Calibration procedure for sensor module, sensor module and intelligent cleaning device

Abstract

The present disclosure provides a calibration method for a sensor module of an intelligent cleaning device, a sensor module, and an intelligent cleaning device. The method comprises: controlling a circuit by a control unit, which is switched on to energize a turbidity sensor in response to a calibration command to the turbidity sensor from a main controller of an intelligent cleaning device; adjusting an input of the turbidity sensor via a calibration circuit, receiving an output of the turbidity sensor via a measuring circuit, and adjusting the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor reaches a preset range; and sending the calibration completion information to the main controller. The present disclosure can determine the degree of coupling between the intelligent cleaning device, such as...the washing machine or dishwasher, and the sensor module with the turbidity sensor, reduce the ease of maintenance of the system, maintain the calibration during operation of the turbidity sensor, improve the long-term usage accuracy of the turbidity sensor and extend the service life of the turbidity sensor.

Description

FIELD OF DISCLOSUREThe disclosure relates to the field of cleaning implements, and more particularly to a calibration method for the smart cleaning implement sensor module, a sensor module, and a smart cleaning implement.BackgroundWith the progress of science and technology and the improvement of the human life standard, smart cleaners such as washing machines and dishwashers have become an important component of household products. Such apparatus are usually equipped with turbidity sensors which measure the turbidity of the water during the cleaning operation to determine the degree of cleanliness of the items being washed and, accordingly, determine the optimum washing time and rinsing time. However, due to influence of various factors such as water quality, temperature, and intensity of the light source, the measurement accuracy of the turbidity sensor may be impaired, resulting in poor cleaning effect or waste of resources.FIGS. 1-3 show schematic representations of some existing turbidity sensors. FIG. 1 shows a schematic diagram of a turbidity sensor without calibration in operation (on-site calibration). Such turbidity sensors are calibrated during manufacture in the factory (factory calibration) and are no longer calibrated during use. When the turbidity sensor is calibrated at the factory, the variable resistance (VR) is set for calibration. R1 can be used for voltage division and current limiting. The voltage and the current of the phototransistor (PTr) can be calculated by measuring the current and the voltage of R1, so that the turbidity of the measurement object can be determined. When the light of the LED irradiates the sensitive area of the PTr, its internal electronic state may change, whereby the resistance or current of the PTr, which is one of the key components of the sensor circuit, may change. A lower voltage of PTr means that a lower current flows through PTr and the turbidity of the liquid is greater. After the turbidity sensor is used for a long period of time, the light path of the turbidity sensor is affected by the dust accumulation in the housing, resulting in a large measurement deviation. FIG. 2 is a schematic illustration of a turbidity sensor having an on-site calibration function. FIG. 3 is a schematic illustration of the connection between the main controller of the device and the turbidity sensor having an on-site calibration function. The control unit 310 in the main controller 300 supplies power to the turbidity sensor 200 via the switching circuit 320, calibrates the turbidity sensor 200 via the calibration circuit 330, and obtains the turbidity data of the turbidity sensor 200 via the measurement circuit 340. Although the turbidity sensor shown in FIGS. 2 and 3 can improve its detection accuracy by on-site calibration, since the calibration process is controlled by the main controller and the control unit, the circuit, the calibration circuit, and the measurement circuit are all present in the main controller and the coupling degree between the main controller and the turbidity sensor is too large, it is unsuitable for product upgrading and the turbidity sensor has low universality.SummaryIn order to solve at least a part of the technical problems of the related art, the present disclosure provides a calibration method for the sensor module of a smart cleaner, a sensor module, and a smart cleaner, which can reduce the coupling degree between the smart cleaner such as a washing machine or a dishwasher and the sensor module having the turbidity sensor, improve maintain maintainability of the system, maintain calibration in operation of the turbidity sensor, improve long-term use accuracy of the turbidity sensor, and extend the use life of the turbidity sensor.According to an embodiment of the first aspect of the present disclosure, there is provided a calibration method for a sensor module of a smart cleaner, the sensor module including a plurality of sensors, a control unit, a circuit, a calibration circuit, and a measurement circuit, the plurality of sensors including at least one turbidity sensor. The method includes: controlling, by the control unit, the switching circuit to be turned on to supply power to the turbidity sensor in response to a calibration command to the turbidity sensor from a main controller of the smart cleaner; adjusting, by the control unit, an input of the turbidity sensor via the calibration circuit, obtaining an output of the turbidity sensor via the measurement circuit, and adjusting the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor reaches a preset range; sending, by the control unit, calibration completion information to the main controller.In an embodiment of the present embodiment, a manner of generating the calibration command for the turbidity sensor from the main controller of the smart cleaner includes the steps of: obtaining washing process data for each time of the turbidity sensor by the control unit; determining whether to calibrate the turbidity sensor based on the washing process data; sending a calibration request to the main controller in response to a determination result that the turbidity sensor needs to be calibrated; and sending the calibration command in response to the calibration request by the main controller.In one embodiment of the present embodiment, the determination of whether the turbidity sensor needs calibration includes: obtaining a data average value, a data average maximum value, and / or a data average minimum value of each washing operation of the smart cleaner; comparing the data average value, the data average maximum value, and / or the data average minimum value with initial data and / or calibrated data and determining that the turbidity sensor needs to be calibrated when a comparison result exceeds a preset range; and sending, by the main controller, the calibration command to the control unit in response to a determination result that the turbidity sensor needs calibration.In one embodiment of the present embodiment, the main controller is communicatively connected to the sensor module via a data bus.In one embodiment of the present embodiment, the controller adjusting the input of the turbidity sensor based on the output of the turbidity sensor comprises: linearly processing turbidity data and voltage data of the turbidity sensor by the controller; adjusting the input of the turbidity sensor based on the result of the linear processing.In one embodiment of the present embodiment, a communication data packet between the master controller and the sensor module includes a data bit indicating whether the master controller requires information from each sensor.In one embodiment of the present embodiment, when the data bit in the communication data packet associated with the turbidity sensor is set to a first value, the control unit determines that there is no need to measure the data of the turbidity sensor and controls the circuit to be turned off; and when the data bit in the communication data packet associated with the turbidity sensor is set to a second value, the control unit determines that there is a need to measure the data of the turbidity sensor and controls the circuit to be turned on.According to an embodiment of the second aspect of the present disclosure, a sensor module for a smart cleaner is provided. The sensor module includes a plurality of sensors including at least a turbidity sensor, a control unit, a circuit, a calibration circuit, and a measurement circuit. The controller is configured to: control the circuit to be turned on to power the turbidity sensor in response to a calibration command to the turbidity sensor from a main controller of the smart cleaner; set an input of the turbidity sensor via the calibration circuit, obtain an output of the turbidity sensor via the measurement circuit, and set the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor reaches a preset range; and transmit information for completion of the calibration to the main controller.In one embodiment of the present embodiment, the main controller is communicatively connected to the sensor module via a data bus.According to an embodiment of the third aspect of the present disclosure, there is provided an intelligent cleaning device. The apparatus includes a main controller and an above-mentioned sensor module communicatively connected to the main controller.Brief Description of the DrawingsOther features and advantages of the present disclosure will be readily understood from the following preferred embodiments, which will be described in detail with reference to the accompanying drawings. In the drawings: FIG. 1 shows a schematic illustration of a turbidity sensor from the prior art. FIG. 2 shows a schematic diagram of another turbidity sensor from the prior art that can be calibrated on site. FIG. 3 is a schematic diagram of the turbidity sensor of FIG. 2 coupled to the master controller. FIG. 4 shows a block diagram of an improved sensor module in an embodiment of the present disclosure. FIG. 5 is a schematic diagram of a calibration method for a sensor module of a smart cleaner in an embodiment of the present disclosure. FIG. 6 is a schematic structural diagram of a sensor module including a turbidity sensor and a main controller according to an embodiment of the present disclosure. FIG. 7 is a schematic structural diagram of another sensor module and the main controller according to an embodiment of the present disclosure. FIG. 8 is a schematic diagram showing the relationship between turbidity (NTU) and voltage (U) according to an embodiment of the present disclosure. FIG. 9 is a schematic diagram of the relationship between turbidity (NTU) and communication data according to an embodiment of the present disclosure.Detailed DescriptionThe application forms and the use of the embodiments will be described in detail below. It should be understood, however, that the discussed embodiments are merely exemplary examples of particular embodiments of the present disclosure and are not intended to limit the scope of the present disclosure. The terms used for the individual components, such as, for example, top, bottom, left, right, top, bottom, etc., are not absolute, but rather relative. When each component is arranged as shown in the diagram, these terms are appropriate, but when the position of each component in the diagram changes, these terms also change accordingly.As shown in FIG. 4, an embodiment of the present disclosure provides a novel sensor module 400 (an all-in-one sensor module) for a smart cleaner. The sensor module 400 includes a plurality of sensors 412, 414, and 416. FIG. 4 shows an example with three sensors, but the number of sensors is not limited. The plurality of sensors includes at least one turbidity sensor 412. The sensor module 400 further comprises a control unit 410, a circuit 420, a calibration circuit 430 and a measurement circuit 440. The plurality of sensors are each connected to the control unit 410. The controller 410 may be configured to: control the switching circuit 420 to be turned on to power the turbidity sensor 412 in response to a calibration command to the turbidity sensor 412 from the main controller of the smart cleaner; adjust the input of the turbidity sensor 412 via the calibration circuit 430, obtain the output of the turbidity sensor 412 via the measurement circuit 440, and adjust the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor reaches the preset range; and transmit the information for completion of the calibration to the main controller.In some examples, the main controller is communicatively coupled to the sensor module via a data bus. The data bus communication can meet not only the higher demands on communication quality as the number and type of sensors in the smart cleaner gradually increase, but also simplify wiring of the apparatus and reduce the complexity of the circuit design of the apparatus. Optionally, the data bus communication may be a UART communication, CAN communication, RS485 communication or the like.As shown in FIG. 5, an embodiment of the present disclosure provides a calibration method 500 for a sensor module of a smart cleaner. The sensor module includes a plurality of sensors, a control unit, a circuit, a calibration circuit, and a measurement circuit. The plurality of sensors includes at least one turbidity sensor. The plurality of sensors may further include one or a combination of a pressure sensor, a temperature sensor, a conductivity sensor, and an accelerometer. The steps of the calibration method 500 may be described as follows.Step 510, the controller controls the circuitry that is turned on to power the turbidity sensor in response to the calibration command to the turbidity sensor from the smart cleaner main controller. In some examples, the manner of generating the calibration command to the turbidity sensor from the main controller of the smart cleaner includes: obtaining, by the controller, the washing process data for each time of the turbidity sensor; determining whether to calibrate the turbidity sensor based on the washing process data; sending a calibration request to the main controller in response to a determination result that the turbidity sensor needs to be calibrated; and sending, by the main controller, the calibration command in response to the calibration request.Step 520, the controller adjusts the input of the turbidity sensor via the calibration circuit, obtains the output of the turbidity sensor via the measurement circuit, and adjusts the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor reaches the preset range.Step 530, the control unit sends the calibration completion information to the main controller. In some examples, after the controller sends the calibration completion information to the master controller, the circuit is turned off when it is determined that the turbidity sensor is no longer needed. In some other examples, the turbidity sensor power supply is a continuous current power supply. In the present disclosure, the power supply to the turbidity sensor is preferably controlled, i.e., when the turbidity sensor needs to operate (when calibration is required or when the smart cleaner performs washing operations), the circuit is turned on to supply power to the turbidity sensor; and when the turbidity sensor does not need to operate, the circuit is turned off to stop the power supply, which can effectively extend the life of the turbidity sensor.The calibration method 500 reduces the degree of coupling between the main controller and the turbidity sensor in the smart cleaner, facilitates product upgrading, and significantly improves the universality of the turbidity sensor and the main controller. For example, when updating a sensor in a product, the main controller does not need to be replaced. Another example is that the same master controller is suitable for multiple different manufacturers and different types of sensors.In some examples, the manner of determining whether to calibrate the turbidity sensor includes: the master controller determining whether to trigger the calibration command to the turbidity sensor by calculating the wash times or the use time of the machine.In some other examples, the manner in which to determine whether the turbidity sensor needs calibration comprises: the turbidity sensor analyzing whether the data has a deviation by comparing and analyzing the data at each wash, determining whether calibration needs to be performed using an appropriate algorithm, and sending turbidity calibration information to the master controller. Further, in some examples, the manner of determining whether to calibrate the turbidity sensor includes: obtaining a data average value, a data average maximum value, and / or a data average minimum value of each washing operation of the smart cleaner; comparing the data average value, the data average maximum value, and / or the data average minimum value with initial data and / or calibrated data and determining that the turbidity sensor needs to be calibrated when a comparison result exceeds a preset range; and sending, by the main controller, the calibration command to the control unit in response to the determination result.As a specific example, in a washing machine using a turbidity sensor, the washing process is considered to be completed when it is determined that the turbidity of the water is below a certain value. When the main controller requests transmission of turbidity data, the turbidity sensor records the data average value, the data average maximum value and the data average minimum value transmitted during a washing operation in a local storage unit. The manner of calculating the data average value may be: calculating the average value within each minute, and then calculating the average value of the average value within each minute in one washing process as the data average value of one washing process. The manner of calculating the average maximum value may be: calculating the average value of the first 100 maximum values in one washing process. The manner of calculating the average minimum value may be: calculating the average value of the first 100 minimum values in one washing process. During each washing operation, the changing tendencies of these values are compared, and when the deviation from the output data or the calibrated data is higher than the preset threshold value, it is determined that calibration is required. The stored data is updated after calibration.FIG. 6 shows a schematic structural diagram of a sensor module 600 and a main controller 650, wherein the sensor module 600 comprises a turbidity sensor. The sensors in the sensor module except for the turbidity sensor are not shown. Optionally, the master controller 650 may be connected to one or more sensor modules via the data bus. The sensor module includes a control unit 610, a turbidity sensor 612, a switching circuit 620, a calibration circuit 630 and a measurement circuit 640. As shown in FIG. 6, the turbidity sensor circuit 620, the calibration circuit 630, and the measurement circuit 640 are disposed on the turbidity sensor module, thereby realizing hardware decoupling between the main controller and the sensor module, thereby improving the universality of the turbidity sensor, the convenience of upgrading the main controller, and the maintainability of the system.In some examples, the calibration process of the turbidity sensor in the sensor module is illustrated in FIG. 6 may proceed as follows: the calibration liquid (e.g., clean water) is injected into the smart cleaner (e.g., washing machine or dishwasher); the main controller 650 sends a calibration command for the turbidity sensor to the sensor module 600 with the turbidity sensor; the control unit 610 in the sensor module sends calibration information back to the main controller 650 and enters a calibration process; the main controller waits for information about the completion of calibration of the turbidity sensor and the control unit 610 turns on the circuit 620; the input of the calibration circuit 630 (typically PWM value or analog voltage value) is adjusted; the output of the turbidity sensor 612 is measured by the measurement circuit 640; the measured voltage value is compared with the calibration standard value, and if the voltage value is equal to the calibration standard value, the next step is initiated, and if the voltage value is not equal to the calibration standard value, the input of the calibration circuit is adjusted again by an algorithm; the input value of the calibration circuit is recorded in the EEPROM of the control unit of the sensor module and can be used for later measurement; and the circuit is turned off, the calibration process of the turbidity sensor is ended, and the information about the completion of the calibration is sent to the main controller.FIG. 7 is a schematic structural diagram of a sensor module 700 and a main controller 750 according to an embodiment of the present disclosure. The sensor module 700 (all-in-one) includes a plurality of sensors 712, 714, 716, and 718. The plurality of sensors 712, 714, 716, and 718 are each connected to the control unit 710. The control unit 710 is communicatively connected to the main controller 750 via the data bus. The plurality of sensors may include one or a combination of a MEMS pressure sensor, a temperature sensor, a turbidity sensor, and a conductivity sensor, but other types of sensors as well. These sensors are connected to the sensor module control unit 710 via suitable hardware circuits. The control unit can be a microcontroller unit (MCU). The MCU collects the data of each sensor, performs algorithm calculation, packages the data, and then transmits it to the main controller via the Universal Asynchronous Receiver / Transmitter (UART) communication port. The main controller uses the data to control the individual components of the washing machine or dishwasher and to complete the washing process. The main controller and the sensor module may be connected one-to-one (i.e., a main controller corresponds to a sensor module) or one-to-many (i.e., a main controller corresponds to a plurality of sensor modules).Further, the sensor module turbidity sensor shown in FIG. 7 may be calibrated in the following manner: the main controller enters a calibration state and sends a calibration command to the sensor module; the sensor module enters a measurement mode to measure the turbidity value at that time and records the turbidity value in a memory (e.g., an EEPROM); a calibrated measurement value is obtained after the calculation based on the measurement value and the check value in the record; and the calibrated measurement value is sent to the main controller, and the information on completion of the calibration is sent to the main controller. In some other examples, the difference between the measurement value and the check value may be sent as a correction value to the master controller to correct the subsequent measurement value.In some examples, the sensor module having the bus structure may perform nonlinear relationship processing. And the signal received from the main controller is the value of the linear physical quantity. By transferring the processing of the non-linear relationship between the voltage and the turbidity, which must be performed by the main controller according to the prior art, to the sensor module, not only the processing amount of the main controller is reduced, but also the coupling degree between the turbidity sensor and the main controller is reduced. FIG. 8 is a schematic diagram of the relationship between turbidity (NTU) and voltage (U) before transmission, and FIG. 9 is a schematic diagram of the relationship between turbidity (NTU) and communication data after transmission. The communication data is the value of the linearly measured physical quantity obtained after linearly processing the voltage.In some examples, the controller adjusts the input of the turbidity sensor based on the output of the turbidity sensor, comprising: the controller linearly processes the turbidity data and the voltage data of the turbidity sensor; and adjusts the input of the turbidity sensor based on the result of the linear processing.In some examples, the communication data packet between the master controller and the sensor module includes the data bit indicating whether the master controller requires information from each sensor. When the data bit associated with the turbidity sensor in the communication data packet is set to a first value (e.g., 0), the control unit determines that there is no need to measure the turbidity sensor data and controls the circuit to be turned off. When the data bit in the communication data packet associated with the turbidity sensor is set to a second value (e.g., to 1), the control unit determines that there is a need to measure the turbidity sensor data and controls the turn-on of the circuit.Another embodiment of the present disclosure provides a smart cleaner including a main controller and a sensor module, the sensor module communicatively connected to the main controller. This embodiment is similar to the above-described embodiment, so the details are not repeated here.Although the present disclosure has been described with reference to specific examples, these examples are merely illustrative and are not intended to limit the present disclosure. It will be apparent to those skilled in the art that changes, additions, or deletions may be made to the disclosed embodiments without departing from the spirit and scope of the present disclosure.

Claims

A calibration method for a sensor module of a smart cleaner, the sensor module comprising a plurality of sensors, a control unit, a circuit, a calibration circuit, and a measurement circuit, the plurality of sensors comprising at least one turbidity sensor, and the method comprising: controlling, by the control unit, the switching on of the circuit to supply power to the turbidity sensor in response to a calibration command to the turbidity sensor from a main controller of the smart cleaner; adjusting, by the control unit, an input of the turbidity sensor via the calibration circuit, obtaining an output of the turbidity sensor via the measurement circuit, and adjusting the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor reaches a preset range; and sending information on completion of calibration by the control unit to the main controller.The calibration method according to claim 1, wherein a manner of generating the calibration command to the turbidity sensor from the main controller of the smart cleaner comprises: obtaining washing process data for each time of the turbidity sensor by the control unit; determining whether to calibrate the turbidity sensor based on the washing process data; sending a calibration request to the main controller in response to a determination result that the turbidity sensor needs to be calibrated; and sending the calibration command by the main controller in response to the calibration request.The calibration method according to claim 2, wherein the determination of whether the turbidity sensor needs to be calibrated comprises: determining a data average value, a data average maximum value, and / or a data average minimum value for each washing operation of the smart cleaner; comparing the data average value, the data average maximum value, and / or the data average minimum value with initial data and / or calibrated data and determining that the turbidity sensor needs to be calibrated when a comparison result exceeds a preset range; and sending, by the main controller, the calibration command to the control unit in response to the determination result.The calibration method of claim 1, wherein the main controller is communicatively connected to the sensor module via a data bus.The calibration method of claim 1, wherein adjusting, by the controller, the input of the turbidity sensor based on the output of the turbidity sensor comprises: linearly processing, by the controller, turbidity data and voltage data of the turbidity sensor; adjusting the input of the turbidity sensor based on the result of the linear processing.The calibration method of claim 1, wherein a communication data packet between the master controller and the sensor module comprises a data bit indicating whether the master controller requires information from each sensor.The calibration method according to claim 6, wherein when the data bit in the communication data packet associated with the turbidity sensor is set to a first value, the control unit determines that there is no need to measure the data of the turbidity sensor and controls the circuit to be turned off; and when the data bit in the communication data packet associated with the turbidity sensor is set to a second value, the control unit determines that there is a need to measure the data of the turbidity sensor and controls the circuit to be turned on.A sensor module for a smart cleaner, comprising: a plurality of sensors including at least one turbidity sensor; a control unit, a circuit, a calibration circuit, and a measurement circuit, wherein the control unit is configured to: control the circuit to be turned on to power the turbidity sensor from a main controller of the smart cleaner in response to a calibration command to the turbidity sensor; set an input of the turbidity sensor via the calibration circuit, obtain an output of the turbidity sensor via the measurement circuit, and set the input of the turbidity sensor based on the output of the turbidity sensor until the output of the turbidity sensor satisfies a preset range; and send information on completion of calibration to the main controller.The sensor module of claim 8, wherein the main controller is communicatively connected to the sensor module via a data bus.A smart cleaner, comprising: a main controller; and a sensor module according to claim 8 or 9, communicatively connected to the main controller.

Images