1. Field of the Invention
This invention relates to floor care, and more specifically, to a floor care appliance having a port for connecting the microprocessor control system to a computer.
2. Summary of the Prior Art
Floor care appliances are well known in the art. Typical floor care appliances include upright vacuum cleaners, canister vacuum cleaners, hard floor cleaners, and extractors. More recently floor care appliances have been provided with increasingly sophisticated microprocessor based control systems for controlling one or more features including, for example, a suction motor, agitator motor, bag full indicators, and the like. Typically, such microprocessors are permanently pre-programmed at the factory with instructions for controlling the features. The microprocessors are not connected to any electronic hardware which would enable programming to be updated if required. It would be desirable to have the flexibility of updating the programming of the microprocessor as more sophisticated programming becomes available. Also, with the addition of hardware to connect to the microprocessor to a computer, the microprocessor becomes more useful. For example, the microprocessor could be programmed to store real time operational data in a log that could be read by a computer for diagnostics purposes. The computer could be a local personal computer or a remote computer.
There does exist in U.S. Pat. No. 6,637,546 for a carpet cleaning machine provided with a microprocessor which controls various components. The microprocessor is software controlled, and can provide sequential operating instructions to the operator, enforce start-up and shut down sequences, store an electronic record of operating parameters for future use, provide auto- and remote diagnostics, and provide remote control. The software is updated via a modem.
However, updating the microprocessor software via a modem is not the only way to update microprocessor software and may not be the most desired means. With the adaption of readily available access to high speed computer network services, such as the Internet, and most homes having a personal computer connected to the Internet, it may be more desirable to update microprocessor software from a personal computer connected to a remote computer through a computer network such as the Internet. Accordingly, there is a need in the art for a floor care appliance having a microprocessor based control system that can be connected to a personal computer.
Accordingly, it is an object of the invention to provide a floor care appliance having a microprocessor based control system that can be connected to a computer.
It is a further object of this invention to provide a floor care appliance having a microprocessor based control system that can be connected to a personal computer.
It is a further object of this invention to provide a floor care appliance having a microprocessor based control system that can be connected to a personal computer via a digital pathway.
It is a further object of this invention to provide a floor care appliance having a microprocessor based control system that can be connected to a personal computer via a wireless connection.
It is a further object of this invention to provide a vacuum cleaner having a microprocessor based control system that can be connected to a remote computer via a modem.
In the preferred embodiment of the invention, a floor care appliance having a programmable microprocessor is provided wherein the microprocessor is programmed to store operational parameters of the appliance as well as real time performance data. The microprocessor is capable of being connected to a computer wherein the programmed operational parameters may be changed and the real time performance data uploaded to the computer. The performance data can then be evaluated to determine the operating condition of the cleaner for repair and maintenance purposes. The performance data may also be used to determine adjustments to be made to the operating parameters of the appliance which are downloaded to the microprocessor from the computer.
In one embodiment of the invention, the computer is a personal computer and the floor care appliance is connected via a digital pathway. The digital pathway could use any one of a number of computer protocols including RS-232, ethernet, Firewire, Blue Tooth, X10, infrared or the newer RS 485. The personal computer can then be used to update the microprocessor software provided on a removable storage media or retrieve it from a remote computer via the Internet or a dial-up connection through a modem.
In an alternate embodiment of the invention, the digital pathway between the floor care appliance and the personal computer is replaced with a wireless connection utilizing a radio frequency.
In another embodiment of the invention, the microprocessor is configured to be a modem so that the floor care appliance can be connected directly to a telephone network for dialing up and connecting to a remote computer for software updates and diagnostics. The microprocessor could be pre-programmed with a toll free or other number of a customer service center of the appliance's manufacturer.
In the instant invention, the subject microprocessor is part of an improved power management system for controlling the total amount of current provided to at least a first and a second load device of an appliance. The power management system is comprised of a microprocessor, an alternating current voltage source, a voltage regulating circuit, a clamping circuit, a clamping circuit, at least two load devices, and a MOC and a triac for each of the at least two load devices. The clamping circuit outputs a fixed voltage during the portion of the ac cycle which is greater than or less than zero and provides a zero or negligible voltage while the ac cycle is at zero voltage. The fixed voltage and the zero or negligible voltage are input to a microprocessor. The microprocessor utilizes these inputs to control the amount of time the current is turned on to each of the at least first and second load devices. The current is turned on to each of the at least first and second load devices by an output from the microprocessor provided to the associated MOC which in turn controls the associated triac for turning the current on to the associated load. One of the at least first and second loads has a sensing circuit which monitors the current drawn by the load. A surge or rise in the current drawn will cause an output from the sensing circuit which is input to the microprocessor. The microprocessor will adjust according to pre-programmed instructions the amount of time the current is turned on to each of the at least first and second loads so that the total current drawn by all of the at least first and second loads does not exceed a pre-determined value. This requires that the microprocessor reduce the current provided to the at least second load to account for the increased amount of current used by the first load.
In one embodiment of the power management system, the at least first and second loads are a motor-fan assembly and an agitator drive motor. The pre-determined level or total current that may be drawn by both motors is 12 amps with the agitator drive motor initially programmed to draw 2 amps. This means that the motor-fan assembly can initially draw 10 amps. An increase in the load placed on the agitator drive motor will cause the amount of current drawn by the agitator drive motor to exceed 2 amps. Necessarily, the microprocessor will adjust the current provided to the motor-fan assembly to less than ten amps.
Reference may now be had to the accompanying drawings for a better understanding of the invention, both as to its organization and function, with the illustration being only exemplary and in which:
a is an electrical schematic of an RS-232 transceiver connected to the microprocessor shown in
b is an electrical schematic of an isolation circuit for isolating the RS-232 transceiver from the telephone network, according to the alternate embodiment of the present invention;
c is an switching circuit for signaling the microprocessor shown in
d is a circuit for connecting the microprocessor to ground; according to the alternate embodiment of the present invention; and
e is a circuit for timing data for the modem of
Referring now to
Located in foot 100 or upper housing 200 is a motor-fan assembly M2 which creates the suction necessary to remove the loosened dust and debris from the floor surface. The motor-fan assembly M2 fluidly connects to foot or suction nozzle 100 by a dirt duct (not shown). The upper housing assembly 200 houses a particle filtration and collecting system 300 for receiving and filtering the dirt-laden air stream which is created by the motor-fan assembly 400. The particle filtration and collecting system 300 may be interposed in the dirt laden airstream between the suction nozzle 100 and the motor-fan assembly M2 as in an “indirect air” system seen in
Referring now to
On the lower portion of upper housing 200 is a data port 700 for connecting floor care appliance 10 to a network. A microprocessor 810located in floor care appliance 10 may be used to control various features of floor care appliance 10. The microprocessor 810 may be part of power management system 800 or otherwise. A microprocessor 810 used for this purpose usually is pre-programmed at the factory with the floor care appliance's 10 operational parameters. Upon connection of floor care appliance 10 to a computer, the operational parameters may be changed through the computer. The microprocessor 810 could also be programmed to collect and store real time performance data which may also be uploaded to the computer. The performance data can be evaluated to determine the operating condition of the floor care appliance 10 cleaner for repair and maintenance purposes. The performance data may also be used to determine adjustments that could made to the operating parameters of the appliance to improve performance which are downloaded to the microprocessor 810 by the computer. Examples of such performance data could include a log of the running time of motors, cleaner suction, agitator brush life, and airflow in the various parts of the appliance.
Referring now to
The microprocessor 810 is programmed to utilize these inputs to control the amount of time the current is turned on to each of the at least first and second load devices M1 and M2. The microprocessor 810 essentially has timers for each of the at least two load devices M1 and M2 that start timing the amount of time the current is turned on to each the at least two load devices M1 and M2 each time the ac current crosses past the “zero voltage threshold”. The current is turned on to each of the at least first and second load devices M1 and M2 by an output from the microprocessor 810 provided to an associated triac driver device MOC1 and MOC2 known as a “MOC” which in turn controls an associated triac U1 and U2 which when activated turns the current on to an associated load device M1 and M2. A triac drive device or “MOC” model no. MOC3010-M made by Fairchild Semiconductor of South Portland, Me. has been found to be suitable for this purpose.
One of the at least first and second loads M1 and M2 has a sensing circuit 870 associated with it which monitors the current drawn by the load device M1 and M2. In the preferred embodiment, the current sensing circuit 870 is associated with M1. A surge or rise in the current drawn by the load device M1 will cause an output from the sensing circuit 870 which is input to the microprocessor 810. The microprocessor 810 will adjust according to pre-programmed instructions the amount of time the current is turned on to each of the at least first and second loads M1 and M2 so that the total current drawn by all of the at least first and second loads M1 and M2 does not exceed a pre-determined value. This requires that the microprocessor 810 reduce the current provided to the at least second load device M2 to account for the increased amount of current used by the first load device M1. When the increased load on the second load device M2 is reduced, the microprocessor's 810 programming will reduce the amount of time that current is turned on to the first load M1 while increasing the amount of time the current is turned on to the second load M2 such that the total current used by both the first and second load M1 and M2 does not exceed the predetermined value.
In one embodiment of the power management system 800, the at least first and second loads M1 and M2 are a motor-fan assembly and an agitator drive motor. The pre-determined level or total current that may be drawn by both motors is 12 amps with the agitator drive motor M1 initially programmed to draw 2 amps. This means that the motor-fan assembly M2 can initially draw 10 amps. An increase in the load placed on the agitator drive motor M1 will cause the amount of current drawn by the agitator drive motor M1 to exceed 2 amps. Necessarily, the microprocessor 801 will adjust the current provided to the motor-fan assembly M2 to less than ten amps. Note that this is only one possible configuration as additional loads M3 through Mn may be added and the microprocessor 810 can be programmed to adjust the current to each of the loads M1 through Mn as the current increases in one of the M1 through Mn loads so that the sum total current used by all loads M1 through Mn does not exceed a predetermined value. With the use of switches SW1 to SWn to turn various features on and off, the microprocessor 810 can control the current to each of the loads M1 through Mn that remain on so that the total current drawn by the loads M1 through Mn does not exceed a pre-determined level. The entire power management system 800 could be embedded on a plug in module which simplifies assembly of floor care appliance 10 and replacement and/or upgrade of power management assembly 800.
Power is supplied to power management system 800 by an ac voltage source 805 which is typically 120 vac at 60 hz. The 120 vac line voltage is reduced through a resistor R1 and capacitor C1 and then the Zener diode D1 which clamps the voltage to around 30 vac. The 30 vac voltage is half-wave rectified to direct current through the diode D2 and smoothed through a capacitor C2. The smoothed direct current is fed into a voltage regulator U1 that outputs a regulated 5 vdc voltage from the 10-35 vdc input. This 5 vdc power is then supplied to the microprocessor and the other low voltage devices and controls discussed above.
The 120 vac voltage source 805 also has its voltage dropped through the resistive divider R2 and R3. On the positive half of the AC wave, the upper diode D4 conducts and the output signal is clamped to 5.7 vdc. On the negative half of the Ac wave, the lower diode D3 conducts and the output signal is clamped to 0 vdc. This square wave pulse train coincides with the zero crossing of the main 120 vac line. This signal is fed into the microprocessor 810 and used to sequence the firing of motors M1 and M2 (or other load devices M3 through Mn) with the main ac voltage line based upon the zero crossing.
The switches SW1 through SWn look for a transition from 0 vdc to 5 vdc or vice versa to recognize a valid press. Each switch SW1 to Swn corresponds with a different mode, feature or speed selection. The LED's L1 through Ln and associated resistors R4 through Rn are used for indication of which mode, feature or speed is currently selected.
Each of the load driver circuits 870 and 880 is comprised of a MOC 1 and MOC 2, respectively used for firing triacs U2 and U3, respectively. MOC 1 and MOC 2 are devices that are used to either block or pass a portion of the 120 vac power to laod devices M1 and M2. When a valid zero cross is determined, timers internal to microprocessor 810 start timing and when the preset time is reached the input signal to MOC 1 and MOC 2 is toggled and the device will allow a portion of the 120 vac wave to pass. The preset times can range from 0 to 7 miliseconds depending on the average voltage that needs to be passed to M1 and M2. Triacs U2 and U3 are devices that switch on and off allowing current to flow to M1 and M2 based upon MOC 1 and MOC 2 and the timing signal coming through the microprocessor 810.
Current sensing circuit 870 is a low ohm power resistor that generates a voltage with respect to the current through the agitator motor. That low voltage AC signal is half-wave rectified through a diode, filtered and smoothed through a resistive/capacitive network. That signal is then fed into an A/D pin on the microprocessor 810 where it is used to determine the load on M1. Based upon the load on M1, decisions can be made to change the speeds of M1 and M2 based upon the surface being cleaned, stall detection, etc.
In the preferred embodiment of the invention, a microprocessor 810 such as the one in power management system 800 or other microprocessor could be configured and programmed to collect and store data related to the operating parameters of the floor care appliance 10 such as was heretofore described related to the control of the current supplied to the at least first and second loads M1 and M2. However, there could be an infinite number of possibilities as to what may be programmed into the microprocessor 810 or other microprocessor as various known and heretofore unknown features are added to floor care appliance 10. The microprocessor 810 or other microprocessor could also be programmed to collect and store real time performance data related to the performance and operation of floor care appliance 10. The performance data can then be evaluated to determine the operating condition of the floor care appliance 10 for repair and maintenance purposes. The performance data may also be used to determine adjustments to be made to the operating parameters of the floor care appliance 10 which are downloaded to the microprocessor 810 or other microprocessor over a network connected to a remote interface. Other possibilities of information that can be programmed into microprocessor 810 includes date of purchase, warranty, serial number, production run number and date, model no., parts lists, etc. A data port 700 connected to the microprocessor 810 or other microprocessor is provided on floor care appliance 10 for this purpose. Data port 700 may be one of several types of data ports such as USB, serial, parallel, RJ-11 or other known or unknown data ports described hereinbelow.
In the preferred embodiment of the connection arrangement, as seen in
In an alternate embodiment of the connection arrangement, as seen in
It should be clear from the foregoing that the described structure clearly meets the objects of the invention set out in the description's beginning. It should now also be obvious that many changes could be made to the disclosed structure which would still fall within its spirit and purview.