ELECTRONIC CONTROL SYSTEM OF A MODULAR CLEANING MACHINE
The present invention refers to an electronic control system of a modular cleaning machine, provided with a steam generating part and a suction part, apt to control the machine so that at least one of the two parts is usable independently from the other, enabling a great versatility of use and a minimisation of power consumption and being efficient and highly reliable. It is known that machines are presently available on the market for cleaning rooms through the combination of the functionalities of both steam generation and suction, in particular with water filter.
However, such machines simultaneously provide both functionalities, i.e. the part related to steam generation and the one related to suction are incorporated in a unique machine body.
This is significantly due to the difficulties of making an electronic control system for controlling the two functionalities of the machine.
It is therefore an object of the present invention to provide an electronic control system of a modular cleaning machine, provided with a steam generating part and a suction part, so that at least one of the two parts is usable independently from the other, the machine consequently having a great versatility of use.
It is another object of the present invention to provide such an electronic system enabling a minimisation of power consumption and being efficient and highly reliable.
It is particular object of the present invention to provide such an electronic control system of a modular machine allowing the suction part, preferably with water filter, to be separated and to be used independently from the steam generating part. It is specific subject matter of this invention an electronic control system of a modular cleaning machine provided with two parts, namely a first suction part and a second steam generation part, the machine assuming a first assembled configuration, wherein said two parts are
connected one to the other, and a second disassembled configuration, wherein said two parts are disconnected and separated one from the other, the electronic system comprising first electronic means for operating and controlling the first suction part, second electronic means for operating and controlling the second steam generation part, and electronic power supply means connected to the first electronic means and/or to the second electronic means, apt to provide power supply for the electronic system, the electronic system being characterised in that in the second disassembled configuration at least one of said two parts of the machine is activable by the respective operation and control electronic means.
Preferably according to the invention, in the second disassembled configuration the first suction part is activable by the first operation and control electronic means, said electronic power supply means being connected to the first electronic means in the second disassembled configuration.
Always according to the invention, in the second disassembled configuration the second suction part may be activable by the second operation and control electronic means, said electronic power supply means being connected to the second electronic means in the second disassembled configuration.
Preferably according to the invention, the first operation and control electronic means and/or the second operation and control electronic means comprise at least one microprocessor.
Still according to the invention, the first electronic means may comprise first visual and/or acoustic signalling electronic means for signalling at least one operating state of the machine, preferably at least one LED (Light Emitting Diode) diode and/or at least one acoustic signaller or buzzer.
Furthermore according to the invention, the first electronic means may be apt to control a suction motor of the first suction part by providing power supply for it according to the mains voltage "zero crossing" technique.
Always according to the invention, the first electronic means may
control said suction motor by means of a first triac driven according to the zero crossing technique.
Still according to the invention, the first electronic means may comprise power up and selection means of said suction motor. Furthermore according to the invention, the second electronic means may comprise power up and selection means for said suction motor.
Always according to the invention, the first suction part may comprise a water filter provided with tank, and the first electronic means may comprise sensing means for sensing the water level of said tank.
Still according to the invention, the second electronic means may comprise second visual and/or acoustic signalling electronic means for signalling at least one operating state of the machine, preferably at least one LED diode and/or at least one acoustic signaller or buzzer. Furthermore according to the invention, the second steam generation part may comprise a boiler inside which a heating resistor is housed, and the second electronic means may be apt to control said resistor by providing power supply for it according to the zero crossing technique. Always according to the invention, the second electronic means may control said resistor by means of a second triac driven according to the zero crossing technique.
Still according to the invention, the second electronic means may comprise thermostat means for controlling the temperature of said resistor. Furthermore according to the invention, the second steam generation part comprises a sensor for sensing the water level in the boiler and a pump for filling the boiler with water from a tank, and the second electronic means is apt to control said pump by providing power supply for it according to the zero crossing technique. Always according to the invention, the second electronic means may control said pump by means of a third triac driven according to the zero crossing technique.
Still according to the invention, the second electronic means may
comprise a sensor for sensing the water level within said tank.
Furthermore according to the invention, in the case when at the power up of steam generation the sensor for sensing the water level within the boiler detects that no water is present within the boiler, the second operation and control electronic means may perform the following operations: a continuous outlet from the pump for a maximum time T1 , during which the resistor is disconnected; if before the maximum time T1 the water within the boiler should reach the sensor for sensing the water level within the boiler, the outlet stops after a latency time T2 from the instant in which the sensor detects the presence of water; if the water has reached the sensor for sensing the water level within the boiler, the resistor begins to heat for making the water within the boiler boil; if, on the contrary, after the maximum time T1 the water does not reach the sensor for sensing the water level within the boiler, the second steam generation part stops.
Always according to the invention, in the case when during steam generation the sensor for sensing the water level within the boiler detects an insufficiency of water within the boiler , the second operation and control electronic means may activate the pump for a first fixed time interval T3, which is followed by a second time interval T4, during which the second operation electronic means may analyse the signal coming from the sensor for sensing the water level within the boiler performing the following operations: if the signal of presence of water within the boiler is clear, the boiler and the resistor continue their normal operation; if, on the contrary, the sensor for sensing the water level within the boiler detects an unclear or uncertain signal in relation to whether water is present within the boiler or not, the pump is activated for a third time interval T5; if the sensor for sensing the water level within the boiler immediately
detects lack of water, the second steam generation part stops.
Still according to the invention, after a long cumulative time interval T6 of steam generation, the second operation and control electronic means may signal that the boiler needs to be cleaned. Furthermore according to the invention, the second operation and control electronic means may deactivate the signalling of necessary cleaning and reset the cumulative time of steam generation when the following operations are performed with the machine turned off, removing the sensor for sensing the water level within the boiler; completely emptying the boiler; reinserting the sensor for sensing the water level within the boiler; turning the machine on.
Always according to the invention, the second steam generation part may comprise a tank for the detergent and a corresponding pump for inletting the detergent in a steam circuit, and the second electronic means may be apt to control said pump for the detergent by providing power supply for it according to the zero crossing technique.
Still according to the invention, the second electronic means may control said pump for the detergent by means of a fourth triac driven according to the zero crossing technique.
Furthermore according to the invention, the second electronic means may comprise means for activating steam generation and for selecting steam level. Always according to the invention, the first electronic means may comprise means for activating steam generation and for selecting steam level.
Still according to the invention, in the first assembled configuration the first operation and control electronic means and the second operation and control electronic means may be connected one to the other through electronic connection means, preferably comprising mechanical means for active electric contact protection.
Furthermore according to the invention, the second operation and
control electronic means may be supplied only in the first assembled configuration of the machine.
Always according to the invention, the machine may be provided with at least one external accessory attachment, connectable to the machine through electromechanical connection means, and the electronic system may further comprise control electronic means, housed within said at least one external accessory attachment, apt to control the operation of at least one of said two parts of the machine.
Still according to the invention, said control electronic means of said at least one external accessory attachment may comprise at least one microprocessor.
Furthermore according to the invention, said control electronic means of said at least one external accessory attachment may comprise third visual and/or acoustic signalling electronic means for signalling at least one operating state of the machine, preferably at least one LED (Light Emitting Diode) diode and/or at least one acoustic signaller or buzzer.
The present invention will be now described, by way of illustration and not by way of limitation, according to its preferred embodiments, by particularly referring to the Figures of the enclosed drawings, in which:
Figures 1A, 1 B, and 1C respectively show a right front perspective view, a left side view and a right side view of a modular machine in a first assembled configuration to which a preferred embodiment of the electronic system according to the invention is applied; Figures 2A and 2B show the two parts of the machine of Figures
1A, 1 B and 1 C in a second disassembled configuration;
Figure 3 shows a first accessory attachment of the machine of Figures 1A, 1 B and 1 C;
Figure 4 shows a second accessory attachment of the machine of Figures 1 A, 1 B and 1 C;
Figure 5 shows a left rear perspective view of the suction part of the machine of Figures 1A, 1 B and 1 C;
Figure 6 shows a circuit diagram of a first portion of the preferred
embodiment of the electronic system applied to the machine of Figures
1A, 1 B and 1 C;
Figure 7 shows a right front perspective view of the steam generating part of the machine of Figures 1 A, 1 B and 1 C; Figure 8 shows a circuit diagram of a second portion of the preferred embodiment of the electronic system applied to the machine of Figures 1A, 1 B and 1 C;
Figures 9A, 9B, 9C, and 9D show the circuit diagrams of the preferred embodiment of the electronic system applied to the machine of Figures 1 A, 1 B and 1 C;
Figure 10 shows the time behaviour of the excitation and power signals according to the zero crossing technique; and
Figure 11 shows the time behaviour of the power signals according to the zero crossing technique of some components of the preferred embodiment of the electronic system according to the invention.
In the Figures, alike elements are indicated by the same references.
In the following, reference will be made to preferred embodiments of the electronic control system of a modular machine wherein the suction part may be separated and used independently from the steam generating part.
However, it should be noted that other embodiments of the control system according to the invention control modular machines wherein it is the steam generating part to be separable and usable independently from the suction part, or modular machines wherein both the suction part and the steam generating part may be separated and used independently from the steam generating part or the suction part, respectively. Such alternative embodiments of the control system are within the scope of protection of the present invention, as defined by the claims. With reference to Figures 1A, 1B and 1 C, it may be observed the modular cleaning machine 1 , provided with a first preferred embodiment of the electronic control system, in a first assembled configuration. In particular, the machine 1 is provided with two side wheels 2 and a little
caster 3 enabling mobility.
With reference to Figures 2A and 2B1 it may be observed the modular machine 1 in a second disassembled configuration, wherein the suction portable part 4 is separated from the steam generation mobile part 5, provided with the side wheels 2 and the little caster 3 and a revolving handle 6. In this regard, the mechanical means enabling the assembling and disassembling of the machine 1 is not part of the present invention and, consequently, it will not be described in the following. In any case, an advantageous implementation of such mechanical means is described in the Italian Patent Application No. RM2003A000028, herein incorporated by reference.
As shown in Figure 2A, the portable part 4 is provided with a front pipe union 7 provided with a first suction duct, with a second duct for the outlet of the steam generated by the mobile part 5, and with electric contacts. The corresponding connector 8 of various accessory attachments of the machine 1 may be connected to such front pipe union 7, accessory attachments such as a nozzle, shown in Figure 3 and provided with a handgrip 9 for controlling functionalities of suction and steam generation of the machine 1 , and an iron 10, shown in Figure 4. Preferably according to the invention, the pipe union 7 is a female electromechanical connector while the connector 8 is a male electromechanical connector.
The preferred embodiment of the electronic control system makes the machine 1 perform what required, through commands, by the user, it controls the total energy balance, it carries out the main controls of the machine 1 , and it signals the operating state of the machine 1 to the user.
The preferred embodiment of the electronic system comprises six electronic boards distributed in the several components of the machine 1. Other embodiments of the invention may provide that there is a different number of electronic boards, higher or lower than six.
In particular, with reference to Figures 5 and 6, the electronic system comprises a main or master board 11 , a power supply board 12 and a first LED (Light Emitting Diodes) board 13, which are located within
the suction portable part 4 of the machine 1. Other embodiments of the invention may advantageously provides that at least some of these boards are incorporated in a sole board; for instance, the master board could incorporate the power supply board. With reference to Figures 7 and 8, the electronic system still comprises a steam board 14 and a second LED board 15, which are located within the steam generation mobile part 5 of the machine 1. Also in this case, other embodiments of the invention may provide that these two boards are incorporated in a sole board. Furthermore, with reference to Fig. 9C, the electronic system comprises a control board 16 located within the handgrip 9 of the nozzle.
Still with reference to Figures 6 and 9A, it may be observed that the power supply board 12 provides power supply for all the components of the machine 1 , through a connection to the mains 17 from which the necessary stabilised d.c. supply and the required a.c. (specifically power) supply are derived. In particular, a master switch 18, located on the portable part 4, closes and opens the connection to the mains 17, carried out by means of a usual electric cable exiting from a hole 19 of the portable part 4, shown in Figure 1 C. The suction portable part 4 comprises a motor 20 (preferably a brushed series collector single-phase motor), a water filter (preferably provided with a separator 21 ), and a water tank 22 of the filter (shown in Figure 6 in section). The master board 11 controls the suction motor 20 through a first triac 23 driven according to the mains voltage zero crossing technique, which enables an optimised management of power consumption. In particular, the speed of the motor 20 is selectable among three different values by means of a suitable button located on the portable part 4 or, in the case when the nozzle of Figure 3 is inserted, by means of a similar button on the handgrip 9 of this one; the motor ignition also occurs by means of these same buttons.
The master board 11 is also connected to two tank level reed sensors 24 and 25, respectively located at the full and empty levels of the tank 22, which preferably interact with a float 26.
The master board 11 also controls signalling of the first LED board
13, the luminous diodes of which are apt to preferably signal the presence of the mains, the maximum level of the water of the filter, and the minimum level of the water of the filter. The master board 11 further controls the activation of an acoustic signaller or buzzer (advantageously mounted o the same master board 11 ) for emitting an alarm signal.
The master board 11 also communicates with the steam board 14 of the mobile part 5, through a, preferably female, electric connection 27 (shown in Figure 5) of the portable part 4 interacting with a corresponding, preferably male, electric connection 28 (shown in Figure 7) of the mobile part 5. Through the electric connections 27 and 28, the power supply board 12 provides power for the components of the mobile part 5, in particular for the steam board 14. The electric connection 27 of the portable part 4 is provided with an elastic cover 29 which automatically closes when the portable part 4 is being separated from the mobile part 5.
With reference to Figures 8 and 9B, it may be observed that the steam board 14 controls usual steam generating devices, comprising: a boiler 30, inside which a resistor 31 is housed, the temperature of which is controlled by a first thermostat 32, preferably a recocking thermostat, and possibly by a second bulb thermostat 33; a first and a second solenoid valve 34 and 35, respectively; a manostat 36; a boiler water level probe 37, preferably a rod sensor with 10 KHz frequency having high impedance towards the electronic circuit; a pump 38, preferably connected to the steam board 14 through a fuse 39, for possibly filling the boiler 30 with water from a tank 40.
The steam board 14 controls the resistor 31 of the boiler 30 and the pump 38 through respective triacs 41 and 42 driven according to the zero crossing technique, for an optimised control of power consumption.
Advantageously, the steam generation mobile part 5 may be further provided with a level sensor for the cold water tank 40. Furthermore, the mobile part 5 may be also provided with a tank for a detergent, possibly provided with a corresponding pump for its inlet in the steam circuit (for instance, in the boiler 30 or directly in the steam duct),
also controlied by a triac driven according to the zero crossing technique.
In particular, in the first assembled configuration, the mobile part 5 sends the generated steam to the front pipe union 7 of the portable part 4 through two corresponding seal connectors 43 and 44, respectively. The steam board 14 also controls signalling of the second LED board 15, the luminous diodes of which are apt to preferably signal the minimum water level of the tank 40 (if any), the minimum detergent level (if any), the condition of steam ready, and the presence of the inserted iron 10. In fact, in this last case, the master board 11 is capable to detect the presence of the inserted iron 10, the diagram of electric connections 45 of which with the pipe union 7 is shown in Figure 9D, and to signal it to the steam board 14 through the electric connectors 27 and 28.
From what has been described, it is evident that, in the preferred embodiment of the system according to the invention, the mobile part 5 is operating only when it is connected to the portable part 4, since only in this case it is supplied by the power supply board 12.
Through the handgrip 9 of the nozzle of Figure 3, the user may turn on and select the speed of the suction motor, he/she may activate the steam generation and select the quantity of steam (in the first assembled configuration of the machine 1), he/she may activate the operation with detergent (if any). Moreover, some luminous indications, preferably LED indications, are on the handgrip 9 indicating: the suction speed (preferably through three LEDs corresponding to the three speeds), the quantity of steam (preferably through three LEDs corresponding to three different quantities), the condition of steam ready, and the activation or not of the operation with detergent (if any).
As said above, in order to control loads (i.e. suction motor 20, resistor 31, pump 38 of the cold water tank 40, and possible detergent pump), the electronic system drives the corresponding triacs 23, 41 , and 42 according to the zero crossing technique, which keeps complete half cycles of the supply voltage applied to the load and modulate the provided power by inserting more or less whole half cycles of the mains voltage. With reference to Figure 10, it may be observe that this is obtained by
enabling the triac at the instant when the mains voltage crosses 0, so avoiding any phase control. This entails as a major advantage the good behaviour of the system with respect to electromagnetic disturbance.
In the electronic system according to the invention, the master board 11 and the steam board 14 apply specific sequences of half cycles, the former to the suction motor 20, and the latter to the resistor 31 and the pump 38. Such sequences are preferably made of 12 complete half cycles (that is 6 whole cycles of mains voltage) which repeat in time while the load is inserted. For the schematic representation, strings having 12 bits each are adopted, where bits have value "1" if the half cycle is inserted (supplied load) and value "0" if the half cycle is disconnected (not supplied load). Figure 11 shows an example of sequences applied to the motor 20 and to the resistor 31 , respectively "100000110010" and "011100010001". The half cycles of the sequences are inserted or excluded through software performed by the microprocessors with which the master board 11 and the steam board 14 are provided.
In the case of the resistor 31 , the developed effective power is proportional to the ratio of inserted half cycles to all the ones forming the corresponding sequence. For instance, for each half cycle inserted in a sequence of 12 half cycles, assuming a rated power of 2200 Watt, the resistor 31 develops a power equal to: Pres = Pr 111 = 2200/12 = 183,33JF which also represents the minimum value for adjusting the same resistor
31. With regard to the motor 20, which is a substantially inductive load, the computation is not proportional as it is for the resistor 31 , because it depends on the transfer function of the same motor 20.
In order to better understand the present invention, some operating modes of the electronic system according to the invention are described in the following.
In the first assembled configuration of the machine 1 , at power up: in the case when the nozzle of Figure 3 is not inserted, by means of the suitable button located on the portable part 4 it is possible to activate the
suction motor at one of the allowed speeds (preferably three allowed speeds); in the case when the nozzle of Figure 3 is inserted, by means of the controls of the handgrip 9 it is possible to activate the suction motor at one of the allowed speeds (preferably three allowed speeds), and to activate the boiler 30 for generating steam selecting its level (preferably three allowed levels); in the case when the iron 10 of Figure 4 is inserted, by means of the controls of this one it is possible to activate the boiler 30 for generating steam selecting its level (preferably three allowed levels).
The operation modes of steam generation and outlet take into account anomalous conditions.
In the case when, at the activation of steam generation, the probe
37 detects that no water is present within the boiler 30, the operation sequence of the boiler is as follows: a continuous outlet from the pump 38 for a maximum time "Pl 1 preferably equal to 110 s (necessary for the initial refill of the boiler 30), during which the resistor 31 is disconnected; if before the maximum time T1 (110 s) the water inside the boiler 30 should reach the probe 37, the outlet stops after a latency time T2, preferably equal to 2 seconds, fro the instant in which the probe 37 detects the presence of water; once successfully terminated the initial refill, the resistor 31 begins to heat for making water of the boiler 30 boil; instead, if after the maximum time T1 (110 s) the water does not reach the probe 37, system stop occurs with, preferably both luminously and acoustically, signalling of lack of water within the tank.
Instead, in the case when, at the activation of steam generation, the probe 37 detects that water is present within the boiler 30, the resistor 31 immediately begins to heat for making water of the boiler 30 boil.
During steam generation (and outlet) operation, the refilling sequence is as follows.
When the probe 37 detects insufficiency of water within the
boiler 30, the software performed by the processor of the steam board 14 proceeds to activate the pump 38 for a first fixed time interval T3, preferably equal to 5 seconds, which is followed by a second time interval T4, preferably equal to 3 seconds, in which the steam board 14 analyses the signal coming from the probe 37: if the signal of presence of water within the boiler 30 is clear, nothing occurs, the boiler 30 continues its normal operation; if on the contrary the probe 37 detects an unclear signal (whereby it is doubtful whether water is present within the boiler 30 or not) the pump 38 is activated for a third time interval T5, preferably still equal to 5 seconds; if the probe 37 immediately signals lack of water, the software proceeds to stop everything and to acoustically signal the error by means of the buzzer.
In the second disassembled configuration of the machine 1 , at power up: in the case when the nozzle of Figure 3 is not inserted, it is possible to activate the suction motor at one of the allowed speeds (preferably three allowed speeds) by means of the suitable button located on the portable part 4; in the case when the nozzle of Figure 3 is inserted, it is possible to activate the suction motor at one of the allowed speeds (preferably three allowed speeds) by means of the controls of the handgrip 9.
Further preferred embodiments of the electronic system according to the invention comprise a LED of indication of limestone removal in the second LED board 15. In such case, the steam board 14 is programmed for warning the user that, after a certain number of hours of using of steam, it is necessary to carry out the cleaning of the boiler 30, in order to prevent limestone formation and consequently improve the performances of the same machine 1. In particular, after a long time interval T6, preferably of the order of several hours, the steam board 14 signals, by means of a suitable LED of the second LED board 15, that the boiler 30 needs to be cleaned. In any case, the system is programmed for operating even if cleaning is not
carried out, such signalling remaining activated, which signalling is removable, with reference to Figures 8 and 9B, by means of a suitable switch 46 of indication of limestone removal.
In order to restore the correct operation of the machine 1 (that is for turning the limestone signalling LED off) it is necessary to perform the following preferred procedure: with the machine turned off, removing the probe 37; opening the drain plug of the boiler 30, for completely emptying it; closing the drain plug of the boiler 30 and reinserting the probe 37; turning the machine on.
Once this series of operations is performed, the software is programmed for resetting and signalling again the need of cleaning the boiler 30 after a further time interval T6. In other words, the steam board 14 is preferably programmed for recognising that after a disconnection and a reinsertion of the probe 37 in the boiler 30, the water level detected by the probe 37 is substantially the empty level.
Other embodiments of the system according to the invention may also operate and control further functionalities of the modular machine to which it is applied. By way of example, and not by way of limitation, the boards of the electronic system (which as said before may be in number different form the six boards present in the preferred embodiment shown in the Figures) may enable the execution of an automatic test of the machine and the control of internal or external accessory attachment, as, for instance, ionizers for air cleaning. The preferred embodiments have been above described and some modifications of this invention have been suggested, but it should be understood that those skilled in the art can make variations and changes, without so departing from the related scope of protection, as defined by the following claims.