Priority is claimed to German Patent Application No. DE 10 2013 102 847.0, filed on Mar. 20, 2013, the entire disclosure of which is hereby incorporated by reference herein.
The present invention relates firstly to a method for adjusting the power of the fan of a vacuum cleaner. The present invention further relates to a control system for implementing the method, and finally also to a vacuum cleaner having a control system for carrying out the method.
High-quality vacuum cleaners allow for automatic control of the suction power. The purpose of this is, on the one hand, to maintain the force required to push the floor nozzle at low levels and, on the other hand, to adapt the power to the floor covering to be cleaned. Control is performed as a function of the measured vacuum as the controlled variable, which is measured at a characteristic point, such as the floor nozzle or the suction connector. The vacuum may be measured using analog-output vacuum sensors, vacuum switches with two switching points, or vacuum switches with a single switching point. Adaptation of the fan power is accomplished, for example, using leading-edge phase angle control. In this case, a phase angle is used as the manipulated variable. The analysis of the sensor signals, the adjustment of the manipulated variable, as well as potential further measurements are usually performed by a microcontroller, hereinafter generally referred to as “electronic control system”.
Analog-output vacuum sensors have the advantage of allowing the deviation from the setpoint to be accurately measured at all times. Therefore, they allow for best control performance. In addition, they are fast and accurate. This advantage is counterbalanced by the relatively high cost of such an analog vacuum sensor. A more cost-effective variant is provided by vacuum switches with two switching points (or, alternatively, by two vacuum switches having different switching points): The setpoint of the controlled variable is between the two switching points (vacuum values), and the fan power can be reliably controlled into the desired target range. Thus, the selected power varies within the setpoint range between the two switching points. An even more cost-effective variant would be to use only one vacuum switch.
The older, not previously published European Patent Application No. 12401010.9 of the applicant proposes a design in which only one vacuum switch having a single switching point is used for adjusting the power of a vacuum cleaner fan. This patent provides that during a first operating phase, the control system of the vacuum cleaner determines, based on the switching point of the vacuum switch, characteristic parameters for determining an operating point of the vacuum cleaner fan. In the first operating phase, a manipulated variable for the fan power is adjusted such that the vacuum switch changes its state as soon as possible. The characteristic parameters for determining the operating point of the vacuum cleaner fan are derived from the time elapsed up to this switch state change and the fan power at the switch state change, more precisely a difference between a maximum power and the fan power at the switch state change. The operating point is approached under the control of the control system by inputting a corresponding manipulated variable. Subsequently, the manipulated variable is changed only slowly. In the process, the manipulated variable is, for example, gradually reduced until the vacuum switch opens. Then, the manipulated variable is gradually increased until the vacuum switch closes, etc. Accordingly, the fan power affected by the manipulated variable oscillates at a low frequency about the operating point of the vacuum cleaner fan.
In an embodiment, the present invention provides a method of adjusting the power of a vacuum cleaner fan comprising a vacuum switch having a single switching point. The method includes tapping off a signal via the vacuum switch. The method also includes filtering the tapped off signal to obtain a resulting signal, the resulting signal being a measure of the vacuum pressure created by the vacuum cleaner fan. The method further includes using the resulting signal as a controlled variable for adjusting the fan power with an electronic control system.
The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. All features described and/or illustrated herein can be used alone or combined in different combinations in embodiments of the invention. The features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
Anaspect of the present invention to provide a way of adjusting the power of a vacuum cleaner fan based on a vacuum switch having a single switching point In particular, an aspect of the present invention is to provide a method for adjusting the power of a vacuum cleaner fan that is not based on iterative approximation to the switching point of the vacuum switch.
In an embodiment, the present invention provides a method in which an electronic control system adjusts the fan power via a suitable manipulated variable as a function of a vacuum created by the vacuum cleaner fan, and a measure of the vacuum pressure is ascertained using a vacuum switch having a single switching point, where a signal that can be tapped off above the vacuum switch is filtered, in particular low-pass filtered, and a signal obtained after filtering is used as a measure of the vacuum pressure and as a controlled variable for adjusting the fan power.
An advantage of the solution proposed herein resides in the discovery that the signal that can be tapped off above the vacuum switch at a vacuum pressure close to the switching point of the vacuum switch, and, above all, the ON time of the pulses in the signal, are directly proportional to the pressure differential applied, and thus to the vacuum created by the vacuum cleaner fan. The vacuum conditions are determined by evaluating the changing states of the pressure switch in the time range of the changeover of the switch. In the region of the switching point, a so-called “switch bouncing” occurs, as a result of which a sequence of pulses having the amplitude of the control voltage (e.g., 5 V) is output. These pulses are then low-pass filtered or arithmetically averaged, resulting in a signal which is then made available as a quasi-analog instantaneous signal for the control or adjustment of the fan power. In other words, the signal that can be tapped off is a sequence of pulses which are produced by the bouncing of the vacuum switch during the changeover phase, and the sequence of pulses is filtered for a predetermined period of time in order to determine the actual value as a measure of the sensed vacuum.
Filtering, in particular low-pass filtering, of this signal results in smoothing of the signal, so that a signal proportional to the vacuum is obtained which can be used to adjust the power of a vacuum cleaner fan. By generating a signal proportional to the vacuum, the vacuum switch which, per se, only provides a purely digital output signal can be used like an analog vacuum sensor. This is achieved by smoothing the output signal of the vacuum switch.
Thus, in accordance with the approach proposed herein, a simple and inexpensive vacuum switch can be used in substantially the same way as a complex and, in particular, expensive analog pressure sensor in a control system for adjusting the power of a vacuum cleaner fan. The vacuum switch, together with its associated circuitry, then functions as an analog pressure sensor. This justifies that the vacuum switch and its associated circuitry for filtering its output signal are together sometimes referred to as “vacuum sensor” hereinafter.
In comparison with previous approaches which use a vacuum switch having exactly one switching point and attempt to maintain an operating point of the fan close to the switching point, more reliable control is achieved without the heretofore system-inherent swinging or at least low-frequency oscillation about the operating point. In general, the concept proposed herein can be used for any application that previously used conventional pressure sensors which monitored only one specific value. In accordance with the approach described herein, it is now possible to use inexpensive vacuum switches in such applications.
In an embodiment, a vacuum cleaner control system adapted to adjust the power of a vacuum cleaner fan is provided with a device for carrying out a method as described here and below. In an embodiment of the method, a value between a minimum value of the resulting signal and a maximum value of the resulting signal is provided as a setpoint to the control system for control. In any case, such a setpoint is within a measurement range of the vacuum sensor provided by the vacuum switch, which measurement range is bounded by the minimum value and the maximum value. In an embodiment of the method, the setpoint used for control is a value exactly in the middle between the minimum value and the maximum value. During control, the measurement range of the vacuum sensor provided by the vacuum switch is then optimally used.
In a further embodiment of the method, a lower threshold and an upper threshold are defined above the minimum value and respectively below the maximum value of the resulting signal of the vacuum sensor provided by the vacuum switch. When the instantaneous value of the signal picked up as an actual value for adjusting the power of a vacuum cleaner fan is between the lower and upper thresholds, a controller of the control system is activated which maintains the respective actual value close to the setpoint. When the instantaneous value is below the lower threshold or above the upper threshold, a controller is activated which brings the actual value at least back into a range between the two thresholds. This controller may be the same one onto which, for example, different amplification factors are imposed according to the respective location of the actual value. Alternatively, it is also possible to use at least two controllers in the control system and switch back and forth between them according to the respective location of the actual value.
In order to carry out an embodiment of the method, there is provided a control system intended for use in a vacuum cleaner. Such a vacuum cleaner control system adapted to adjust the power of a vacuum cleaner fan includes means which make it possible to carry out a method as described here and below.
The device provided for carrying out the method includes a vacuum switch having a single switching point and a filter provided in communication with the vacuum switch. The filter is electrically connected in parallel to the vacuum switch and filters a signal that can be tapped off above the vacuum switch.
In an embodiment of the control system, the filter is a low-pass filter. If the low-pass filter takes the form of an RC circuit, it is particularly simple in design, yet satisfies the purposes of the application presented here. A low-pass filter of this kind is inexpensive, and the filter characteristics can be easily defined and controlled by using a variable resistance and/or a variable capacitance.
In another embodiment of the control system, there is provided a plurality of series-connected vacuum switches which each have exactly one switching point. A filter for filtering the signal that can be tapped off above the series connection of vacuum switches is arranged electrically in parallel with the series connection of vacuum switches. Such a series connection of a plurality of vacuum switches makes it possible to extend the measurement range of the vacuum sensor so formed. Extension of the measurement range results in an extended value range within which the control system can maintain the resulting vacuum as close as possible to the predetermined setpoint by adjusting the power of the vacuum cleaner fan.
Overall, the present invention is also a vacuum cleaner having means for carrying out a method as described here and below. A control system having the features described here and below may be used as the means for carrying out such a method.
Altogether, the approach presented herein also proposes a novel use of a vacuum switch, namely the use of a vacuum switch together with a special circuitry associated therewith as a vacuum sensor. The vacuum switch concerned is one having a single switching point. The circuitry is special in that a filter is provided in communication with the vacuum switch and electrically connected in parallel therewith to filter a signal that can be tapped off above the vacuum switch. The filter may be, for example, a low-pass filter. The vacuum sensor so formed provides an analog sensor signal, which means that during operation of such a vacuum sensor, an analog sensor signal can be tapped off therefrom. According to the above-mentioned principle, such a vacuum sensor can be upgraded to one with extended measurement range by using a plurality of vacuum switches which each have different switching points. Instead of a plurality of vacuum switches which each have one switching point, it is then also possible to use one or more vacuum switches having a plurality of switching points. This relativizes the condition formulated throughout herein to facilitate the understanding of the description, according to which a vacuum switch having exactly one switching point or at least one vacuum switch having exactly one switching point is used. If more than one vacuum switch having exactly one switching point is used, then the use of one or more vacuum switches having a plurality of switching points is an equivalent embodiment which, in any case, is understood as being encompassed by the specification “a plurality of vacuum switches which each have exactly one switching point.”
An exemplary embodiment of the present invention is shown in the drawings in a purely schematic way and will be described in more detail below. Corresponding objects or elements are identified by the same reference numerals in all figures. The or each exemplary embodiment should not be understood as a restriction of the invention. Rather, variations and modifications which can be inferred by the person skilled in the art with regard to achieving the object for example by combination or modification of individual features or method steps that are described in connection with the general or specific part of the description and are contained in the claims and/or the drawings, and, by way of combinable features, lead to a new subject matter or to new method steps or sequences of method steps are also possible in the context of the present disclosure.
The view of
The vacuum created by vacuum cleaner fan 12 is used as the controlled variable in control system 16. A vacuum switch 24 is provided to determine an indication of the vacuum pressure created during operation. The vacuum switch 24 used is one having a single switching point. In
The view of
A simple vacuum switch 24 includes a flexible diaphragm which mechanically actuates a switch contact, an adjustable return spring, and a housing having one or more ports for attachment of vacuum hoses 26 or the like. A switching point of such a vacuum switch 24 is not of the snap-action type, but of the slow-action type. Because of this slow action, a slightly varying pressure close to the switching point results in bouncing of the switch contact. Due to this bouncing and the resulting, virtually uncontrolled opening and closing of the switch contact, a kind of a pulse-width modulation (PMW) pattern is produced.
Signal 30 is characterized in that the duration of the individual pulses is directly proportional to the pressure differential applied to vacuum switch 24. However, the signal pattern is not uniform, but, as it were, chaotic. By smoothing signal 30 by a filter, in particular a low-pass filter 28 (
It should be noted at this point that the signal waveforms shown in
The sensor signal 32 of vacuum switch 24 obtained after smoothing can be fed as a controlled variable to an analog controller or subjected to analog-to-digital conversion and then fed to a digital controller. The controllers and control schemes (P control, PI control, PD control, PID control) that may be used are well known in the art and need not be specifically described herein. Such a controller forms part of control system 16.
Due to the relatively simple circuitry associated with vacuum switch 24, including a downstream filter, in particular a low-pass filter 28, a limited analog signal 32, which is a measure of the vacuum pressure in the path of the suction air stream, can be generated from the signal waveform across vacuum switch 24. The obtainable analog sensor signal 32 is limited because the observed bouncing of the switch contact of vacuum switch 24 and the resulting signal pattern occur only in the vicinity of its switching point.
The limitation of the resulting sensor signal 32, hereinafter referred to as limited measurement range 34 (
The view of
Since the measurement range 34 of the sensor is quite narrow, the respective controller may perform control, for example, with a higher amplification factor outside the measurement range 34; i.e., in a first range 36 below measurement range 34 and a second range 38 above measurement range 34, and is thereby able to rapidly return to measurement range 34. The two ranges 36, 38 are shown in the view of
A voltage value of ½ UV(DC) is input as a setpoint into control system 16 and the controller included therein (see
The view of
Thus, various salient aspects of the description given herein can be briefly summarized as follows: Disclosed are a method for adjusting the power of a vacuum cleaner fan 12, a control system 16 for implementing the method, and a vacuum cleaner 10 having such a control system 16. In accordance with the method, a signal 30 that can be tapped off above a vacuum switch 24 having a single switching point is smoothed by a filter 28, and the resulting signal 32 is processed by control system 16 like a sensor signal of an analog vacuum sensor for adjusting the fan power.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below.
The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B and C” should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of “A, B and/or C” or “at least one of A, B or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.
10 vacuum cleaner
12 vacuum cleaner fan
14 fan motor
16 control system
18 suction hose
20 suction connector
22 dust bag
24 vacuum switch
26 vacuum hose
28 filter/low-pass filter
30 signal (output signal of the vacuum switch)
32 signal/sensor signal (output signal of the combination of the vacuum switch and the (low-pass) filter)
34 measurement range
36 first range (range below the measurement range)
38 second range (range above the measurement range)
40 lower threshold
42 upper threshold
Number | Date | Country | Kind |
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10 2013 102 847.0 | Mar 2013 | DE | national |