Improved Dust Collector Motor Control

Abstract

A method for controlling the operation of a dust collector, the method comprising: obtaining sensor data (235) related to an air flow (240) entering the dust collector (step S1); determining whether the dust collector is operating in a high air flow operation range based on the sensor data (235) (step S2); and, in the case where the dust collector is operating in the high air flow operation range, controlling a fan motor (210) of the dust collector to reduce the air flow (240) to a reduced flow rate (330, 3301) that is at or above a predetermined air flow rate (340) and below an available flow rate (310), wherein the predetermined air flow rate (340) is associated with the dust suction capacity of the dust collector (100).

Description

Technical Field

[0001] The present disclosure relates to a heavy-duty dust extraction device for use with construction equipment. Methods and control units for controlling a fan motor included in a dust extraction device are disclosed. Background Art

[0002] Dust and slurry are generated by cutting, drilling, grinding, and / or demolishing concrete, bricks, and other hard construction materials. The dust and slurry can be collected by a dust extractor and removed from the construction site in a controlled manner. A dust extractor is a vacuum device that collects dust and slurry by creating a negative pressure generated by a fan or impeller and motor equipment, i.e., similar to a vacuum cleaner. Some dust extractors include a pre-filter or separator, followed by a filter, such as a high-efficiency particulate air (HEPA) filter.

[0003] Dust extractors typically include an electric motor powered by a power supply and are thus limited by the power supply capacity. It is desirable to minimize the energy and peak power consumed from the power supply so as not to overload the power supply. For example, some dust extractors consume high power during startup, which can be a problem at construction sites where the main power grid has fuse limitations.

[0004] Dust extractors typically use filtration equipment in order to collect smaller dust particles from an airflow carrying the particles and to retain these smaller dust particles. These filters need to be cleaned and / or replaced regularly. Filter replacement makes the operation expensive because the operation typically needs to be paused during filter maintenance. It is desirable to extend the filter replacement interval. Summary of the Invention

[0005] An object of the present disclosure is to provide a method, a control unit, and a heavy-duty dust extractor that mitigate the above problems. This object is achieved by a method for controlling the operation of a dust extractor. The method includes obtaining sensor data related to an airflow entering the dust extractor. The method further includes determining, based on the sensor data, whether the dust extractor is operating in a high airflow operation range, and, in the case where the dust extractor is operating in the high airflow operation range, controlling a fan motor of the dust extractor to reduce the airflow to a reduced flow rate that is at or above a predetermined airflow level and below an obtainable flow rate, wherein the predetermined airflow level is associated with the dust extraction capacity of the dust extractor.

[0006] Thus, as will be explained below, the motor is only used at maximum capacity when actually needed, and although the airflow is reduced, the dust extraction capacity remains at a sufficient level for the upcoming dust extraction application. This reduces the motor peak power at startup, which is an advantage. A more constant airflow simplifies the optimization of a cyclone separator or a pre-filter, which is an advantage. Additionally, somewhat surprisingly, due to the disclosed method, more dust and debris are collected in the pre-separation step.

[0007] According to various aspects, wherein the sensor data includes any one of the following: a pressure sensor value indicating a negative pressure or vacuum level associated with the airflow entering the dust collector, an airflow sensor value associated with the airflow entering the dust collector, the amount of current consumed by the fan motor, and pressure data from a pitot tube sensor device configured to sense the airflow entering the dust collector. Thus, the devices and methods disclosed herein can be implemented in many different ways, which is an advantage. Different sensors and sensor data types can be used alone or in combination to increase robustness.

[0008] The present disclosure also relates to a dust collector and a dust generator assembly, wherein the cooperation between the dust collector and the dust generator allows or improves dust suction. Here, the dust generator is arranged to provide information about the current usage to the dust collector, so that the dust collector can adapt the dust suction to the current operating scenario.

[0009] For a given usage, the appropriate operating parameters can be obtained, for example, from a wireless link to the dust generation equipment, from a remote server, or from an operator via a manual data input device.

[0010] According to some of these aspects, the high airflow operation range is defined based on data obtained from the dust generation equipment connected to the dust collector.

[0011] According to other such aspects, the high airflow operation range is defined based on data obtained from a remote server device.

[0012] According to additional such aspects, the high airflow operation range is defined based on data obtained from a manual input device.

[0013] According to various aspects, determining whether the dust collector is operating in the high airflow operation range can be performed, for example, by comparing the estimated current airflow level with a range of airflow values, by comparing the estimated current negative pressure level with a range of negative pressure values, or by a combination of both.

[0014] The present disclosure also relates to a control unit and a dust collector associated with the above advantages.

[0015] In general, unless otherwise explicitly defined herein, all terms used in the claims will be interpreted according to their ordinary meaning in the technical field. Unless otherwise explicitly stated, all references to "an element, apparatus, component, device, step, etc." will be construed broadly to refer to at least one instance of the element, apparatus, component, device, step, etc. Unless explicitly stated, the steps of any method disclosed herein need not be performed in the exact order disclosed. Other features and advantages of the present invention will become apparent when studying the appended claims and the following description. Those skilled in the art will recognize that, without departing from the scope of the present invention, different features of the present invention can be combined to create embodiments other than those described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present disclosure will now be described in more detail with reference to the drawings, in which:

[0017] Figure 1 An exemplary dust collector is shown;

[0018] Figure 2 A fan motor control arrangement is schematically shown;

[0019] Figure 3 is a diagram showing the relationship between air flow and negative pressure or vacuum level;

[0020] Figure 4 A dust collector and dust generator assembly is schematically shown;

[0021] Figure 5 is a flowchart showing a method;

[0022] Figure 6 An exemplary control unit is shown; and

[0023] Figure 7 A computer program product is schematically shown. DETAILED DESCRIPTION

[0024] The present invention will now be described more fully hereinafter with reference to the drawings, in which certain aspects of the invention are shown. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments and aspects set forth herein; rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. Throughout the specification, like reference numerals denote like elements.

[0025] It should be understood that the present invention is not limited to the embodiments described herein and shown in the drawings; rather, those skilled in the art will recognize that many changes and modifications can be made within the scope of the appended claims.

[0026] Figure 1 illustrates an exemplary dust collection device 100. The dust collection device can be connected via a hose to a dust generator ( Figure 1 not shown), such as a hollow drill, a floor grinder, a concrete saw, etc. The hose is fixed by an optional locking mechanism 130. Dust and slurry from the dust generator enter the dust collector via an inlet 110. A pre-filter 120 is arranged after the inlet, i.e., downstream with respect to the air flow direction. The pre-filter 120 can include, for example, a cyclone device for separating larger debris particles from the particle-carrying air flow entering the inlet 110. It should be noted that the techniques disclosed herein can be applied to dust collection devices with and without a pre-filter unit.

[0027] One or more air filters 150 are arranged downstream of the pre-filter 120. Such an air filter 150 can be, for example, a high-efficiency particulate air (HEPA) filter, but other air filters can also be used. HEPA (also known as high-efficiency particulate absorption and high-efficiency particulate arrestance) is an efficiency standard for air filters. Filters meeting the HEPA standard must meet a certain efficiency grade. HEPA was commercialized in the 1950s, and initially the term became a registered trademark and later became a general term for high-efficiency filters. It should be noted that the techniques disclosed herein can be applied to dust collection devices having any number of air filters 150, including dust collection devices having a combination of different air filters.

[0028] A fan and motor assembly is arranged in a compartment 170 downstream of the one or more air filters 150. The fan and motor assembly generates a suction force that sucks the particle-carrying air flow through the inlet 110, causing the air flow to pass through the pre-filter 120 and through the one or more air filters 150. The upstream direction is the direction in which the air flow is towards the inlet, and the downstream direction is the direction away from the inlet.

[0029] The dust collector 100 also includes a control unit 160 schematically shown in Figure 1 . The control unit 160 is configured to control various operations performed by the dust collector, such as activating the motor to drive the fan. This control unit will be discussed in more detail below.

[0030] Figure 2 An exemplary fan and motor assembly including a control unit 160 is schematically shown. The control unit is configured to control a fan motor 210 that sucks a particle-carrying air flow 240 into the dust collector. A sensor device 230 is arranged to be connected to the air flow 240, where the sensor device is configured to obtain sensor data 235 related to the air flow, such as a pressure level in kPa at atmospheric pressure (sometimes referred to as a vacuum level) and / or an air flow rate (usually in m 3measured in units of / h).

[0031] Fans used in vacuum devices are sometimes referred to as impellers. The terms fan and impeller will be used interchangeably herein. Vacuum devices including a pre-filter 120 and an air filter 150 are generally known and will not be discussed in more detail herein.

[0032] This disclosure is based on the recognition that the more clogged the air filter 150 becomes, the higher the resistance the motor encounters when sucking air through the air filter 150. However, the load on the fan motor 210 actually decreases as the resistance to sucking air through the air filter 150 increases. In other words, the more difficult it is to suck air through the air filter 150, the easier it is for the motor to rotate the fan. This is because as the vacuum level downstream of the air filter 150 increases, the fan blades rotate more easily due to the reduced air pressure. In fact, in a complete vacuum, the fan blades will not encounter any friction or resistance from the air anyway.

[0033] This means that when the air filter 150 is new and the air flow is large, i.e., when the dust collector is operating in the high air flow operating range where the minimum suction is required, the normal fan motor consumes the most power.

[0034] This also means that when the air filter 150 is completely clogged, i.e., when the dust collector is operating outside the high air flow operating range where the maximum suction is actually required, the normal fan motor consumes the least power.

[0035] According to this implementation, it is proposed herein to detect when the dust collector 100 is operating in the high air flow operating range and reduce the air flow 240 when the dust collector is operating in the high air flow operating range (i.e., when the air filter 160 is not overly clogged). This reduction in air flow will reduce the requirements for the motor starting current and allow for more optimized overall operation of the dust collector 100.

[0036] The sensor device 230 for obtaining sensor data 235 related to the air flow 240 entering the dust collector 100 can include, for example, a pressure sensor (such as a pitot tube device) to determine the negative pressure level or vacuum level associated with the air flow 240. An air flow sensor can also be used to determine the air flow rate associated with the air flow 240 entering the dust collector 100, for example, in units of m 3 / h. The sensor data 235 related to the air flow 240 entering the dust collector 100 can also be obtained indirectly from various relevant information sources, such as the amount of current consumed by the fan motor 210. When the fan motor 210 is operating under high load, it consumes more current than when the air filter becomes clogged and the motor load decreases. Generally speaking, the higher the torque of the motor shaft, the greater the current consumed by the motor.

[0037] The position of the sensor device 230 along the air flow 240 depends on the type of the device. A pressure sensor arranged to determine the negative pressure level is preferably arranged somewhere in the negative pressure region between the fan and the air filter 150. However, the negative pressure can also be measured at other positions in the air flow 240. The air flow sensors can be arranged at multiple positions along the air flow 240. Multiple air flow sensors can provide more accurate sensor data 235. A sensor arranged to determine the amount of current consumed by the motor must be arranged to be connected to the power supply of the motor.

[0038] In this document, the negative pressure value indicates the difference in pressure in the air flow 240 that is lower than a reference pressure level such as the atmospheric pressure. Negative pressure is sometimes also referred to as the vacuum level.

[0039] The air flow can be measured in a variety of different ways. For example, the air flow can be measured according to the volume of air (in m 3 3) passing through a point in the system per unit time (e.g., one hour h) at a certain reference pressure.

[0040] The techniques disclosed in this document do not depend on any exact definition of negative pressure or air flow, and those skilled in the art can adjust the disclosed methods to work with most definitions and reference values.

[0041] Figure 3 A diagram showing the relationship between the negative pressure (in kPa) and the air flow (in m 3 3 / h) illustrates some of the proposed techniques. The air flow is the Figure 2 shown air flow 240. In this diagram, as the pressure decreases in kPa to the right, and as the air flow 240 increases upward. An increasing negative pressure means that the air pressure has dropped. A dust collector 100 with a new unclogged air filter will be able to generate an air flow 240 within the high air flow value range 350 starting at the peak air flow level 320. Then, as the air filter becomes increasingly laden with particulate matter, the maximum achievable flow level 310 decreases and eventually enters the low air flow value range 351. As the air flow decreases, the negative pressure increases from the low negative pressure value range 360 to the high negative pressure value range 361. This is because the resistance to sucking air through the air filter 150 increases, and this resistance forms the negative pressure.

[0042] It should be understood that the dust collector can be associated with the high air flow operating ranges 350, 360 where the air flow is relatively high and the negative pressure is relatively low.

[0043] Detecting whether the dust collector is operating in the high air flow operating range can be performed by comparing the current air flow with certain thresholds or with a range of air flow values.

[0044] Detecting whether the dust collector is operating in the high air flow operating range can also be performed by comparing the current negative pressure with certain thresholds or with a range of negative pressure values.

[0045] The dust collector described herein is configured to reduce the air flow 240 to a reduced air flow rate 330, 330' that is lower than the available flow rate 310 by an amount 331, 331' when the dust collector is operating in the high air flow operating ranges 350, 360, and to maintain the air flow at or above a predetermined air flow rate 340. As described above, when the air filter 150 is not overly carrying particulate matter, it is relatively easy to generate an air flow through the dust collector system. The predetermined air flow rate 340 is configured to be at a level that generates sufficient suction. In other words, the predetermined air flow rate 340 is associated with the dust collection capacity of the dust collector 100. Accordingly, the motor power can be reduced while maintaining sufficient air flow for the upcoming application.

[0046] It should be understood that the air flow 240 can be reduced by an amount 331 to drop to a constant level, such as the predetermined air flow rate 340, or can be reduced by some smaller amount 331' to reach an intermediate air flow rate 330' between the available flow rate 310 and the predetermined air flow rate 340. Since the predetermined air flow rate 340 corresponds to an air flow sufficient to generate sufficient suction for the upcoming dust collection application, the dust collection capacity is maintained as long as the air flow is not reduced to a level far below the predetermined air flow rate 340. For some exemplary dust collectors, the predetermined air flow rate can be on the order of 150 - 2000 m 3 / h, preferably between 150 - 700 m 3 / h, but it should be understood that these levels are application - related and machine - related and can be determined by actual experiments or other forms of analysis (such as computer simulation).

[0047] Some known dust collectors, such as the dust collector disclosed in US 2013 / 0019901, include means for detecting an unused state and reducing the air flow in response to detecting the unused state, in order to, for example, save energy and reduce the generated noise. This can be advantageous, for example, in a household dust collector including a suction nozzle which is usually lifted off the ground (unused state), in which case suction is not required. It should be understood that the means disclosed herein are fundamentally different, since the air flow rate is only reduced to a predetermined air flow rate 340 or above which is configured to maintain sufficient air flow for the upcoming application. In other words, although the air flow is reduced, the dust collector still maintains its dust suction ability. In addition, since the dust collector with reduced air flow is still in use, it does not respond to detecting an unused state despite the reduced air flow. As the air filter becomes increasingly laden with particulate matter, it becomes increasingly difficult to maintain the air flow at the predetermined air flow rate 340. At a certain point in time, the reduced flow rates 330, 330' approach the maximum achievable flow rate 310, as shown by the point "A" in Figure 3 When this occurs, the dust collector 100 is no longer operating in the high air flow operating ranges 350, 360 where it may be possible to reduce the motor power but still provide sufficient air flow for the upcoming application. When the dust collector leaves the high air flow operating ranges 350, 360, the motor must be supplied with full power in order to provide sufficient air flow to meet the requirements of the upcoming dust suction task.

[0048] The dust collector 100 is also associated with an air flow rate threshold 370 below which sufficient suction can no longer be delivered. At this operating point, as shown by the point "B" in Figure 3 the particulate-laden air filter 150 needs to be cleaned. This air filter cleaning can include briefly but forcefully pushing air backwards through the filter, servicing or cleaning the filter or even replacing the air filter 150.

[0049] Figure 4 A dust collector system 400 including a dust collector 100 having a control unit 160 is shown. The dust collector 100 is connected, for example, via the Figure 1 shown inlet 110 to dust generating equipment 410. Most dust collectors can be connected to a variety of different dust generating equipment. Some types of equipment generate more dust than others, and even the same type of equipment can produce an air flow 240 carrying variable amounts of particulate matter depending on how it is used. In addition, some dust suction tasks require extracting and removing the maximum amount of dust in a controlled manner, while other dust suction tasks are performed in an environment where only a slightly restricted amount of the generated dust is desired. Therefore, it should be understood that Figure 3 the various operating levels of the shown dust collector can be configured according to the current dust suction operation scenario.

[0050] The dust collector 100 can be connected to the dust generating equipment 410 via, for example, a cable or a wireless link 420. Then, the dust generating equipment can notify the dust collector device, for example, how much dust can be expected. The dust generating equipment can also, for example, use a photodiode system to monitor the amount of generated dust in real time and notify the dust collector of the amount of generated dust via the communication link 420. Then, the high airflow operation ranges 350, 360 can be defined based on the data obtained from the dust generating equipment 410 connected to the dust collector 100. In addition, the reduced flow level 330 and the predetermined airflow level 340 can be set based on the data obtained from the dust generating equipment.

[0051] A database can be maintained, for example, on a remote server 430, and the remote server can be accessed to set different levels according to the dust collector operation scenarios. In this way, the high airflow operation range can be defined based on the data 440 obtained from the remote server device 430. For example, assume that the dust generating equipment identifies itself to the dust collector via, for example, a product code or the like. Then, the dust collector can use the data 440 to download appropriate operation parameters for the remote server, such as the setting of the predetermined airflow level 340 and the setting of the airflow level threshold 370.

[0052] The dust collector 100 can also include a manual input device 450, such as a display and a touch screen or a keyboard, thereby allowing the operator to define the predetermined airflow level 340 and / or the airflow level threshold 370. In this way, the high airflow operation range is defined based on the data obtained from the manual input device 450. For example, the operator can input what type of dust generating equipment 410 is currently connected to the dust collector 100. Then, the dust collector 100 can access the internal memory to configure the operation parameters customized for the connected dust generating equipment. In this way, the operation of the dust collector can be optimized and a more efficient dust collection process can be obtained. The operator can also input a dust collection level via the manual input device 450. This dust collection level can be, for example, on a scale from one to ten, thereby indicating how much dust and debris are to be collected. Some construction sites may have higher requirements for dust collection than others. In this way, the operator can customize the operation for the current construction site.

[0053] In summary, Figure 4 A dust collector system 400 is shown, in which one or more communication links 420, 440 are used to configure the operation of the dust collector according to the current operation scenario. This configuration can, for example, include setting airflow levels such as the predetermined airflow level 340 and / or the airflow level threshold 370. This configuration can be performed by the operator manually inputting via the manual input device 450, or automatically performed using the communication link between the dust collector 100 and the dust generating equipment 410 and / or the communication link 440 between the dust collector 100 and the remote server 440.

[0054] Figure 5is a flowchart showing a method for summarizing the exemplary operation of the above-described dust collector 100. Some aspects of the method are performed by the control unit 160, and some aspects of the method are performed jointly with the dust generation equipment and / or the remote server 430 discussed above Figure 4 discussed.

[0055] Figure 5 shows a method for controlling the operation of the dust collector 100. The method includes obtaining sensor data 235 related to the airflow 240 entering the dust collector 100 (step S1). The purpose of obtaining sensor data related to the airflow is mainly to determine whether and when the dust collector is operating in a high-airflow operation range, in which the airflow is higher than the airflow required to meet the application requirements.

[0056] Various types of sensors or combinations of sensor types can be used for this purpose. For example, the sensor data 235 may include a pressure sensor value indicating the negative pressure or vacuum level associated with the airflow 240 entering the dust collector 100 (step S11). This reading indicates, for example, an operating point along Figure 3 the x-axis or the negative pressure axis in. Therefore, by monitoring the airflow pressure, the control unit 160 can determine whether the dust collector 100 is operating in the low negative pressure value range 360.

[0057] The sensor data 235 may also include an airflow sensor value associated with the airflow 240 entering the dust collector 100 (step S12). This sensor reading provides information related to the operating point along Figure 3 the y-axis (i.e., the airflow axis) in. Therefore, by monitoring the data from the airflow sensor, the control unit can determine whether the dust collector 100 is operating in the high airflow value range 350.

[0058] The motor load can also indicate which operating range the dust collector is currently in, i.e., whether it is in the high-airflow operation range. Therefore, according to some aspects, the sensor data 235 includes the amount of current consumed by the fan motor 210 (step S13).

[0059] A pitot tube or a pitot tube device can also be used to determine the airflow pressure. Therefore, according to some aspects, the sensor data 235 includes pressure data from a pitot tube sensor device configured to sense the airflow 240 entering the dust collector 100 (step S14). A pitot tube or a pitot tube (also known as a pitot probe) is a flow measurement device used to measure the fluid flow rate. A basic pitot tube consists of a tube that points directly into the fluid flow. Since this tube contains the fluid, the pressure can be measured; since there is no outlet to allow the flow to continue, the moving fluid is stopped (stagnated). This pressure is the stagnation pressure of the fluid, also known as the total pressure or (especially in aviation) the pitot pressure.

[0060] The method further includes determining whether the dust collector 100 is operating in high airflow operation ranges 350, 360 based on sensor data 235 (step S2), and in the case where the dust collector 100 is operating in a high airflow operation range, controlling the fan motor 210 of the dust collector 100 to reduce the airflow 240 to a reduced airflow level 330 that is lower than the available flow level (step S3). Thus, if the airflow generated by the dust collector is more than that necessary to complete the dust collection task, the motor power is reduced. This action of course saves energy, which is an advantage. However, the action of reducing the airflow also improves the efficiency of the air filter and allows for a more constant airflow, which in turn allows for improved optimization of the entire dust collection process.

[0061] As described above, a variety of different options can be used to determine whether the dust collector is operating within a high airflow operation range. For example, the method can include determining whether the dust collector 100 is operating in a high airflow operation range by comparing the estimated current airflow level with the airflow value range 350 (step S21). According to other aspects, the method can include determining whether the dust collector 100 is operating in a high airflow operation range by comparing the estimated negative pressure level with the negative pressure value range 360 (step S22). Of course, several methods can be used in combination to determine when the dust collector is operating within a high airflow operation range. It should also be understood that when the dust collector is operating outside the high airflow operation range, this detection can be performed through alternative detection.

[0062] Of concern is that the high airflow operation range can be defined based on data obtained from the dust generating equipment 410 connected to the dust collector 100 (step S23). Thus, it should be understood that the relative term "high" here depends on the dust collection application. Some dust collection applications involve extracting a large amount of heavy debris, which may require a relatively large airflow. In these cases, the high airflow state may be relatively small and close to the maximum airflow available to the dust collector. However, some other applications may require a relatively small amount of airflow to extract sufficient dust and debris, and in these cases, the high airflow state may span a larger range of airflow values 350 and / or a larger range of negative pressure values 360. The dust generating equipment 410 can be arranged to provide the dust collector with information indicating a set of requirements or requests for a given range or airflow value or negative pressure value.

[0063] Reference Figure 4 and the method can include determining the current operation scenario and controlling the fan motor 210 of the dust collector 100 according to the operation scenario to obtain an airflow level (step S4).

[0064] According to some aspects, the high airflow operation range may be defined based on data obtained from the remote server device 430 (step S24). The remote server may, for example, tabulate dust collector settings corresponding to different usage scenarios. The dust collector may access the remote server, submit the current usage scenario, and receive return data related to suitable operating parameters such as a predetermined airflow level 340, an airflow level threshold 370, etc.

[0065] According to additional aspects, the high airflow operation range is defined based on data obtained from the manual input device 450 (step S25). Of course, the dust collector 100 may also include means for manually configuring the above-mentioned operating parameters. For example, an operator may input the current usage scenario of operating the dust collector, i.e., what type of dust generating equipment is connected to the dust collector, what the requirements for dust suction are, and so on. The control unit 160 may then process the manually input data into suitable operating parameters such as a predetermined airflow level 340, an airflow level threshold 370, etc.

[0066] The control of the fan motor 210 to reduce the airflow to the predetermined airflow level 340 may be implemented in a variety of ways, which may be applied individually or in combination.

[0067] For example, the method may include controlling the fan motor 210 by reducing the power supply voltage of the fan motor 210 to reduce the airflow 240 below the achievable flow level (step S31). Reducing the power supply voltage is a direct way to reduce the motor power, thus achieving a reduced airflow. Alternatively, or in combination, the method may also include controlling the fan motor 210 by reducing the engine speed of the fan motor 210 to reduce the airflow 240 below the achievable flow level (step S32).

[0068] The fan itself may also be used to regulate the airflow and the motor load. For example, the method may include controlling the fan motor 210 by adjusting the blade pitch of the fan driven by the fan motor 210 to reduce the airflow 240 below the achievable flow level (step S33). Thus, when the dust collector 100 is operating in the high airflow operation range, the airflow can be reduced to a reduced level by adjusting the blade pitch. This will change the blade load and thus produce the desired effect of maintaining the operation at the predetermined airflow level 340.

[0069] Similarly, in order to adjust the blade pitch, an automatic arrangement for controlling the fan motor 210 may be achieved by adjusting the distance between the fan blade tip of the fan driven by the fan motor 210 and the fan housing (step S34). In this case, the fan housing may be formed to have a tapered shape along the axial direction of the fan, and the fan may move up and down within the housing, thereby adjusting the distance between the fan blade tip of the fan driven by the fan motor 210 and the fan housing.

[0070] Another option includes controlling the fan motor 210 by restricting the intake air to the fan driven by the fan motor 210 to reduce the air flow 240 below an achievable flow rate (step S35). This restriction can be arranged before the pre-filter 120 (i.e., upstream of the pre-filter 120) or downstream of the pre-filter 120. The restriction can also be arranged on either side of one or more air filters 150.

[0071] According to various aspects, the method further includes, when the dust collector 100 is operating in the high air flow operation ranges 350, 360, controlling the fan motor 210 of the dust collector 100 to keep the operation below a constant predetermined air flow rate 340 (step S36). Thus, it should be understood that the rate 340 can be a constant rate as Figure 3 shown. However, according to other aspects, the rate is not constant but is defined as a function of, for example, the air flow or negative pressure rate. For example, the predetermined air flow rate 340 can be configured to have a slope or can be any function of the negative pressure rate, such as a square function, etc.

[0072] For example, the predetermined air flow rate 340 can be between 150 - 2000 m 3 / h, preferably between 150 - 700 m 3 / h.

[0073] According to additional aspects, controlling the fan motor 210 of the dust collector 100 to reduce the air flow 240 includes reducing the air flow to between 20 - 30% of the peak air flow rate 320, preferably to 25% of the peak air flow rate (step S37).

[0074] The method can further include triggering an alarm (step S5) in response to the obtained sensor data 235 indicating that the current air flow rate is below the air flow rate threshold 370, such as a low air flow alarm or a clogged filter alarm. Thus, it should be understood that the above air flow sensor can be used for various purposes, such as controlling the fan motor operation and detecting an air flow below the operating requirements.

[0075] Figure 6 The general components of the control unit 160 are schematically shown in accordance with a plurality of functional units. The processing circuitry 610 is set up using any combination of one or more of a suitable central processing unit CPU, multi-processor, microcontroller, digital signal processor DSP, etc. that can execute software instructions stored, for example, in a computer program product in the form of a storage medium 630. The processing circuitry 610 can also be set up as at least one application specific integrated circuit ASIC or field programmable gate array FPGA.

[0076] In particular, the processing circuitry 610 is configured such that the device 160 performs a set of operations or steps, such as in combinationFigure 5 and the methods discussed above. For example, the storage medium 630 may store the set of operations, and the processing circuitry 610 may be configured to retrieve the set of operations from the storage medium 630 to cause the device to execute the set of operations. The set of operations may be provided as a set of executable instructions. Accordingly, the processing circuitry 610 is thus arranged to execute the methods as disclosed herein.

[0077] The storage medium 630 may further include a permanent storage medium, which may be, for example, any one or combination of a magnetic memory, an optical memory, a solid-state memory, or even a remotely installed memory.

[0078] The device 160 may further include an interface 620 for communicating with at least one external device. Thus, the interface 620 may include one or more transmitters and receivers, and thus includes analog and digital components and an appropriate number of ports for wired or wireless communication.

[0079] The processing circuitry 610 controls the general operation of the control unit 160, for example, by sending data and control signals to the interface 620 and the storage medium 630, by receiving data and reports from the interface 620, and by retrieving data and instructions from the storage medium 630.

[0080] In summary, also referring to Figures 1 to 3 、 Figure 6 FIG. schematically shows a control unit 160 for controlling the operation of a dust collector 100. The control unit includes a processing circuitry 610 that is configured to;

[0081] obtain sensor data 235 related to the airflow 240 entering the dust collector 100 (step S1x),

[0082] determine whether the dust collector 100 is operating in a high airflow operation range 350, 360 based on the sensor data 235 (step S2x), and

[0083] in the case where the dust collector (100) is operating in a high airflow operation range, control the fan motor 210 of the dust collector 100 to reduce the airflow 240 below the maximum available flow rate 310 (step S3x).

[0084] According to different aspects, the control unit 160 may also be arranged to perform other method steps discussed above in connection with Figure 5 discussion.

[0085] Also disclosed herein is a dust collector 100 arranged to perform the above methods. For example, the dust collector includes a control unit 160 and is thus arranged to perform the different method steps discussed above.

[0086] According to various aspects, the dust collector 100 includes one or more sensor devices 230 arranged to provide sensor data 235 related to the air flow 240. The sensor device(s) can be communicatively coupled to the control unit 160, for example, which can control the dust collector 100 based on the sensor data 235. The sensor data 235 includes pressure sensor values indicating the negative pressure or vacuum level associated with the air flow 240 entering the dust collector 100.

[0087] According to various aspects, the sensor data 235 provided by the one or more sensor devices 230 includes air flow sensor values associated with the air flow 240 entering the dust collector 100.

[0088] According to various aspects, the sensor data 235 provided by the one or more sensor devices 230 includes the amount of current consumed by the fan motor 210. The current consumed by the electric motor can be measured in various known ways. Therefore, the measuring device will not be discussed in more detail herein.

[0089] According to various aspects, the sensor data 235 provided by the one or more sensor devices 230 includes pressure data from a pitot tube sensor device configured to sense the air flow 240 entering the dust collector 100. The pitot tube sensor device is also known.

[0090] The dust collector 100 is optionally arranged to determine whether the dust collector 100 is operating in a high air flow operating range by comparing an estimated current air flow level with an air flow value or air flow value range 350. This high air flow operating range was exemplified and discussed above, for example, in connection with Figure 3 and discussed.

[0091] The dust collector 100 is optionally arranged to determine whether the dust collector 100 is operating in a high air flow operating range by comparing an estimated current negative pressure level with a negative pressure value or negative pressure value range 360. This high air flow operating range was exemplified and discussed above, for example, in connection with Figure 3 and discussed.

[0092] The high air flow operating range can be defined based on data obtained from the dust generating equipment 410 connected to the dust collector 100. This feature provides many advantages, some of which have been discussed in connection with Figure 4 and discussed. The high air flow operating range can also be at least partially defined based on data obtained from the remote server device 430 and / or based on data obtained from the manual input device 450.

[0093] The dust collector 100 can control the fan motor in different ways, and some of these ways can also be used in combination. For example, the dust collector can be arranged to control the fan motor 210 by reducing the supply voltage of the fan motor 210 to reduce the air flow 240 below the achievable flow rate. The dust collector 100 can also be arranged to control the fan motor 210 by reducing the engine speed of the fan motor 210 to reduce the air flow 240 below the achievable flow rate. Other ways to control the fan motor include adjusting the blade pitch of the fan driven by the fan motor 210 and adjusting the distance between the fan blade tip of the fan driven by the fan motor 210 and the fan housing to reduce the air flow 240 below the achievable flow rate. This fan housing can be formed to have a tapered shape along the axial direction of the fan. In addition, the fan motor 210 can be controlled by restricting the intake air to the fan driven by the fan motor 210 to reduce the air flow 240 below the achievable flow rate.

[0094] It should be understood again that different combinations of the above control methods for controlling the fan motor 210 can be advantageously used. For example, the voltage can be controlled to fine-tune the fan motor air flow, while the distance between the fan blade tip of the fan driven by the fan motor 210 and the fan housing can be adjusted in discrete steps to obtain a large change in the air flow.

[0095] Some aspects of the disclosed dust collector include a dust collector arranged to control the fan motor 210 of the dust collector 100 to maintain operation at a constant predetermined air flow rate 340 when the dust collector 100 operates in the high air flow operation ranges 350, 360. Thus, the air flow is adjusted towards the target air flow rate. This predetermined air flow rate 340 can be between 150 - 2000 m 3 / h, preferably 150 - 700 m 3 / h.

[0096] Other aspects of the disclosed dust collector 100 include a dust collector arranged to determine the current operating scenario and control the fan motor 210 of the dust collector 100 according to the operating scenario to obtain an air flow rate.

[0097] In addition, the dust collector can be arranged to trigger an alarm in response to obtaining sensor data 235 indicating that the current air flow rate is lower than the air flow rate threshold 370.

[0098] To avoid obscuring the concepts presented herein, other components of the dust collector and the control unit and related functions are omitted.

[0099] Figure 7 A computer-readable medium 710 carrying a computer program is shown, the computer program including program code means 720 for performing when the program product runs on a computer Figure 5The method shown. The computer-readable medium and the code loading device can together form a computer program product 700.

Claims

1. A method for controlling the operation of a heavy-duty dust collector (100), the method comprising: Obtaining sensor data (235) related to an air flow (240) entering the dust collector (100) (step S1), wherein the air flow includes dust generated at a construction site; Determining whether the dust collector (100) is operating in a high air flow operation range (350, 360) based on the sensor data (235) (step S2); and In the case where the dust collector (100) is operating in the high air flow operation range, controlling a fan motor (210) of the dust collector (100) to reduce the air flow (240) to a reduced flow rate (330, 330') that is at or above a predetermined air flow level (340) and below an obtainable flow level (310), wherein the predetermined air flow level (340) is associated with the dust suction capacity of the dust collector (100). Wherein the sensor data (235) includes a pressure sensor value indicating a negative pressure or vacuum level associated with the air flow (240) entering the dust collector (100) (step S11). The method further includes measuring the negative pressure or vacuum level at a position where a negative pressure is generated by the fan. Wherein, the predetermined air flow rate (340) is between 150 - 2000 m 3 / h to generate sufficient suction force for the dust collector (100), The method further includes: connecting the dust collector (100) to dust generating equipment (410) via a communication link (420) to obtain data on the amount of dust generated by the dust collector (100) from the dust generating equipment (410), and defining the high air flow operation range based on the data obtained from the dust generating equipment (410).

2. The method according to claim 1, wherein, The dust collector (100) includes a cyclone separator device.

3. The method according to claim 1, wherein The sensor data (235) includes an air flow sensor value associated with the air flow (240) entering the dust collector (100) (step S12).

4. The method according to claim 1, wherein The sensor data (235) includes the amount of current consumed by the fan motor (210) (step S13).

5. The method according to claim 1, wherein, The sensor data (235) includes pressure data from a pitot tube sensor device configured to sense the air flow (240) entering the dust collector (100) (step S14).

6. The method according to claim 1, comprising determining whether the dust collector (100) is operating in the high air flow operation range by comparing an estimated current air flow level with an air flow value or an air flow value range (350) (step S21).

7. The method according to claim 1, comprising determining whether the dust collector (100) is operating in the high air flow operation range by comparing an estimated current negative pressure level with a negative pressure value or a negative pressure value range (360) (step S22).

8. The method according to claim 1, wherein Defining the high air flow operation range according to data obtained from a remote server device (430) (step S24).

9. The method according to claim 1, wherein Defining the high air flow operation range according to data obtained from a manual input device (450) (step S25).

10. The method according to any one of claims 1 to 9, comprising controlling the fan motor (210) by reducing the supply voltage of the fan motor (210) to reduce the air flow (240) below the achievable flow level (step S31).

11. The method according to any one of claims 1 to 9, comprising controlling the fan motor (210) by reducing the engine speed of the fan motor (210) to reduce the air flow (240) below the achievable flow level (step S32).

12. The method according to any one of claims 1 to 9, comprising controlling the fan motor (210) by adjusting the blade pitch of the fan driven by the fan motor (210) to reduce the air flow (240) below the achievable flow level (step S33).

13. The method according to any one of claims 1 to 9, comprising controlling the fan motor (210) by adjusting the distance between the tip of the fan blade of the fan driven by the fan motor (210) and the fan housing (step S34).

14. The method according to claim 13, wherein, The fan housing has a tapered shape along the axial direction of the fan.

15. The method according to any one of claims 1 to 9, comprising controlling the fan motor (210) by restricting the intake of the fan driven by the fan motor (210) to reduce the air flow (240) below the achievable flow level (step S35).

16. The method according to any one of claims 1 to 9, comprising, when the dust collector (100) operates in the high air flow operation range (350, 360), controlling the fan motor (210) of the dust collector (100) to remain operating at a constant predetermined air flow level (340) (step S36).

17. The method according to claim 16, wherein, The predetermined air flow rate (340) is between 150 - 700 m 3 / h.

18. The method according to any one of claims 1 to 9, wherein, Controlling the fan motor (210) of the dust collector (100) to reduce the air flow (240) comprises reducing the air flow to between 20 - 30% of the peak air flow level (320) (step S37).

19. The method according to claim 18, wherein, Controlling the fan motor (210) of the dust collector (100) to reduce the air flow (240) comprises reducing the air flow to 25% of the peak air flow level (step S37).

20. The method according to any one of claims 1 to 9, comprising determining the current operation scenario and controlling the fan motor (210) of the dust collector (100) according to the operation scenario to obtain an air flow level (step S4).

21. The method according to any one of claims 1 to 9, comprising triggering an alarm (step S5) in response to obtaining sensor data (235) indicating that the current air flow level is lower than an air flow level threshold (370).

22. The method according to any one of claims 1 to 9, wherein The heavy - duty dust collector (100) is an air cleaner.

23. The method according to any one of claims 1 to 9, wherein The construction site is a construction site where cutting, drilling, grinding, and / or demolition operations are carried out on concrete, bricks, and other hard building materials.

24. A computer program (720) comprising program code means for performing the steps of any one of claims 1 to 23 when the program is run on a computer or on a processing line (610) of a control unit (160).

25. A control unit (160) for controlling the operation of a dust collector (100), the control unit comprising a processing line (610) configured to perform the following operations: Obtain sensor data (235) related to the airflow (240) entering the dust collector (100) (step S1x), wherein, The air flow includes dust generated at a construction site. Determine whether the dust collector (100) is operating in a high air flow operation range (350, 360) based on the sensor data (235) (step S2x); and In the case where the dust collector (100) is operating in the high air flow operation range, control the fan motor (210) of the dust collector (100) to reduce the air flow (240) to a reduced flow rate (330, 330') that is at or above a predetermined air flow rate (340) and below an available flow rate (310), wherein the predetermined air flow rate (340) is associated with the dust suction capacity of the dust collector (100) (step S3x), wherein the sensor data (235) includes a pressure sensor value indicating a negative pressure or vacuum level associated with the air flow (240) entering the dust collector (100) (step S11), wherein the sensor data (235) is obtained by a sensor device (230), wherein the sensor device (230) includes a pressure sensor disposed in the air flow (240) at a location where the fan generates a negative pressure, Wherein, the predetermined air flow rate level (340) is between 150 - 2000 m 3 / h to generate sufficient suction force for the dust collector (100).

26. The control unit (160) according to claim 25, wherein, The construction site is a construction site where cutting, drilling, grinding, and / or demolition operations are performed on concrete, bricks, and other hard building materials.

27. A dust collector (100) comprising the control unit (160) according to claim 25 or 26.

28. The dust collector (100) according to claim 27, wherein, The dust collector (100) is an air cleaner.

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