecontroller 116 uses the amount of current change needed to maintain a constant brushroll speed, as well as whether the current change is an increase or decrease to determine the kind of floor type thevacuum cleaner 10 is operating on, and thecontroller 116 adjusts the current supplied to thebrushroll motor 108 to maintain the speed of thebrushroll 94 at a speed desired for the particular floor type. In this way, thecontroller 116 determines the type of floor surface using the change in brushroll motor current needed to maintain a speed compared to predetermined thresholds and automatically operates thebrushroll motor 108, and optionally the suction motor, in a manner corresponding to the type of floor surface. In some cases, thecontroller 116 may turn off thebrushroll motor 108 if the current exceeds the threshold current value. Thecontroller 116 may include overload protection programming. -
FIGS. 12-14 illustrate apressure sensor 110′ according to another embodiment that can be used in conjunction with the vacuum cleaner 10 (e.g., instead of thepressure sensor 110 or in addition to the pressure sensor 110). - The
pressure sensor 110′ includes abase portion 120′ and acap portion 118′ that cooperate to define apressure sensor housing 114′. In some embodiments, thebase portion 120′ is integrally formed with a wall bounding the airflow path of thevacuum cleaner 10. Thehousing 114′ contains adiaphragm 123′ holding amagnet 142′ that is movable with respect to thehousing 114′ when thediaphragm 123′ flexes (FIG. 13 ). Thediaphragm 123′ is sandwiched between thebase portion 120′ and thecap portion 118′ such that thediaphragm 123′ creates a substantially airtight seal between thebase portion 120′ and thecap portion 118′. Accordingly, thediaphragm 123′ is subject to pressure forces resulting from any pressure imbalance between air contained within thebase portion 120′ and air contained within thecap portion 118′. - The air inlet of the
pressure sensor 110′ is configured as a fitting 125′, such as a hose barb or nipple, a threaded fitting, compression fitting, or other fitting. In the illustrated embodiment, the fitting 125′ extends from thebase portion 120′. The fitting 125′ can be integrally formed with thebase portion 120′ as a single piece, or alternatively, the fitting 125′ can be formed separately and attached to thebase portion 120′ by threads or another type of suitable airtight connection. The fitting 125′ (i.e. the air inlet for thepressure sensor 110′) is in fluid communication with thesuction chamber 70 such that the pressure at the sensor air inlet is representative of the pressure within thesuction chamber 70. In some embodiments, the fitting 125′ receives one end of a tube (not shown) that extends to the suction chamber 70 (e.g., to the pressure sensor inlet 122 (FIGS. 8 and 9 ) on theupper portion 62 of the floor nozzle 58) to allow for fluid communication between thepressure sensor 110′ and thesuction chamber 70. In other embodiments, thepressure sensor 110′ can be directly connected to thesuction chamber 70. - In the illustrated embodiment, a hall-
effect sensor 150′ is located on thecap portion 118′ (FIG. 13 ). The hall-effect sensor 150′ may be incorporated onto acircuit board 146′. Alternatively, all or a portion of the hall-effect sensor may be positioned on or adjacent thecap portion 118′ and electrically connected to a circuit board positioned in a separate location. Thecap portion 118′ may include attachments for securing thecircuit board 146′ or the hall-effect sensor 150′ to thecap portion 118′. In other embodiments, the hall-effect sensor 150′ can be located on thebase portion 120′. Negative pressure within thesuction chamber 70 generated by the suction source pulls on thediaphragm 123′, causing it to deform and movemagnet 142′ away from thecircuit board 146′ and the hall-effect sensor 150′. Therefore, the relative distance ofmagnet 142′ from the hall-effect sensor 150′ is correlated to the suction pressure within thechamber 70. Specifically, the higher the suction (i.e., the lower the pressure) within thesuction chamber 70, the further themagnet 142′ moves away from the hall-effect sensor 150′, and vice versa. Accordingly, the hall-effect sensor 150′ is used to determine a sensed pressure. - In some embodiments, the
diaphragm 123′ is afirst diaphragm 123′ that is interchangeable with a second diaphragm (not shown) having different deflection characteristics under pressure. In such embodiments, the first and second diaphragms can be interchanged in order to vary the responsiveness or operating pressure range of thepressure sensor 110′. In one embodiment, thefirst diaphragm 123′ has a first attribute selected from a group consisting of thickness, durometer, shape, and material, and where the first diaphragm is replaceable with a second diaphragm having a second attribute selected from a group consisting of thickness, durometer, shape, and material. For example, thefirst diaphragm 123′ may be made from a polyurethane material and the second diaphragm may be made from butyl rubber providing different response characteristics. In another example, thefirst diaphragm 123′ may have a flat shape or uniform thickness and the second diaphragm may have a concave shape that is thicker near its perimeter, or alternatively thinner near its perimeter, providing different response characteristics, or in yet another alternative, the second diaphragm may have a shape having ribs, apertures, protrusions, grooves, or other shapes. In another example, thefirst diaphragm 123′ may have a durometer of 25 Shore A and the second diaphragm may have a durometer of 40 Shore A, providing different response characteristics. In another example, the second diaphragm may be thinner than thefirst diaphragm 123′ and therefore experience greater deflection than thefirst diaphragm 123′ at a particular pressure difference between thebase portion 120′ and thecap portion 118′. - For particular embodiments, the
diaphragm 123′ may be made from materials such as butyl rubber, polyurethane, silicone rubber, and other synthetic rubbers, thermoplastic elastomer (TPE), rubber, thermoplastic vulcanizates (TPV), thermoplastics, and other materials to provide response characteristics under pressure as desired for the application. Thediaphragm 123′ may have a durometer between about 15 and 80 Shore A, or for particular embodiments between about 20 and 40 Shore A, or other hardnesses as desired to provide response characteristics under pressure as desired for the application. In one embodiment, thediaphragm 123′ is a thermoplastic elastomer having a durometer between 20 and 30 Shore A. - It was found that the
pressure sensor vacuum cleaner 10 can be used indicate more than one system condition, as shown inFIG. 15 . For example, if the user does not install a filter (e.g., a pre-motor filter or a post-motor filter in some embodiments), the pressure reading at thesensor controller 116 may illuminate a signal to the user indicating that the filter is missing, and/or may turn off the suction motor to prevent damage to thevacuum cleaner 10. - Another common condition occurs when the
dirt cup 46 is filled with debris and needs to be emptied. The pressure reading at thesensor dirt cup 46 fills, and when the pressure reaches a predetermined value, thecontroller 116 may illuminate a signal to the user indicating that thedirt cup 46 is full, and/or may turn off the suction motor. When thesensor controller 116 may provide a signal, such as a light or other display, to the user to indicate that thevacuum 10 is operating normally. - In certain conditions, the
vacuum cleaner 10 may pick up a large object or enough debris to form a blockage in the air path, or a filter or filter bag in the vacuum may become clogged (i.e. may contain enough debris that vacuum cleaner performance is reduced). When a clog occurs, the system pressure, as measured by thesensor controller 116 may provide a signal such as a light or other display to the user indicating that a clog has developed, and/or may turn off the suction motor. - Accordingly, one
pressure sensor vacuum cleaner 10 to provide system information for a variety of operating conditions. In one embodiment, onepressure sensor vacuum cleaner 10 to provide two or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation. Alternatively, onepressure sensor vacuum cleaner 10 to provide three or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation. In yet another alternative, onepressure sensor vacuum cleaner 10 to provide four or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation. In such embodiments, thecontroller 116 continuously or periodically monitors the pressure sensor and provides a signal such as a light or other display to the user indicating a system condition, and/or may turn off the suction motor. - Various features and advantages of the invention are set forth in the following claims.
Claims (21)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US15/196,412 US20170000305A1 (en) | 2015-06-30 | 2016-06-29 | Vacuum cleaner with brushroll control |
US16/544,662 US20190365177A1 (en) | 2015-06-30 | 2019-08-19 | Vacuum cleaner with brushroll control |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US201562187001P | 2015-06-30 | 2015-06-30 | |
US201562186998P | 2015-06-30 | 2015-06-30 | |
US15/196,412 US20170000305A1 (en) | 2015-06-30 | 2016-06-29 | Vacuum cleaner with brushroll control |
Related Child Applications (1)
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US16/544,662 Continuation US20190365177A1 (en) | 2015-06-30 | 2019-08-19 | Vacuum cleaner with brushroll control |
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EP (1) | EP3316752B1 (en) |
CN (1) | CN107920705A (en) |
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Also Published As
Publication number | Publication date |
---|---|
AU2016285841A1 (en) | 2018-01-25 |
EP3316752A1 (en) | 2018-05-09 |
AU2019100290A4 (en) | 2019-05-02 |
CN107920705A (en) | 2018-04-17 |
AU2019100291A4 (en) | 2019-05-02 |
EP3316752B1 (en) | 2022-01-12 |
AU2016285841B2 (en) | 2018-12-20 |
AU2019100292A4 (en) | 2019-05-02 |
US20190365177A1 (en) | 2019-12-05 |
WO2017004131A1 (en) | 2017-01-05 |
WO2017004131A9 (en) | 2021-07-08 |
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