FLOOR CLEANER

Abstract

A method of operating a cleaning system is provided herein. The method includes receiving a first battery pack including a first battery controller, receiving a first signal from the first battery controller, outputting, in response to receiving the first signal, a first control signal, operating a motor at a first predetermined constant power based on the first control signal, receiving a second battery pack including a second battery controller, receiving a second signal from the second battery controller, outputting, in response to receiving the second signal, a second control signal, and operating the motor at a second predetermined constant power based on the second control signal.

Description

BACKGROUND

Embodiments described herein relate to floor cleaners, such as vacuum cleaners and extractors.

SUMMARY

Typically, when a floor cleaner is turned on, the suction motor operates at a single voltage or power. For example, a battery-powered floor cleaner conventionally draws a power from a battery pack coupled to the floor cleaner. However, battery packs have different capacities. Drawing a high power level from a battery pack with a high capacity is useful, but drawing the same high power level from a low capacity battery pack can deplete the battery quickly, causing frequent recharging of the battery pack. It is desired for a floor cleaner to include a controller that can determine the voltage level of a battery pack and adapt operation to accommodate the voltage level of the battery pack.

Additionally, it is often the case that a floor cleaner is used to clean a variety of surfaces. However, these surfaces vary greatly, requiring various floor cleaning operations. For example, a user may need a high suction, high rotational speed setting for a carpet and a low suction, low rotational speed for an area rug. Therefore, there is a need for a floor cleaner with suction, rotation, and, in some cases, fluid controls that can be controlled based on user preferences.

In addition, floor cleaners conventionally operate the same regardless as to whether the floor cleaner is moving forward, rearward, or if the floor cleaner is no longer contacting a surface. In order to save power consumption, there is a desire to detect the motion and status of the floor cleaner and control the operation of the floor cleaner based on the motion and status of the floor cleaner.

Finally, floor cleaners often have at least two printed circuit boards (PCBs) that each include separate control circuitry. For example, a floor cleaner includes a first PCB for controlling a suction motor and a second PCB for controlling other aspects of the floor cleaner (e.g., indicators, sensors, etc.). There is a need to integrating the PCBs onto a single PCB that controls all operations of the floor cleaner.

One embodiment described herein provides a method of operating a cleaning system. The method includes receiving a first battery pack including a first battery controller, receiving a first signal from the first battery controller indicative of a first battery capacity, outputting, in response to receiving the first signal, a first control signal, operating a motor at a first predetermined constant power based on the first control signal, receiving a second battery pack including a second battery controller, receiving a second signal from the second battery controller indicative of a second battery capacity, outputting, in response to receiving the second signal, a second control signal, and operating the motor at a second predetermined constant power based on the second control signal.

One embodiment described herein provides a cleaner. The cleaner comprises a suction motor, a control system, and a user interface. The suction motor is operable to create a suction airflow from a suction inlet to an exhaust outlet. The control system is configured to control the suction motor that is operable at predetermined suction levels corresponding to a plurality of user selectable modes. The user interface is operatively connected to the control system and has a first user-actuatable input and a second user-actuatable input. The first user-actuatable input is configured to select and operate the control system from among the plurality of user selectable modes. One of the plurality of user selectable modes is a favored mode. The second user-actuatable input is configured to operate the control system in a favored mode.

One embodiment described herein provides a cleaner. The cleaner comprises a housing, a suction motor, a sensor, and a control system. The housing includes a base portion that is movable along a surface to be cleaned. The suction motor is within the housing and is operable to create a suction airflow from a suction inlet to an exhaust outlet. The sensor is within the housing and is operable to generate a sensor signal. The sensor signal is a first signal corresponding to the cleaner moving in a forward direction along the surface and a second signal corresponding to the cleaner moving in a rearward direction along the surface. The control system is configured to receive the sensor signal and control operation of the suction motor based on the received sensor signal.

One embodiment described herein provides a cleaner. The cleaner comprises a suction motor and a control system. The suction motor is operable to create a suction airflow from a suction inlet to an exhaust outlet. The control system is configured to control operations of the cleaner and the suction motor. The control system includes a motor control circuit operable to control at least one of an average voltage of the suction motor and a power of the suction motor and a cleaner control circuit operable to control operations of the cleaner. The motor control circuit and the cleaner control circuit are disposed on a first circuit board.

Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components.

Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value.

It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and/or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vacuum cleaner according to an embodiment of the invention.

FIG. 2 is a cross-sectional view of a portion of the vacuum cleaner of FIG. 1.

FIG. 3 is a perspective view of an extractor according to an embodiment of the invention.

FIG. 4 is a perspective view of the extractor of FIG. 3.

FIG. 5 is a block diagram of a control system of the vacuum cleaner of FIG. 1 and the extractor of FIG. 3.

FIGS. 6-7 are a block diagram of a method according to an embodiment of the invention.

FIG. 8 is a block diagram of a method according to an embodiment of the invention.

FIG. 9 is a block diagram of a method according to an embodiment of the invention.

FIG. 10 is a block diagram of a method according to an embodiment of the invention.

FIG. 11 is a block diagram of a method according to an embodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 illustrates a floor cleaner 100 according to one embodiment. In the illustrated embodiment, the floor cleaner is a vacuum cleaner 100 that includes a base 105, a body 110 pivotally coupled to the base 105, and a handle 115. The body 110 is pivotal relative to the base 105. The vacuum cleaner 100 further includes a separator assembly 130 supported by the body 110. The vacuum cleaner 100 receives power from a battery 135 that is mounted to a battery receptacle 150 (FIG. 2) supported by the body 110. The battery 135 may be a rechargeable lithium-ion battery. The illustrated vacuum cleaner 100 is an upright style vacuum cleaner. In other embodiments, however, the vacuum cleaner 100 may include other form factors (e.g., handheld, canister, etc.).

FIG. 2 is a cross-sectional view of a portion of the vacuum cleaner 100. The base 105 is movable over the surface to be cleaned. In the illustrated embodiment, the base 105 includes wheels 142 to facilitate moving the base 105 over the surface. The base 105 includes a suction inlet 140. In some embodiments, the cleaner 100 includes a brush roll 138 (FIG. 1) adjacent to the suction inlet 140. The body 110 supports a suction source 145 operable to generate an airflow through the suction inlet 140 to draw debris with the airflow through the suction inlet 140. The suction source 145 includes a suction motor and a fan. The separator assembly 130 is downstream from the suction inlet 140 and separates the debris from the airflow.

The illustrated battery 135 is removably coupled to the battery receptacle 150. In some embodiments, the battery 135 is slidably received on the battery receptacle 150 in a direction generally parallel to the longitudinal axis A1 of the shaft portion 120. When the battery 135 is coupled to the battery receptacle 150, the battery 135 provides power to the vacuum cleaner 100. For example, the battery 135 may power an electric motor of the suction source 145. The battery 135 may additionally power other components, such as a brush roll motor 465 (FIG. 5) provided on the base 105. In some embodiments, the battery 135 is a battery pack 440 selected from a plurality of battery packs that can be used interchangeably with the vacuum cleaner 100 and/or other battery operated products. For example, the battery pack may be one of an 18V 2.0 Ah pack, 18V 3.0 Ah pack, and an 18V 4.0 Ah pack. In other embodiments, the vacuum cleaner 100 includes a power cord to supply power to the vacuum cleaner (e.g., via a wall outlet).

FIG. 3 illustrates an extractor 200 according to one embodiment. In the illustrated embodiment, the extractor 200 includes a base 205 and a body 210 pivotally coupled to the base 205. The body 210 is pivotal relative the base 205 about a first axis between an upright storage position (FIG. 1) and an inclined operating position. The extractor 200 further includes a supply tank 215, a recovery tank 220, and a vacuum source. The supply tank 215 is configured to store a cleaning fluid and the extractor 200 is operable to dispense the cleaning fluid onto a surface 240 to be cleaned. The suction source includes a suction motor and a fan. The suction motor and the fan are operable to draw the cleaning fluid from the surface 240 into the recovery tank 220. In some embodiments, the extractor 200 includes a brush roll motor that operates a brush roll within the base 205. In some embodiments, the brush roll is adjacent to a suction inlet 245.

The base 205 is movable over the surface 240 to be cleaned. In the illustrated embodiment, the base 205 includes wheels 235 to facilitate moving the base 205 over the surface 240. The base 205 includes the suction inlet 245 in fluid communication with the suction source and the recovery tank 220. The cleaning fluid is drawn from the surface 240 through the suction inlet 245 and into the recovery tank 220. The base 205 further includes a fluid distribution system operable to distribute fluid to the surface 240. The fluid distribution system includes a distribution nozzle in fluid communication with the supply tank 215. The distribution nozzle dispenses the cleaning fluid toward the surface 240.

The extractor 200 further includes a handle 225. The handle 225 includes a grip 230 for holding the handle 225 and an actuator 270 adjacent the grip 230. In some embodiments, the actuator 270 controls the flow of cleaning fluid from the supply tank 215 through the distribution nozzle.

The extractor 200 further includes a battery that provides power to the extractor 200. The battery may be a rechargeable lithium-ion battery. The battery is removably coupled to the battery receptacle as discussed above with respect to vacuum cleaner 100. In one embodiment, the battery is the vacuum cleaner battery 135. In some embodiments, the battery provides power to the suction motor, the brush roll motor, and the fluid distribution system, among other components of the extractor 200.

FIG. 4 is a perspective view of the extractor 200 according to one embodiment. The extractor 200 includes a user interface 275. In one embodiment, the user interface 275 includes a power button, a mode button, and a favorite button. In some embodiments, the user interface 275 includes additional control buttons. In one embodiment, the vacuum cleaner 100 (FIG. 1) includes a user interface that is substantially the same as user interface 275.

FIG. 5 is a block diagram of a control system 400, according to one embodiment. The control system 405 includes a controller 405, a suction motor controller 410, a brush roll motor controller 415, a fluid distribution system controller 420, sensors 425, a user interface 430, actuators 435, and a battery pack 440. The fluid distribution system controller 420 is omitted for cleaners that do not have the fluid distribution system 470, such as the vacuum cleaner 100. Similarly, the brush roll motor controller 415 is omitted for cleaners that do not have a motorized brush roll or agitator. The controller 405 includes a processing unit 445, a memory 450, and input and output (I/O) units 455. The processing unit 445 includes a microprocessor, an electronic processor, an electronic controller, a microcontroller, or another suitable programmable device. The memory 450 may be a non-transitory computer readable medium and may include a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as a ROM, a RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 445 is connected to the memory 450 and executes software instruction that are capable of being stored in a RAM of the memory 450 (e.g., during execution), a ROM of the memory 450 (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. The controller 405 is configured to retrieve instructions and programs from the memory 450 and execute the instructions and programs according to the methods described herein.

The suction motor controller 410 is connected to the controller 405 and controls a suction motor 460. The suction motor controller 410 varies the suction level of the suction motor 460 by changing the power supplied to the suction motor. In some embodiments, the suction motor controller 410 uses pulse-width modulation (PWM) signals to control the suction motor 460. For example, the suction motor controller 410 may use a PWM duty cycle to maintain a predetermined average voltage or to maintain a predetermined average power of the suction motor 460.

The brush roll motor controller 415 is connected to the controller 405 and controls a brush roll motor 465. The brush roll motor controller 415 varies the power provided to the brush roll motor 465 to vary the rotational speed of a brush roll that is driven by the brush roll motor 465. In some embodiments, the brush roll motor controller 415 uses pulse-width modulation (PWM) signals to control the brush roll motor 465.

The fluid distribution system controller 420 is connected to the controller 405 and controls the fluid distribution system 470. The fluid distribution system 470 includes a pump and/or a valve. The fluid distribution system controller 420 controls the distribution of fluid to the surface to be cleaned. In some embodiments, the fluid distribution system controller 420 actuates the valve or the pump to provide fluid to the surface. For example, the fluid distribution system controller 420 varies the fluid distribution from the pump by changing the power supplied to the pump. In some embodiments, the fluid distribution system controller 420 controls whether the pump is on or off. As another example of the fluid distribution system controller 420 controlling the fluid distribution system 470, the fluid distribution system controller 420 may vary the power provided to the pump in order to vary a fluid flow rate, providing two or more non-zero flow rates. In some embodiments, the fluid distribution system controller 420 varies the fluid distribution from the valve by opening and closing the valve. Additionally, or alternatively, in some embodiments, the valve is configured by the fluid distribution system controller 420 for providing two or more non-zero flow rates.

The user interface 430 is connected to the controller 405 and communicates with the suction motor controller 410, the brush roll motor controller 415, and the fluid distribution system controller 420. In some embodiments, the user interface 430 is configured to enable a user to select an operational mode that operates the vacuum cleaner 100 or extractor 200 at a predetermined suction level and/or brush roll speed. In some embodiments, the user interface 430 includes a first mode selector button that is configured to switch between operating modes upon each press of the first mode selector button. For example, the user may press the first mode selector button multiple times until they reach the operating mode that they require.

The control system 400 operates the floor cleaner according the operating mode. For example, the floor cleaner may be the vacuum cleaner 100 or the extractor 200. In some embodiments, the operation modes correspond to different power levels for operating the suction motor 460. In one embodiment, the control system 400 includes five predetermined operational power levels from 100 W to 300 W. In some embodiments, the operation modes correspond to modes selected from high suction, high rotational speed brush roll; high suction, low rotational speed brush roll; high suction, brush roll off; medium suction, high rotational speed brush roll; medium suction, low rotational speed brush roll; medium suction, brush roll off; low suction, low rotational speed brush roll; and low suction, brush roll off. Various other suction levels and brush roll speeds are contemplated.

In some embodiments, the suction motor controller 410 provides power in the range of 200 W to 300 W to the suction motor 460 when the suction motor 460 is operating in the high suction operating mode. In some embodiments, the suction motor controller 410 provides power in the range of 150 W to 200 W to the suction motor 460 when the suction motor 460 is operating in the medium suction operating mode. In some embodiments, the suction motor controller 410 provides power in the range of 75 W to 150 W to the suction motor 460 when the suction motor 460 is operating in the low suction operating mode.

In some embodiments, the brush roll motor controller 415 operates the brush roll motor 465 to provide a brush roll speed greater than 2500 RPM when the brush roll motor 465 is operating in the high brush roll operating mode. In some embodiments, the brush roll motor controller 415 operates the brush roll motor 465 to provide a brush roll speed in the range of 1000 RPM to 2500 RPM when the brush roll motor 465 is operating in the medium brush roll operating mode. In some embodiments, the brush roll motor controller 415 operates the brush roll motor 465 to provide a brush roll speed between 100 RPM and 1000 RPM when the brush roll motor 465 is operating in the low brush roll operating mode.

In some embodiments, the operating modes correspond to various surfaces that are cleaned by a floor cleaner. For example, the floor cleaner may be the vacuum cleaner 100 or the extractor 200. In some embodiments, the surface operating modes correspond to modes selected from carpet mode (e.g. high suction, high rotational speed brush roll), low pile carpet mode (e.g. high suction, low rotational speed brush roll), high pile carpet mode (e.g. medium suction, low rotational speed brush roll), surface mode (e.g. medium suction, low rotational speed brush roll), hard floor mode (e.g. high suction, brush roll off), floor mat mode (e.g. medium suction, brush roll off), rug mode (e.g. low suction, low rotational speed brush roll), delicate surface mode (e.g. low suction, brush roll off), and hose accessory tool mode (e.g. high suction, brush roll off). Various other suction levels and brush roll speeds can be used in the above surface operating modes and other surface operating modes as desired for the application.

In some embodiments having the fluid distribution system 470, the operating modes include various levels of fluid distribution. In some embodiments, the operating modes correspond to modes selected from high flow rate, medium flow rate, low flow rate, and fluid distribution off. In some embodiments, the fluid distribution may be in addition to varying suctions levels and/or brush roll rotational speeds.

In some embodiments, the fluid distribution system controller 420 operates the fluid distribution system 470 with a fluid flow rate between 200 and 400 mL/min when in the high flow rate operating mode. In some embodiments, the fluid distribution system controller 420 operates the fluid distribution system 470 with a fluid flow rate between 100 and 200 mL/min when in the medium flow rate operating mode. In some embodiments, the fluid distribution system controller 420 operates the fluid distribution system 470 with a fluid flow rate between 50 and 100 mL/min when in the low flow rate operating mode.

In some embodiments, the controller 405 saves the operating mode that the floor cleaner is operating in prior to the floor cleaner being turned off and initiate the saved operating mode the next time the floor cleaner is turned on.

In some embodiments, the user interface 430 includes a “favorite” button that allows a user to return to one or more favorite operating modes and/or power levels by actuating the “favorite” button. The user may quickly choose the “favorite” button on the user interface 430 and the control system 400 will operate according to the programed operating mode. In one embodiment, a user programs a first favorite mode that corresponds to one press of the “favorite” button and a second favorite mode that corresponds to two presses of the “favorite” button. For example, the user may use a first operating mode that is suitable for cleaning hardwood floors and a second operating mode that is suitable for cleaning delicate area rugs. Programming the “favorite” button enables the user to efficiently get between the operating modes they most use.

In some embodiments, the user programs the “favorite” button by performing a predetermined setting activity. For example, when the cleaner is operating in a favored mode the user may hold down the “favorite” button for a duration of time (e.g., 3 seconds, 5 seconds, etc.), or simultaneously press the “favorite” button and the operating mode button, or press a combination or sequence of buttons on the user interface 430. In some embodiments, the “favorite” button is programmed automatically when the control system 400 determines an operating mode that is used for a greater amount of time than other operating modes. For example, the control system records the amount of time the cleaner operates in each mode over a duration, for example 1 operating hour, or 2 operating hours, or other desired operating time. The control system assigns the mode having the greatest value of accumulated time over the duration to be the “favorite” mode. Additionally, or alternatively, the control system 400 may consider an operating mode a favorite when a user has operated the floor cleaner in that operating mode for a certain duration of time.

In some embodiments, the user interface 430 does not include a dedicated “favorite” button and the control system 400 changes to a favorite operating mode when the user interacts with an operating mode button or other button on the user interface 430. For example, the user performs a predetermined setting activity to set the current operating mode as a favorite operating mode. The use may then double tap the operating mode button or perform another predetermined sequence to return to the favorite operating mode when operating the floor cleaner.

In some embodiments, the control system 400 and the user interface 430 are configured to enable the user to return to the previous mode, or “prior mode,” in which the user operated the cleaner. In some embodiments, the user interface 430 includes a “prior” button that a user may select to operate the floor cleaner in the last known operating mode. The controller 405 determines and stores the current operating mode within the memory 450. When the user changes the operating mode and a new current operating mode is determined, the mode that was previously the current operating mode becomes the prior operating mode and is assigned to be activated when the “prior” button is actuated. To avoid accidental or unintended settings, in one embodiment the control system 400 determines the current operating mode after the cleaner remains operating in the mode for more than a predetermined number of seconds, such as 5 seconds, or 10 seconds, or other desired operating time.

The control system 400 operates the floor cleaner using power from the battery pack 440. For example, the battery pack may be one of an 18V 2.0 Ah pack, 18V 3.0 Ah pack, and an 18V 4.0 Ah pack. The controller 405 communicates with a battery management system of the battery pack 440 that monitors the battery cells and the state of charge of the battery cells. The controller 405 determines the battery pack 440 capacity and status of the battery pack 440 charge based on the communication with the battery management system. The controller 405 communicates with the suction motor controller 410, the brush roll motor controller 415, and/or the fluid distribution system controller 420 to adjust the power level provided to the components of the floor cleaner in accordance with the battery pack 440 capacity and/or charge level.

In some embodiments, the communication between the controller 405 and the battery management system of the battery pack 440 includes information for the controller 405 to determine the type of battery and/or the capacity of the battery. In some embodiments, the battery management system calculates its state of charge and output voltage and communicates them to the controller 405. In some embodiments, the controller 405 measures the battery pack 440 output voltage and calculates the state of charge based on the type of battery and/or the capacity of the battery.

In some embodiments, the controller 405 uses the output voltage of the battery pack 440 as an indicator of the battery pack 440 charge level and operates the floor cleaner based on the battery pack 440 voltage. The controller 405 may control the power output level from the battery pack 440 based on the battery pack 440 voltage. The adjustment of the power output level is by way of PWM duty cycle.

In some embodiments, the battery pack 440 may define a charged voltage and a shut-off voltage. The shut-off voltage is a predetermined voltage at which the battery pack 440 ceases to deliver power to the control system 400 because the battery cells are depleted. The charged voltage is a voltage at which the battery pack 440 is considered to be charged. For one example 18V battery pack, the charged voltage is about 20 volts and the shut-off voltage is 13.5 volts.

The controller 405 is configured to provide power to the various components of the control system 400 based on the battery pack 440 voltage. The controller 405 communicates with the suction motor controller 410 to provide power to the suction motor 460. In some embodiments, the suction motor controller 410 uses a PWM duty cycle to maintain a predetermined average voltage of the suction motor 460. In another embodiment, the suction motor controller 410 also uses measured current through the suction motor 460 and uses a PWM duty cycle to maintain a predetermined power of the suction motor 460. More specifically, the suction motor controller 410 uses a PWM duty cycle to limit the battery pack 440 voltage to an average voltage and multiplies the measured current and the average voltage to calculate an effective power level. The suction motor controller 410 continually calculates and monitors the effective power level and adjusts the PWM duty cycle to adjust the average voltage to maintain a predetermined effective power level. To maintain the power, the suction motor controller 410 uses a proportional-integral-derivative controller (PID control) based on the battery voltage communicated to the suction motor controller 410 via the controller 405 and measured current signals of the suction motor 460 sensed from a sampling circuit within the suction motor controller 410.

In some embodiments, the controller 405 may reduce the power level drawn from the battery pack 440 in order to extend the run time of battery packs having smaller capacities. Specifically, the controller 405 may operate the suction motor 460 at a higher power level for battery packs having a larger capacity and operate the suction motor 460 at a decreased power for battery packs having a smaller capacity to extend the runtime of the smaller capacity battery packs. For example, the controller 405 may operate at the suction motor 460 at a higher power level for a 4.0 Ah battery pack and at a lower power output for a 2.0 Ah and 3.0 Ah battery packs.

In some embodiments, the controller 405 determines the battery capacity of the battery pack 440 when the floor cleaner is turned on by communication with the battery management system. The suction motor controller 410 operates the suction motor 460 using a PWM duty cycle to maintain a predetermined effective power level of the suction motor 460. The PWM duty cycle may be selected according to the capacity of the battery pack 440. For one example, with a 2.0 Ah pack the suction motor 460 power level will be set at 260 W, 280 W for a 3.0 Ah pack, and 300 W for a 4.0 Ah pack. In another example, with a 2.0 Ah pack the suction motor 460 power level will be set at 150 W, 200 W for a 3.0 Ah pack, and 250 W for a 4.0 Ah pack. The predetermined power levels are set suitable for the application and the battery packs available for the application, considering run time to deplete a battery pack, expected use environment of the cleaner, anticipated user expectations, and cleaner performance at various power levels.

The suction motor controller 410 monitors the battery pack 440 voltage applied to the suction motor 460 and the current through the suction motor 460 and adjusts the duty cycle to maintain the effective power level. The PWM duty cycle reaches 100% when the battery pack 440 voltage drops to the voltage required to maintain the predetermined power level (the constant power threshold). When the battery pack voltage drops to the constant power threshold, the suction motor controller 410 operates the suction motor 460 at 100% duty cycle until the battery pack 440 voltage drops to the predetermined shut-off voltage. When the battery pack reaches the shut-off voltage, one or both of the battery management system and controller 405 stop power to turn off the floor cleaner.

The controller 405 may control the operation of a floor cleaner based on the operational state of the floor cleaner. For example, the controller 405 may determine whether the floor cleaner is operated in a forward direction, a rearward direction, and/or if the floor cleaner has been lifted off a surface that is being cleaned. Cleaning is typically effective in both the forward and rearward directions. However, operating the floor cleaner in a forward direction may yield a higher efficiency than the rearward direction. Further, the floor cleaner may be less efficient when the floor cleaner is lifted above the surface that is being cleaned. In order to save power consumption, the controller 405 may detect the motion and status of the floor cleaner and control the operation of the floor cleaner based on the motion and status of the floor cleaner.

In some embodiments, the controller 405 determines when the cleaner is in a forward movement or stroke, and when the cleaner is in a rearward movement or stroke based on sensor data from at least one of the sensors 425. The detection could be based on sensed current of the brush roll motor 465, and/or the suction motor 460, and/or the rotational direction of wheels on the floor cleaner in contact with the floor or other surface to be cleaned. In some embodiments, the controller 405 monitors the current of the brush roll motor 465 to determine when the unit is moving forward and rearward. On many surfaces, the load on the brush roll motor 465 increases when the cleaner moves rearward. The controller 405 correlates the increase in brush roll motor current to the rearward movement and controls the operation of the floor cleaner for rearward movement. When the brush roll motor current reduces on the forward stroke, the controller 405 correlates the decrease in brush roll motor current to the forward movement and controls the operation of the floor cleaner for forward movement.

In some embodiments, a sensor of the sensors 425 is provided on the floor cleaner to monitor the rotation of one or more wheels in contact with the surface. For example, a magnet is provided on the wheel and one or more hall effect sensors are provided on the floor cleaner. The controller 405 monitors the sensor to determine when the floor cleaner is moving forward and rearward.

The controller 405 is configured to operatively provide power to the suction motor 460, via the suction motor controller 410. The suction motor controller 410 increases and decreases power to the suction motor 460 based on whether the cleaner is in forward motion or rearward motion. In one embodiment, the suction motor controller 410 provides a high power to the suction motor 460 for forward movement and a lower power to the suction motor 460 for rearward movement. For example, the suction motor controller 410 applies between 200 and 300 W to the suction motor 460 in the forward stroke and between 75 and 150 W to the suction motor 460 in the rearward stroke.

In one embodiment, the controller 405 monitors whether the floor cleaner has been lifted from the ground. In one embodiment, the brush roll motor controller 415 monitors the current of the brush roll motor 465 and the controller 405 may determine when the floor cleaner is lifted from the surface based on a change in current. For example, when the floor cleaner is lifted, the brush roll will rotate largely unobstructed, thereby reducing the current of the brush roll motor 465 to a minimum. The controller 405 correlates the low current of the brush roll motor 465 to being lifted and controls the operation of the floor cleaner for being lifted. In some embodiments, the suction motor controller 410 reduces the power to the suction motor 460 when the floor cleaner is lifted. In some embodiments, the brush roll motor controller 415 reduces the power to the brush roll motor 465 when the cleaner is lifted.

In one embodiment, the floor cleaner incudes a lift sensor, and the controller 405 monitors the lift sensor to determine when the floor cleaner has been lifted.

As is evident by the above disclosure, the components of the control system 400 are connected and communicate with one another. In some embodiments, the physical components that correspond to the components of the control system 400 are integrated on a single unitary printed circuit board (PCB). In prior cleaners, motor controllers were provided on a PCB associated with the motor. For example, a prior motor controller for a BLDC suction motor was provided on a motor control board that accompanied the suction motor. In one present embodiment, the controllers are combined onto one PCB. For example, the suction motor controller 410, the brush roll motor controller 415, and/or the fluid distribution system controller 420 may be combined with the other control system components on a single PCB. The combined PCB can also control the power on/off of the brushed motor for the brush roll.

FIGS. 6-7 are a block diagram of a method 500 of operating a floor cleaner according to some embodiments. The floor cleaner may be one of the vacuum cleaner 100 and the extractor 200. At block 505, the floor cleaner receives a first battery pack in the battery receptacle. For example, the battery pack may be one of a 18V 2.0 Ah pack, a 18V 3.0 Ah pack, and a 18V 4.0 Ah pack. The battery pack includes a first battery management system (i.e., a first battery pack controller). At block 510, the controller 405 receives a first signal from the first battery pack indicative of the first battery pack capacity. In some embodiments, the first battery pack controller communicates the first signal to the controller 405 indicative of the first battery pack capacity. In some embodiments, the controller 405 reads a code or other information from or on the first battery pack and generates the first signal indicative of the first battery pack capacity. At block 515, the controller 405 outputs a first control signal in response to receiving the first signal. In some embodiments, the controller outputs the first control signal to at least one of the suction motor controller 410, the brush roll motor controller 415, and the fluid distribution system controller 420. At block 520, the controller 405 operates a motor at a first predetermined constant power based on the first control signal. For example, the suction motor controller 410 may operate the suction motor 460 based on the first control signal from the controller 405. In some embodiments, the suction motor 460 is operated to maintain a first predetermined power using a PWM signal. For one example, the first battery pack may be a 4.0 Ah pack, and the first signal indicative of the 4.0 Ah capacity, and the suction motor controller 410 may operate the suction motor 460 at a first predetermined power of 300 W.

At block 525, the floor cleaner receives a second battery pack in the battery receptacle. In some embodiments, the first battery pack must be removed from the battery receptacle for the floor cleaner to receive the second battery pack. At block 530, the controller 405 receives a second signal from a second battery pack controller indicative of the second battery pack capacity. At block 535, the controller 405 outputs a second control signal in response to receiving the second signal from the second battery pack. At block 540, the controller 405 operates the motor to maintain a second predetermined constant power. For example, the suction motor controller 410 may operate the suction motor 460 based on the second control signal from the controller 405. For one example, the second battery pack may be a 2.0 Ah pack, and the second signal indicative of the 2.0 Ah capacity, and the suction motor controller 410 may operate the suction motor 460 at a second predetermined power of 260 W. The method 500 proceeds to block A of FIG. 7.

At block 545, the controller 405 receives a third signal from the second battery pack controller. In some embodiments, the third signal is the voltage signal of the second battery pack. For example, the third signal may indicate the voltage of the second battery pack is less than a fully charged voltage. At block 550, the controller 405 outputs a third control signal in response to receiving the third signal from the second battery pack. At block 555, the controller 405 operates the motor at 100% duty cycle. When the third signal indicates that the battery voltage is at the constant power threshold, the suction motor controller 410 operates the suction motor 460 at 100% duty cycle until the battery pack 440 reaches the shut-off voltage.

At block 560, the controller 405 receives a fourth signal from the second battery pack controller. In some embodiments, the fourth signal is the voltage signal of the second battery pack indicating the voltage of the second battery pack is at a shut-off voltage. At block 565, the controller 405 outputs a fourth control signal in response to receiving the fourth signal from the second battery pack. At block 555, the controller 405 ceases operation of the motor based on the fourth control signal. In some embodiments, the suction motor controller 410 ceases operation of the suction motor 460 based on the voltage of the second battery pack being at the shut-off voltage.

FIG. 8 is a block diagram of a method 700 of operating a floor cleaner according to some embodiments. The floor cleaner may be one of the vacuum cleaner 100 and the extractor 200. At block 705, the controller 405 receives an input. In some embodiments, the input is from the user interface 430 that is connected to and in communication with the controller 405. At block 710, the controller 405 determines whether the input was a first input or a second input. In some embodiments, the first input corresponds to a first button on the user interface 430 and the second input corresponds to a second button on the user interface. In some embodiments, one of the inputs indicates a favorite operating mode. If the controller 405 determines that the input is a first input, the method 700 proceeds to block 715. At block 715, the controller 405 operates the floor cleaner according to the first input. If the controller 405 determines that the input is a second input, the method 700 proceeds to block 720. At block 720, the controller 405 operates floor cleaner according to the second input. In some embodiments, the first input and the second input correspond to operating modes of the floor cleaner. For example, the first input may correspond to a favorite operating mode.

FIG. 9 is a block diagram of a method 800 of operating a floor cleaner according to some embodiments. The floor cleaner may be one of the vacuum cleaner 100 and the extractor 200. At block 805, the controller 405 receives a sensor signal. In some embodiments, the sensor signal is from a sensor within the floor cleaner that senses whether the floor cleaner is being moved in a forward direction or a rearward direction. At block 810, the controller 405 determines whether the sensor signal was a first signal or a second signal. In some embodiments, the first signal corresponds to the forward direction and the second signal corresponds to the rearward direction. If the controller 405 determines that the sensor signal is a first signal, the method 800 proceeds to block 815. At block 815, the suction motor controller 410 operates the suction motor 460 at a first average voltage and/or first average power. If the controller 405 determines that the sensor signal is a second signal, the method 800 proceeds to block 820. At block 820, the suction motor controller 410 operates the suction motor 460 at a second average voltage and/or second average power. In some embodiments, the first average voltage and first average power are greater than the second average voltage and the second average power.

FIG. 10 is a block diagram of a method 900 of operating a floor cleaner according to some embodiments. The floor cleaner may be one of the vacuum cleaner 100 and the extractor 200. At block 905, the controller 405 receives a first sensor signal and a second sensor signal. In some embodiments, the sensor signals are from a sensor within the floor cleaner that senses the brush roll motor 465 current. In some embodiments, the sensor signals are from a sensor within the floor cleaner indicative of the direction of cleaner movement. At block 910, the controller 405 determines whether there is a difference between the first sensor signal and the second sensor signal. If the controller 405 determines that there is a not difference between the first sensor signal and the second sensor signal, the method 900 proceeds to block 915. At block 915, the controller 405 determines that the floor cleaner is moving in the forward direction. The brush roll motor 465 current does not change as the floor cleaner moves in the forward direction. If the controller 405 determines that there is a difference between the first sensor signal and the second sensor signal, the method 900 proceeds to block 925. At block 920, the controller 405 determines that the cleaner is moving in a rearward direction. The brush roll motor 465 current increases as the floor cleaner moves rearward, and the controller 405 determines the rearward direction based on the change in current. The controller 405 continuously calculates the difference in sensor signals to determine the direction that the floor cleaner is moving.

FIG. 11 is a block diagram of a method 1000 of operating a floor cleaner according to some embodiments. At block 1005, the controller 405 receives a lift signal. In some embodiments, the lift signal is received from a sensor that monitors the current of the brush roll motor 465. When the floor cleaner is lifted, the brush roll motor 465 current is reduced to a minimum. In some embodiments, the sensor signals are from a sensor within the floor cleaner indicative of the cleaner being lifted. At block 1010, the controller 405 determines that the floor cleaner has been lifted from the surface that it is cleaning. At block 1015, the controller 405 sends signals to the suction motor controller 410 and the brush roll motor controller 415 to operate the suction motor 460 and the brush roll motor 465 at a reduced power, respectively.

Thus, embodiments described herein provide, among other things, systems and methods of controlling a floor cleaner. Various features and advantages are set forth in the following claims.

Claims

1. A cleaner comprising: a housing including a base portion that is movable along a surface to be cleaned;a suction motor within the housing, the suction motor operable to create a suction airflow from a suction inlet to an exhaust outlet;a sensor within the housing, the sensor operable to generate a sensor signal as a first signal corresponding to the cleaner moving in a forward direction along the surface and a second signal corresponding to the cleaner moving in a rearward direction along the surface; anda control system configured to receive the sensor signal, wherein the control system controls operation of the suction motor based on the received sensor signal; anda brush roll disposed adjacent the suction inlet, the brush roll driven by a brush roll motor,wherein the sensor measures a brush roll motor current and determines movement in the forward direction and rearward direction based on a relative difference between the first signal and the second signal.

2. The cleaner of claim 1, wherein the control system operates the suction motor at a first power when the control system receives the first signal and a second power when the control system receives the second signal, wherein the first power is greater than the second power.

3. The cleaner of claim 1, wherein the control system operates the suction motor at a first average voltage when the control system receives the first signal and a second average voltage when the control system receives the second signal, wherein the first average voltage is greater than the second average voltage.

4. The cleaner of claim 1 further comprising: a lift sensor operable to generate a lift signal when the cleaner is lifted from the surface,wherein the control system operates the suction motor at a reduced power when the control system receives the lift signal.

5. The cleaner of claim 4, wherein the control system operates a brush roll motor at a reduced power when the control system receives the lift signal.

6. A method of operating a cleaning system, the method comprising: receiving a first battery pack including a first battery controller;receiving a first signal from the first battery controller indicative of a first battery pack capacity;outputting, in response to receiving the first signal, a first control signal;operating a motor at a first predetermined constant power based on the first control signal;receiving a second battery pack including a second battery controller;receiving a second signal from the second battery controller indicative of a second battery pack capacity;outputting, in response to receiving the second signal, a second control signal; andoperating the motor at a second predetermined constant power based on the second control signal.

7. The method of claim 6, wherein the motor is a suction motor.

8. The method of claim 6 further comprising: operating the motor at the first predetermined constant power based on a first PWM signal.

9. The method of claim 8 further comprising: continuously calculating the first PWM signal based on the first signal to provide an average voltage to maintain the motor at the first predetermined constant power.

10. The method of claim 8 further comprising: receiving a third signal from the second battery controller;outputting, in response to receiving the third signal, a third control signaloperating the motor at 100% PWM duty cycle;receiving a fourth signal from the second battery controller; andoutputting, in response to receiving the fourth signal, a fourth control signal ceasing operation of the motor.

11. The method of claim 10, wherein the third signal is indicative of a constant power threshold.

12. The method according to claim 6, wherein the first battery pack capacity is greater than the second battery pack capacity, and wherein the first predetermined constant power is greater than the second predetermined constant power.

13. The method of claim 6, wherein receiving the first battery pack includes receiving the first battery pack in a battery receptacle, and wherein receiving the second battery pack includes receiving the second battery pack in the battery receptacle.

14. The method of claim 6, wherein the first control signal includes a signal indicative of a first battery voltage and the second control signal includes a signal indicative of a second battery voltage.

15. A cleaner comprising: a suction motor operable to create a suction airflow from a suction inlet to an exhaust outlet;a control system configured to control the suction motor operable at predetermined suction levels corresponding to a plurality of user selectable modes; anda user interface operatively connected to the control system, the user interface having a first user-actuatable input and a second user-actuatable input;wherein the first user-actuatable input is configured to select and operate the control system from among the plurality of user selectable modes;wherein one of the plurality of user selectable modes is a favored mode; andwherein the second user-actuatable input is configured to operate the control system in the favored mode.

16. The cleaner of claim 15, wherein the favored mode is user selected, and wherein the control system and the user interface are configured to receive input from the user interface identifying a predetermined setting activity assigning the favored mode to the second user-actuatable input.

17. The cleaner of claim 15, wherein the control system determines the favored mode by recording an amount of time the cleaner operates in each of the plurality of modes over a duration, and wherein the control system assigns the second user-actuatable input to activate the mode having a greatest value of accumulated time in which the cleaner operates over the duration.

18. The cleaner of claim 15, wherein the control system determines the favored mode by assigning the second user-actuatable input to activate the mode in which a user previously operated the cleaner.

19. The cleaner of claim 15 further comprising: a brush roll disposed adjacent the suction inlet, the brush roll driven by a brush roll motor,wherein the control system is configured to control the brush roll motor operable at predetermined speeds corresponding to the plurality of user selectable modes.

20. The cleaner of claim 19, wherein the plurality of user selectable modes includes a mode having a combination of a suction motor power level and a brush speed.

21. The cleaner of claim 20, wherein the suction motor power level is one of high suction, medium suction, and low suction.

22. The cleaner of claim 20, wherein the brush speed is one of high rotational speed, medium rotational speed, low rotational speed, and no speed.

23. The cleaner of claim 19 further comprising: a fluid distribution system operable to deliver fluid to a surface to be cleaned,wherein the control system is configured to control the fluid distribution system operable at a plurality of predetermined fluid flow rates corresponding to the plurality of user selectable modes.

24. The cleaner of claim 23, wherein the plurality of user selectable modes includes a mode having a combination of at least two of a suction motor power level, a brush speed, and a fluid flow rate.

25. The cleaner of claim 24, wherein the suction motor power level is one of high suction, medium suction, and low suction.

26. The cleaner of claim 24, wherein the brush speed is one of high rotational speed, medium rotational speed, low rotational speed, and no speed.

27. The cleaner of claim 24, wherein the fluid flow rate is one of high flow rate, medium flow rate, low flow rate, and no fluid distribution.

28. A cleaner comprising: a suction motor operable to create a suction airflow from a suction inlet to an exhaust outlet; anda control system configured to control operations of the cleaner and the suction motor, the control system including: a motor control circuit operable to control at least one of an average voltage of the suction motor and a power of the suction motor; anda cleaner control circuit operable to control operations of the cleaner;wherein the motor control circuit and the cleaner control circuit are disposed on a first circuit board.

29. The cleaner of claim 28, wherein the suction motor is one of a permanent magnet direct current motor and a brushless direct current suction motor.

30. The cleaner of claim 28 further comprising: a brush roll disposed adjacent the suction inlet, the brush roll driven by a brush roll motor,wherein the control system further comprises a brush roll motor control circuit, andwherein the brush roll motor control circuit is disposed on the first circuit board.