Drive system for floor cleaner

Abstract

A drive system for a floor cleaner includes a longitudinally extending drive housing. The motor and the gear arrangement are located at least partially within the drive housing and are disposed longitudinally relative to each other. The drive output of the electric machine provides drive to the output member through a gear arrangement comprising an asymmetric planetary gear set having two planetary gears of different sizes. A cleaning head assembly including the drive system, a cleaning head for a cleaner, and a wet floor cleaner are also disclosed.

Description

Technical Field

[0001] The present invention relates to a drive system for a floor cleaner, and to a cleaning head assembly and a cleaning head comprising such a drive system, and to a floor cleaner comprising such a cleaning head. Background Art

[0002] Wet floor cleaners with motor-driven rotating mop rollers are becoming increasingly popular. Such cleaners outperform conventional mops because the motor-driven mop roller can treat many more stains at any given time than is possible with a conventional mop.

[0003] Preferably, a wet floor cleaner is as light and compact as possible to aid maneuverability and access to small spaces when in use, and to allow for easy and neat storage. However, the need for compactness presents some challenges for motor-driven wet floor cleaners due to the need for onboard motors, cooling systems, power transmission, and power supply. Furthermore, the use of electric motors in wet environments presents additional challenges due to the need to keep water away from the electrical system.

[0004] When used to clean floors, wet floor cleaners often hit baseboards or furniture. This impact can damage the system of the motor-driven wet floor cleaner.

[0005] It is in this context that the present invention has been developed. Summary of the invention

[0006] In a first aspect, the present invention provides a drive system for a floor cleaner, comprising: a longitudinally extending drive housing; a motor at least partially located within the drive housing; and a gear arrangement at least partially located within the drive housing, wherein the motor and the gear arrangement are longitudinally arranged relative to each other, and wherein the drive output of the motor is configured to provide drive to an output member via the gear arrangement, wherein the gear arrangement includes an asymmetric planetary gear set having a sun gear, a ring gear and two planet gears, wherein the two planet gears have different sizes.

[0007] The drive system of the present invention is advantageous because it provides greater packaging flexibility for components within the drive housing by effectively facilitating the offset between the drive shaft of the motor and the gear arrangement output. In some embodiments, the motor is located entirely within the drive housing. In some embodiments, the gear arrangement is located entirely within the drive housing, but in other embodiments, the motor is located partially within the drive housing and partially outside the drive housing.

[0008] Optionally, the drive housing comprises a radially symmetrical longitudinal axis, wherein the gear arrangement comprises a central drive axis, and wherein the central drive axis of the gear arrangement is offset from the radially symmetrical longitudinal axis of the drive housing. This configuration allows for non-central positioning of the gear arrangement relative to the drive housing, thereby providing additional packaging space within the drive housing, and may allow for drive connection to additional driven members disposed adjacent the drive housing.

[0009] An asymmetric planetary gear set can provide a reduction stage in the drive system.

[0010] The gear arrangement optionally further comprises at least one, and preferably a plurality of, primary reduction stages to allow a substantial reduction in motor speed.

[0011] Each primary reduction stage may include a planetary gear set for efficient packaging and speed reduction capability within the limited packaging space of the drive housing.

[0012] In one example, the output member is a ring gear of an asymmetric planetary gear set. This is beneficial because an agitating member configured to rotate about the drive system can be easily attached to the ring gear.

[0013] Alternatively, an asymmetric planetary gear set is configured to provide drive to both the primary driven member and the secondary driven member such that the electric machine can be used to power two devices.

[0014] The asymmetric planetary gear set may optionally include another output member, wherein the output member is configured to provide drive to the primary driven member and the other output member is configured to provide drive to the secondary driven member.

[0015] Another output member can be driven by one of the two planetary gear asymmetric planetary gear sets. In one example, another output member is driven by the larger of the two planetary gears.

[0016] In a second aspect, the present invention provides an agitator head assembly for a floor cleaner, comprising the above drive system and an agitating member mounted to rotate about the drive assembly, wherein the agitating member is operably connected to the output member. The agitating member can be configured to contact the floor and thus be used to clean the floor. The rotation of the agitating member against the floor can provide improved cleaning.

[0017] Optionally, the agitator head includes a debris remover element mounted to rotate alongside the agitating member, wherein the output of the asymmetric planetary gear set is operably connected to the debris remover element and is configured to provide drive to the debris remover element in use. The debris remover element may be configured to remove debris and / or liquid from the agitating member in use. The debris remover element may include one or more brushes and / or scraper elements for removing debris and / or liquid from the agitating member.

[0018] One of the two planetary gears of the asymmetric planetary gear set may optionally be configured to provide drive to a debris remover element in use.

[0019] The larger of the two planetary gears may be configured to provide drive to the debris remover element in use.

[0020] In a third aspect, the present invention provides a cleaning head for a floor cleaner, comprising one or more agitator head assemblies as described above mounted within a cleaning head housing.

[0021] In a fourth aspect, the invention provides a floor cleaner comprising such a cleaning head.

[0022] Features described in conjunction with the first aspect of the invention are equally applicable to the second, third and fourth aspects of the invention, and vice versa. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 shows a perspective view of a cleaning head for a wet floor cleaner;

[0024] Figure 2 A perspective view of a mop assembly of a cleaning head is shown, wherein the mop roller is shown in phantom;

[0025] Figure 3 A longitudinal cross-sectional view of a drive system of a mop assembly is shown;

[0026] Figure 4 Shown along Figure 3 A cross-sectional view of line AA;

[0027] Figure 5 Shown along Figure 3 A cross-sectional view of line BB;

[0028] Figure 6 yes Figure 3 A partial stereogram of the drive system;

[0029] Figure 7 yes Figure 3 Another partial stereoscopic diagram of the drive system;

[0030] Figure 8 a cross-sectional view showing the fan and diffuser arrangement of the drive system;

[0031] Fig. 9 Shows Figure 8 Exploded view of the fan and diffuser arrangement;

[0032] Fig.10a Shows Figure 3 a longitudinal cross-sectional view of an alternative air inlet to the one shown; and

[0033] Fig.10b Shows Figure 3 A longitudinal cross-section of an alternative air inlet is shown. DETAILED DESCRIPTION

[0034] Figure 1 A perspective view of a cleaning head 1 for a wet floor cleaner is shown. Figure 1 In the example shown, the cleaning head 1 comprises two mop assemblies 8 located in a cleaning head housing 2. Each mop assembly 8 comprises a mop roller 10, a mop cleaner 11 and a drive system 20, which will be described in more detail below. The cleaning head housing 2 is provided with a boss 3 for connecting to a handle of a wet floor cleaner.

[0035] although Figure 1 The exemplary cleaning head 1 shown includes two mop assemblies 8 , but it should be understood that the cleaning head 1 may include only one mop assembly 8 , or may include more than two mop assemblies 8 .

[0036] Reference now Figure 2 , the mop assembly 8 includes a mop roller 10 (shown in phantom) mounted for rotation on a drive system 20. A mop cleaner 11 in the form of a rotating roller or brush bar is arranged next to the mop roller 10. In use, the mop cleaner 11 rotates to clean the mop roller 10 from dirt and debris that sticks to the mop roller 10 during use. The drive system 20 is configured to rotate the mop roller 10 and the mop cleaner 11, which will be described in more detail below.

[0037] Figure 3 A longitudinal cross-sectional view of a drive system 20 is shown, the drive system comprising a tubular drive housing 22 having a first end 23 and a second end 24. An air inlet 30 is located at the first end 23 of the drive housing 22, and an electric motor 50 and a planetary gear system 60 are located within the drive housing 22. The planetary gear system 60 comprises a primary reduction stage 61 and a secondary reduction stage 62. An output shaft 63 extends from the output of the planetary gear system 60 through the second end 24 of the drive housing 22.

[0038] The second planetary gear system 70 is located at the second end 24 of the drive housing 22. The output shaft 63 of the planetary gear system 60 provides input drive to the sun gear 71 of the second planetary gear system 70. The planetary gear system 60 and the second planetary gear system 70 together form the gear arrangement 55 of the drive system 20, and the second planetary gear system 70 forms the final reduction stage of the gear arrangement 55.

[0039] The primary reduction stage 61 of the planetary gear system 60 receives a driving input of its sun gear 52 from the output shaft 51 of the motor 50. The output of the primary reduction stage 61 is transmitted to the sun gear 65 of the secondary reduction stage 62 through a short shaft (not shown) on which the planetary gears 53 of the primary reduction stage 61 are mounted. The planetary gears 53 of the primary reduction stage 61 are engaged between the sun gear 52 of the primary reduction stage 61 and the ring gear 64. The ring gear 64 is common to the primary and secondary reduction stages 61, 62 of the planetary gear set 60. The ring gear 64 is fixed relative to the housing 22.

[0040] Figure 4 It passes through Figure 3 The cross-sectional view along the line AA of FIG. 6 shows the secondary reduction stage 62 of the planetary gear system 60. The driving input received by the sun gear 65 is transmitted to the output star gear 68 through the short shaft 67, and the planetary gears 66 of the secondary reduction stage 62 are mounted on the short shaft 67. The planetary gears 66 of the secondary reduction stage 62 are engaged between the sun gear 65 and the ring gear 64 of the secondary reduction stage 62.

[0041] like Figure 4 As shown, the planetary gear system 60 is not in the center of the drive housing 22. Instead, the central drive axis of the planetary gear system 60 is offset relative to the radially symmetrical central axis of the drive housing 22 to allow the power supply line 90 to pass through the planetary gear system 60 to the motor 50. The ribs 69 located on the outer surface of the ring gear 64 position the planetary gear system 60 between the ribs 25 located on the inner surface of the drive housing 22. The ribs 69 define a channel through which the line 90 passes.

[0042] Figure 5 It passes through Figure 3 The cross-sectional view of the line BB of FIG. 5 shows the second planetary gear system 70. The drive input of the second planetary gear system 70 is received by the sun gear 71 and transmitted to the ring gear 74 through the first and second planetary gears 72, 73. The ring gear 74 forms the output of the second planetary gear system 70 and thus the output of the gear arrangement 55. Figure 5 As shown, the first and second planetary gears 72, 73 of the second planetary gear system 70 have different sizes to compensate for the offset of the output shaft 63 (and the sun gear 71) relative to the drive housing 22. The sizes of the first and second planetary gears 72, 73 can be specified in any suitable manner, such as by pitch diameter, pitch diameter, or number of teeth.

[0043] Refer again Figure 2 The mop roller 10 of the mop assembly 8 is mounted on and driven by the ring gear 74 of the second planetary gear system 70. The mop roller 10 extends away from the ring gear 70 so that the drive housing 22 and the air inlet 30 are located inside the mop roller 10. Figure 2In the illustrated exemplary mop assembly 8, the mop roller extends beyond the end of the air inlet 30. However, in other embodiments, the mop roller 10 may be any suitable length.

[0044] Reference now Figure 3 , Figure 6 and Figure 7 The second planetary gear 73 of the second planetary gear system 70 is connected to an output shaft 75, which provides drive to an input gear 81 of a gear train set 80, which is located outside the second planetary gear system 70 relative to the second end 24 of the housing 22. The second planetary gear 73 thus forms another output of the gear arrangement 55. The gear train set 80 includes an input gear 81, an idler gear 82 and an auxiliary drive gear 83. The idler gear 82 is arranged so that the rotation direction of the auxiliary drive gear 83 is the same as the rotation direction of the input gear 81.

[0045] A drive adapter 84 connects the auxiliary output gear 83 to the mop cleaner 11. In another arrangement, the idler gear 82 may be omitted, or an additional idler gear may be used between the idler gear 82 and the auxiliary drive gear 83 so that the direction of rotation of the mop cleaner 11 is opposite to the direction of rotation of the mop roller 10 in use.

[0046] It can be seen that in this example, the idler gear 82 and the auxiliary drive gear 83 have a lower number of teeth than the input drive gear 81. This means that the gear train 80 has the effect of increasing the rotational speed of the other output connected to the mop cleaner 11 compared to the rotational speed of the mop roller 10. It has been found that this improves the cleaning of the mop roller 10.

[0047] Although several reduction stages are provided in this embodiment, including a primary reduction stage 61, a secondary reduction stage 62 and another reduction stage 70, in some embodiments, one or both of the primary reduction stage 61 and the secondary reduction stage 62 may be omitted, depending on the capacity of the motor and the desired output speed.

[0048] Reference now Figure 3 , Figure 8 and Fig. 9 The drive system 20 includes an air inlet 30 and an air inlet fan assembly 40. The air inlet 30 is located at the first end 23 of the drive housing 22, and the air inlet fan assembly 40 is located in the drive housing 22 between the motor 50 and the air inlet 30.

[0049] The intake fan assembly 40 includes an intake nozzle 49, a fan 41 in the form of a radial impeller 41, and a diffuser 42 attached to the drive housing 22. The fan 41 is operably connected to the output shaft 51 of the motor 50 through a pair of interlocking drive pawl connectors 43, 45 located within the channel 48 of the diffuser 42. The drive pawl 43 provides attachment to the impeller 41 and the drive pawl 45 provides attachment to the motor. The drive pawl connectors 43, 45 are held in place in the channel 48 by bearings 47 and circlips 46. Screws 44 are used to attach the impeller drive pawl 43 to the impeller 41. The bearing 47 is sandwiched between the impeller 41 and the drive pawl 43.

[0050] In use, the fan 41 is rotated by the motor 50 so that air is drawn into the nozzle 49 via the air inlet 30. The nozzle directs the air into the center of the fan 41. Upon leaving the fan 41, the air passes through the diffuser 42 and enters the drive housing 22 to cool the motor 50.

[0051] In the above example, the fan 41 is a radial impeller. However, any other suitable type of fan may be used, such as a mixed flow or axial flow impeller, or other type of fan. Depending on the type of fan used, the nozzle 49 may not be required.

[0052] The impeller-side connector 43 has a plurality of protrusions (also referred to as fingers) to allow interlocking with the motor-side connector 45. The motor-side connector 45 has a plurality of grooves corresponding to the protrusions of the impeller-side connector 43. The protrusions of the impeller-side connector 43 engage with the grooves of the motor-side connector 45. This allows the drive of the motor to be transmitted to the impeller while separating the impeller from the motor to protect the impeller from shock or vibration transmitted from the motor mass.

[0053] Although in this case, the impeller-side connector 43 has a protrusion that fits into the groove of the motor-side connector 45, in an alternative arrangement, the protrusion may be provided on the motor-side connector and the corresponding groove provided on the impeller-side connector. In some embodiments, the protrusion may be provided on both connectors.

[0054] The distance between the fan 41 and the motor 50 may make the fan 41 susceptible to vibration and shock caused by the cleaning head 1 hitting or colliding with a wall or furniture during use. Such shocks may be amplified by the similar overhanging mounting of the fan 41 on the motor drive shaft 51, making the fan 41 particularly susceptible to damage. Providing two interlocking drive connectors 43, 45 has the effect of separating the fan 41 from the motor 50, which can help stabilize the fan 41 and reduce the risk of damaging the fan 41. To further alleviate this situation, one or both of the connectors 43, 45 may include a flexible or elastically deformable material, such as rubber, to absorb shock and help reduce or prevent the impact energy from being transferred to the fan 41. It should be understood that the connection between the drive shaft 51 and the radial impeller 41 can be achieved by a connector other than a claw connector, and any other suitable type of connector can be used.

[0055] The air inlet 30 includes an elongated tubular body 31 including a plurality of openings 32. The openings 32 are covered by a mesh 33 to prevent dust and other small particles from entering the interior of the drive system 20.

[0056] The air inlet 30 also includes a plurality of outwardly extending annular fins 34 spaced along the length of the tubular body 31. In use, the annular fins 34 help prevent water from entering the interior of the drive system 20 by deflecting water droplets or streams passing through the interior of the mop cylinder 10 to the air inlet 30.

[0057] A plurality of outwardly extending projections 35 are located at a distal end 36 of the air inlet 30 relative to the first end 23 of the drive housing 22. The outwardly extending projections 35 help support the drive system 20 within the cleaning head housing.

[0058] Fig.10a and 10b An alternative configuration of the air inlet 30 is shown. Fig.10a In the embodiment, the spacing of the outwardly extending annular fins 34 varies along the length of the tubular body 31, so that the spacing between adjacent annular fins 34 at the distal end 36 of the air inlet 30 is greater than the spacing between adjacent annular fins 34 at the proximal end 37 of the air inlet 30. This arrangement provides stronger waterproof protection at the proximal end 37 of the air inlet 30.

[0059] In an alternative arrangement, the spacing between adjacent annular fins 34 at the distal end 36 of the air inlet 30 may be smaller than the spacing between adjacent annular fins 34 at the proximal end 37 of the air inlet 30 to provide greater water protection toward the distal end 36 of the air inlet 30. In another alternative arrangement, the spacing between adjacent annular fins 34 at the ends 36, 37 of the air inlet 30 may be smaller than the spacing between adjacent annular fins 34 toward the center of the air inlet 30, or vice versa, to provide greater water protection toward the center or ends of the air inlet 30. The specific positioning of the annular fins 34 can be adjusted to best fit any particular mop assembly 8.

[0060] Fig.10b Another alternative arrangement of the air inlet 30 is shown in which the annular fin 34 is angled relative to the tubular body 31. This arrangement provides greater protection against water droplets and jets having a steeper angle of incidence relative to the axis of the air inlet 30.

[0061] In another alternative arrangement of the air inlet 30 (not shown), the annular fin 34 varies in length along the axis of the tubular body 31. In one example, the fin 34 at the distal end 36 of the air inlet 30 is longer than the annular fin 34 at the proximal end 37 of the air inlet 30 to provide stronger water protection toward the distal end 36 of the air inlet 30. This arrangement provides stronger water protection toward the distal end 36 of the air inlet 30.

[0062] In another example, the fins 34 at the proximal end 37 of the air inlet 30 are longer than the annular fins 34 at the distal end 36 of the air inlet 30 to provide stronger waterproof protection toward the proximal end 37 of the air inlet 30 .

[0063] It should be understood that Fig.10b The spacing between the inclined fins 34 shown in FIG. 3 can be as large as that in the above reference. Fig.10a and the alternatives thereof may be varied in the same manner as described.

Claims

1. A drive system for a floor cleaner, comprising: a longitudinally extending drive housing; a motor, at least partially located within the drive housing; and a gear arrangement, at least partially located within the drive housing, wherein the motor and the gear arrangement are longitudinally arranged relative to each other, and wherein a drive output of the motor is configured to provide drive to an output member via the gear arrangement, wherein the gear arrangement comprises an asymmetric planetary gear set having a sun gear, a ring gear and two planet gears, wherein the two planet gears have different sizes.

2. The drive system of claim 1, wherein the drive housing comprises a radially symmetric longitudinal axis, and wherein the gear arrangement comprises a central drive axis, wherein the central drive axis of the gear arrangement is offset from the radially symmetric longitudinal axis of the drive housing.

3. A drive system according to any one of the preceding claims, wherein the gear arrangement further comprises at least one primary reduction stage.

4. A drive system according to any one of the preceding claims, wherein the gear arrangement comprises a plurality of primary reduction stages.

5. A drive system according to claim 3 or 4, wherein each primary reduction stage comprises a planetary gear set.

6. A drive system according to any one of the preceding claims, wherein the output member is a ring gear of the asymmetric planetary gear set.

7. A drive system according to any one of the preceding claims, wherein the asymmetric planetary gear set is configured to provide drive to a primary driven member and a secondary driven member.

8. The drive system of claim 7, wherein the asymmetric primary gear set is operably coupled to another output member, and wherein the output member is configured to provide drive to the primary driven member, and the another output member is configured to provide drive to the secondary driven member.

9. The drive system of claim 8, wherein the further output member is driven by one of the two planetary gears of the asymmetric planetary gear set.

10. A drive system according to claim 9, wherein the further output member is driven by the larger of the two planetary gears.

11. An agitator head assembly for a floor cleaner comprising a drive system according to any preceding claim, and an agitating member mounted for rotation about the drive assembly, wherein the agitating member is operatively connected to the output member.

12. An agitator head assembly according to claim 11, comprising a debris remover element mounted for rotation alongside the agitating member, wherein the output of the asymmetric planetary gear set is operatively connected to the debris remover element and is configured to provide drive to the debris remover element in use.

13. An agitator head assembly according to claim 12, wherein one of the two planetary gears of the asymmetric planetary gear set is configured to provide drive to the debris remover element in use.

14. An agitator head assembly according to claim 13, wherein the larger of the two planetary gears is arranged to provide drive to the debris remover element in use.

15. A cleaning head for a floor cleaner comprising one or more agitator head assemblies according to any one of claims 11 to 14 mounted within a cleaning head housing.

16. A floor cleaner comprising the cleaning head according to claim 15.

Images