Surface treatment machine and method

Abstract

A surface treatment machine comprises a powered surface treatment system, a control system configured to at least partially control operation of the surface treatment system, a power management system

Description

The present invention relates to a surface treatment machine and method for managing the power requirements of a surface treatment machine. Particularly, though not exclusively, the invention relates to an autonomous or semi-autonomous floor treatment machine having an accessible removable power source and backup power source. Conventional autonomous or semi-autonomous floor treatment machines typically use integrated energy storage devices to power a processor, display, actuators, communication means, sensors, lights and other on-board equipment. These energy storage devices need to be recharged or replaced when partially or fully discharged to provide the necessary power for further cleaning operation or other actions. Typically, recharging the energy storage devices involves plugging the machine into an appropriate power source. Conventional recharging operations involve docking the machine into a separate charging station or wireless charging. In order to improve efficiency of the operation the docking station may also refill the clean water tank and empty the dirty water tank. Alternatively, some autonomous or semi-autonomous floor treatment machines have removable energy storage devices. When recharging is required, the energy storage devices are removed from the machine and charged offline. Thus, the energy storage devices can be swapped for fully charged similar devices. Therefore, this method does not require a physical or close connection between the machine and a docking station or charging source. The existing recharging operations interrupt the cleaning routine and result in reduced productivity while the devices are charging or being swapped. Thus, it is an object of the present invention to provide a floor treatment machine that enhances efficiency of the recharging operation. According to a first aspect of the invention there is provided a surface treatment machine comprising: a powered surface treatment system; a control system configured to at least partially control operation of the surface treatment system; a power management system associated with the control system for managing the power requirements of the surface treatment system and the control system, the power management system comprising a primary energy storage means and a secondary energy storage means; wherein the primary energy storage means provide power for the surface treatment system, the control system and the secondary energy storage means, and wherein the primary energy storage means comprises at least one removable energy storage device; and wherein the secondary energy storage means is configured to selectively power the control system on removal of the energy storage device(s) of the primary energy storage means. Advantageously, the machine of the invention enables the primary power source to be removed and replaced quickly and efficiently without the requirement for a complete system shutdown of the onboard computer / control system. This allows enhanced productivity by reducing redundant time while batteries are removed and replaced. The surface treatment machine may include any surface cleaning device which is manually operated, semi-autonomous or autonomous. The surface treatment machine may comprise a floor cleaner. The surface treatment machine may comprise an autonomous and / or semi-autonomous floor treatment machine. The powered surface treatment system may comprise at least one surface treatment tool. The surface treatment tool may comprise one or more workheads. The surface treatment tool(s) may be configured to contact, scrub, agitate, polish or the like. The surface treatment tool(s) may comprise at least one brush, scrubber pad, cleaning tool or the like. Alternatively, or additionally, the powered surface treatment system may comprise a waste recovery system. The waste recovery system may include a suction source and an inlet, the suction source and the inlet fluidly connected to a suction conduit. The waste recovery system may further contain a waste container coupled to a distal end of the suction conduit, for the containment of waste recovered via the inlet and suction conduit. Alternatively, or additionally, the powered surface treatment system may comprise a fluid delivery and / or distribution system including a fluid source, pump, and fluid delivery conduit with an outlet for selective delivery of fluid to a surface in use. The control system may be configured to control operation of the one or more surface treatment tool(s), the waste recovery system, the fluid delivery system, and / or other powered components, motors and the like to perform any cleaning function. The surface treatment machine may further comprise a powered propulsion system configured to enable movement of the machine. The control system may be arranged to at least partially control operation of the propulsion system. Thus, the control system and the propulsion system may be configured to allow autonomous or semi-autonomous movement of the machine within its environment. The propulsion system may include a powered drive mechanism, directional control and at least one wheel or roller. The wheel(s) / roller(s) may comprise a signal wheel or roller, a pair, or, a set of wheels / rollers arranged in a suitable configuration to assist with movement of the machine over a surface. The control system of the surface treatment machine may be configured to cause selective movement of the machine via the propulsion system in response to control system commands. The control system may comprise hardware and software for controlling at least some of the functions of the surface treatment machine. The hardware may comprise a sensor array, a communication means, and interconnected electronic components to achieve the required functionality and electrically connect the control system to the surface treatment system, the energy storage means and the propulsion system. The control system may comprise a processor programmed to control operation of the surface treatment system and the power management system. The software may be pre-programmed and contain algorithms that are capable of supporting at least some of the following tasks: receiving and transmitting selected data; executing commands; filtering and processing sensor data; mapping the environment surrounding the machine; detecting obstacles in the environment surrounding the machine; localisation of the machine within its environment; path planning; navigation; controlling movement of the machine; collision avoidance; execution of cleaning programs; troubleshooting and problem solving; operation and control of the propulsion system and / or a safety system. Thus, the control system may act as a brain to enable the machine to perform a variety of cleaning functions autonomously or semi-autonomously such as waste recovery, wet and dry scrubbing, while retaining the ability to navigate and manoeuvre safely within its environment. The power management system may be configured to monitor the state of charge of the primary and secondary energy storage means. The power management system may be configured to supply data regarding the state of charge of the primary and secondary energy storage means to the control system. The power management system may be configured to manage the power requirements of the systems on board the surface treatment machine, including but not limited to: the control system, the surface treatment system, the propulsion system, and / or a safety system. The control system may comprise a user interface, visual display and / or communication means. The user interface and / or visual display may display information regarding a status of the machine. The communication means may be configured to communicate with a remote device and transmit information regarding a status of the machine to the remote device. The user interface, visual display and / or communication means may be configured to display information derived from the battery management system. The user interface, visual display and / or communication means may be configured to provide information regarding the status of the primary energy storage means via a display and / or remote communication respectively. The user interface, visual display and / or communication means may be configured to provide information regarding the status of the secondary energy storage means via a display and / or remote communication respectively. The user interface, visual display and / or communication means may be configured to provide data regarding the state of charge of the primary and / or secondary energy storage means via a display and / or remote communication respectively. The current state of charge data for the energy storage means may be presented as a percentage value of a fully charged energy storage means, an estimate of remaining runtime, and / or any other relevant method to convey the state of charge data. The user interface, visual display, and / or communication means may be configured to provide an alert via a visual display and / or issue a remote communication when the state of charge of the primary and / or secondary energy storage means passes a predetermined threshold. The alert may comprise a visible signal, audible alarm, tactile notification and / or other means of communication to alert a user to a state of charge below a threshold value. The user interface, visual display, and / or communication means may be configured to provide a notification via a visual display and / or communication to a remote device respectively, when the primary energy storage means passes below a predetermined threshold and requires replacement. Thus, advantageously, the control and power management systems may monitor and transmit information on the state of charge of the primary and / or secondary energy storage means enabling a user to track the power requirements of the surface treatment machine. Further, the control system may alert and / or notify an operator when the state of charge passes below a pre-determined threshold and the primary energy storage means needs to be replaced. The primary energy storage means may be removable and replaceable. Typically, the primary energy storage means is removed and replaced when the state of charge of the primary energy storage means decreases below a predetermined threshold. The primary energy storage means may be detachable from the machine to enable the primary energy storage means to be removed and replaced. The surface treatment machine may comprise an enclosure in which the primary energy storage means is located. The enclosure may support the primary energy storage means and comprise electrical contacts for electrically connecting the primary energy storage means with the control and power management systems. The enclosure may also comprise a mechanical retainer to secure the primary energy storage means within the enclosure. The enclosure may be accessible via an opening in an exterior of the surface treatment machine. Thus, the invention enables ‘hot-swapping’ of the primary energy storage means allowing one primary energy storage means to be removed and replaced with another primary energy storage means to allow fast changing of the primary power source and minimal down time for the machine. The secondary energy storage means may be electrically connected to the primary energy storage means such that it is chargeable by the primary energy storage means. Recharging of the secondary energy storage means by the primary storage means may be controlled by the power management system. The secondary energy storage means may be fully chargeable using less than around 20% of the full capacity of the primary energy storage means. The secondary energy storage means may be fully chargeable using between around 5 and 15% of the full capacity of the primary energy storage means. The power management system may be configured such that the primary energy storage means automatically recharges the secondary energy storage means when the state of charge of the primary energy storage means exceeds a predetermined threshold. The power management system may be configured such that the secondary energy storage means automatically powers the control system when the state of charge of the primary energy storage means is below a predetermined threshold. The power management system may be configured to initiate a programmed shut down of the control system when the state of charge of the secondary energy storage means passes below a predetermined threshold. Thus, if a situation arises in which the secondary energy storage means lacks the required power to support the control system a planned shut down of the surface treatment machine can be initiated. The secondary energy storage means may comprise at least one energy storage device. The secondary energy storage means may be retained within the machine. The secondary energy storage means may be non-removable during normal use of the surface treatment machine. The power management system may comprise a detection mechanism for detecting the presence and / or absence of at least one energy storage device of the primary energy storage means. The detection mechanism may comprise an electric detection mechanism. Alternatively, the detection mechanism may comprise a mechanical detection mechanism. On detection of the removal and / or absence of at least one of the primary energy storage devices, the secondary energy storage means is configured to power the control system. Thus, advantageously, the removal and replacement of the primary energy storage means triggers the provision of power to the control system from the secondary energy storage means to power essential systems of the surface treatment machine. This avoids the need to power down, reboot, and set up the control system following replacement of the primary battery, thereby enhancing productivity and minimising down time. The primary and secondary energy storage means may have different voltage ratings. The secondary energy storage means may comprise a voltage rating that is lower than a voltage rating of the primary energy storage means. The primary and secondary energy storage means may have different capacities. The secondary energy storage means may comprise a lower Watt-hour rating than a Watthour rating of the primary energy storage means. The primary and secondary energy storage device(s) may comprise at least one cell or battery pack. The primary energy storage means may comprise at least two energy storage devices. The secondary energy storage means may comprise one energy storage device. The energy storage means may comprise the same or different types of energy storage devices. The energy storage devices may comprise batteries of various chemistries including lithium ion, sodium ion, or solid state, fuel cells, or similar, which may be replaced and recharged when depleted. According to a second aspect of the invention, there is provided a method of managing the power requirements of a surface treatment machine, the method comprising the steps of: providing a powered surface treatment system, a control system and a power management system; at least partially controlling operation of the surface treatment system using the control system; managing the power requirements of the surface treatment system and the control system using the power management system, the power management system having a primary energy storage means comprising at least one removable energy storage device, and a secondary energy storage means; powering the surface treatment system, the control system and the secondary energy storage means using the primary energy storage means; and selectively powering the control system using the secondary energy storage means on removal of the energy storage device(s) of the primary energy storage means. The above-described aspects of the invention may be combined with any other aspect, feature or embodiment described in the specification or shown in the figures. Embodiments of the invention are now described with reference to the following drawings in which: Figure 1 is a schematic diagram showing the interrelation of systems of the invention; and Figure 2 is a flow diagram demonstrating a method of the invention. According to a first embodiment of the invention, there is provided a surface treatment machine in the form of an autonomous machine. The autonomous machine has an outer housing enclosing a chassis which supports a propulsion mechanism, a surface treatment system, a connected control system and a power management system, which systems include a plurality of mechanical, electrical and cleaning components. The autonomous machine is capable of autonomously moving safely within an environment and performing a variety of cleaning functions such as suction, wet and dry scrubbing and the like. A driveable wheel assembly is mounted on the chassis to facilitate movement of the machine. The machine is configured to travel over ground and floor surfaces using any suitable propulsion mechanism capable of controlling motion (speed and direction) of the machine. Suitable propulsion mechanisms are well known in the art. The surface treatment system includes a pair of rotatable workheads mounted on parallel vertical axes. The workheads are selectively drivable by an associated motor. The surface treatment system further includes a waste recovery system having a suction inlet mounted between and behind the workheads (relative to the normal direction of travel of the machine). The suction inlet is fluidly connected to a suction source and a waste tank via a suction conduit. A squeegee collector assembly is provided behind the workheads to assist with the recovery of waste via the inlet. The waste tank is supported by the chassis of the machine and is provided to contain the waste recovered via the inlet and suction conduit. The surface treatment system further includes a fluid delivery and distribution system. The fluid delivery and distribution system includes a tank containing cleaning fluid, a pump for dispensing the fluid along a fluid delivery conduit to an outlet. The outlet includes a spray nozzle located substantially centrally in front of the workheads (relative to the normal direction of travel of the machine). Thus, the surface treatment system enables fluid to be delivered to the floor surface via the outlet nozzle, the workheads can work the cleaning fluid into the surface facilitate cleaning of the floor and the suction inlet recovers fluid and waste into the storage tank. The machine further includes a control system for controlling the surface treatment and propulsion systems. The control system provides the machine with operative functionality by combining the necessary hardware, electronics, software and processing capabilities to enable the machine to map, localise, plan, navigate and manoeuvre in its environment and carry out a range of service (cleaning) tasks in a safe, efficient and cost-effective manner. The control system comprises: a processor with algorithms for controlling a plurality of functions; a user interface; communication equipment; and an array of sensors. The processor receives data from the sensor array and other on-board systems, which data is processed to provide information on the performance and status of the machine, as well as its position and features of an environment surrounding the machine. The control system includes a visual display to convey important information to an operator. The communication equipment includes a transmitter for transfer of processed data to one or more remote devices in communication with the control system of the machine. The communication equipment is provided to deliver important information regarding a status of the machine to the remote device(s). The machine has a power management system associated with the control system and connected to a primary and a secondary energy storage means as depicted schematically in figure 1. The primary energy storage means provides power for all functionalities of the machine as well as charging the secondary energy storage means. The secondary energy storage means provides power for the control system when the primary energy storage means is depleted or removed. The power management system monitors the state of charge of both the primary and secondary energy storage means and controls which of the energy storage means is supplying power to the machine. This ensures the machine is maximally efficient and the control system and essential functions remain powered by the secondary energy storage means when the primary energy storage means is removed and replaced. The autonomous machine has an enclosure supported by the chassis with electrical contacts, which electrically connect the primary energy storage means to the systems and components of the machine requiring power. The outer housing of the machine has a lockable opening to allow access to the enclosure and the primary energy storage means therein. The dimensions of the enclosure are selected according to the size and shape of the energy storage devices which make up the primary energy storage means. According to the present example, the primary energy storage means comprise two energy storage devices in the form of rechargeable lithium-ion batteries known as Numatic® NX300. The NX300 energy storage devices have a rating of 36V and 300Wh. The energy storage devices may be accessed via the opening in the outer housing and selectively detached from the electrical contacts within the enclosure to enable removal of the devices when they need to be recharged. The secondary energy storage means is located within the machine proximate the hardware of the control system. During normal use, the secondary energy storage means is not removable by an operator of the machine. The secondary energy storage means is electrically connected to selectively power the control system including all non-cleaning functionalities of the robot as well as telemetry. The secondary energy storage means includes a single rechargable lithium ion battery pack known as 4s1 p and with a rating of 12.8V and 50Wh. The power management system is configured to detect removal of the primary energy storage means and monitor the state of charge of the primary energy storage means. In the event of removal of the primary energy storage means or detection of a state of charge below a predetermined threshold level, the power management system switches to the secondary energy storage means to power the control system. When the primary energy storage means depletes past a voltage threshold the secondary energy storage means is engaged by the power management system to support the essential functions of the machine. The secondary energy storage means continues to provide power until a fully charged alternative, or recharged, primary energy storage means is inserted into the enclosure and electrically connected via the contacts. Based on the anticipated consumption and the capacity of the secondary energy storage means, it can provide around one hour of uninterrupted power to the control system. According to the present example, if the secondary energy storage means depletes below a threshold state of charge, the power management system initiates a controlled shutdown of the control system. The visual display and / or the remote device(s) in communication with the machine using the telemetry / control system can provide information on the state of charge of the primary and secondary energy storage means. Once the state of charge of the primary energy storage means depletes beyond a predetermined threshold level (for example, less than 10% of full capacity) an alert is issued to prompt an operator to change one or both of the primary energy storage devices. An example of the method of the invention is depicted in the flow diagram of figure 2. In use, the machine operates autonomously or semi-autonomously to move, navigate and clean a floor surface safely. The on-board electrical components are powered by the primary energy storage means enabling full functionality. When the state of charge of the primary energy storage means depletes beyond the predetermined threshold level, the operator receives an alert on a remote device and / or through checking the visual display on the machine. The machine is stopped allowing access to the enclosure containing the energy storage devices of the primary energy storage means. The devices are removed from the enclosure and replaced with similar fully charged energy storage devices. Throughout this operation, the power management system switches to the secondary energy storage means to provide power for the control system. On replacement of the fully charged primary energy storage means, the power management system again reverts to the primary power source, which is also used to recharge the secondary energy storage means. According to the present example, less than 10% of the primary energy storage means is required to fully recharge the secondary energy storage means. The described method ensures that the autonomous machine has a continuous power source, avoiding the need for complete power down and system reboot on each occasion that the primary energy storage means is replaced. Modifications and improvements can be made without departing from the scope of the invention. Components and systems described with reference to the embodiments are illustrative only and are not intended to limit the scope of the invention. The example provided describes a surface treatment machine in the form of an autonomous machine, however, the machine (and applicable method) may be any suitable surface treatment machine of any type. The number, type and arrangement of the energy storage devices can be varied according to the power requirements of the surface treatment machine. For example, larger surface treatment machines with multiple functions may include a plurality of primary energy storage devices. Smaller surface treatment machines may contain a single primary energy storage device and use smaller devices / batteries with lower charge capacity for the primary and / or secondary energy storage means.

Claims

1. A surface treatment machine comprising:a powered surface treatment system;a control system configured to at least partially control operation of the surface treatment system;a power management system associated with the control system for managing the power requirements of the surface treatment system and the control system, the power management system comprising a primary energy storage means and a secondary energy storage means;wherein the primary energy storage means provide power for the surface treatment system, the control system and the secondary energy storage means, and wherein the primary energy storage means comprises at least one removable energy storage device; andwherein the secondary energy storage means is configured to selectively power the control system on removal of the energy storage device(s) of the primary energy storage means.

2. A surface treatment machine according to claim 1, wherein the secondary energy storage means is chargeable by the primary energy storage means and wherein recharging of the secondary energy storage means by the primary storage means is controlled by the power management system.

3. A surface treatment machine according to claim 1 or claim 2, wherein the power management system is configured to monitor the state of charge of the primary and secondary energy storage means.

4. A surface treatment machine according to claim 3, wherein the power management system is configured such that the secondary energy storage means automatically provides power to the control system when the state of charge of the primary energy storage means is below a predetermined threshold.

5. A surface treatment machine according to claim 3 or claim 4, wherein the power management system is configured such that the primary energy storage meansautomatically recharges the secondary energy storage means when the state of charge of the primary energy storage means exceeds a predetermined threshold.

6. A surface treatment machine according to any one of claims 3 to 5, wherein the control system comprises at least one of a visual display and / or a remote communication means, and wherein the control system alerts an operator via the visual display and / or the remote communication means when the state of charge of the primary energy storage means passes below a pre-determined threshold.

7. A surface treatment machine according to any preceding claim, wherein the energy storage device(s) are detachable from the machine to enable the primary energy storage means to be removed, allowing replacement of the primary energy storage device(s) when the state of charge of the primary energy storage device(s) decreases below a predetermined threshold.

8. A surface treatment machine according to any one of claims 3 to 7, wherein the power management system is configured to initiate a programmed shut down of the control system when the state of charge of the secondary energy storage means passes below a predetermined threshold.

9. A surface treatment machine according to any preceding claim, wherein the power management system comprises a detection mechanism for detecting the presence and / or absence of the energy storage device(s) of the primary energy storage means, such that on detection of the absence of the primary energy storage device(s), the secondary energy storage means is configured to power the control system.

10. A surface treatment machine according to any preceding claim, wherein the primary and secondary energy storage means have different voltage ratings.

11. A surface treatment machine according to claim 10, wherein the secondary energy storage means has a voltage rating that is lower than a voltage rating of the primary energy storage means.

12. A surface treatment machine according to any preceding claim, wherein the secondary energy storage means has a watt hour rating that is lower than a watt hour rating of the primary energy storage means.

13. A surface treatment machine according to any preceding claim, wherein the secondary energy storage means is fully chargeable by the primary energy storage means using less than 20% of the capacity of a fully charged primary energy storage means.

14. A kit of parts comprising a surface treatment machine according to any preceding claim.

15. A method of managing the power requirements of a surface treatment machine, the method comprising the steps of:providing a powered surface treatment system, a control system and a power management system;at least partially controlling operation of the surface treatment system using the control system;managing the power requirements of the surface treatment system and the control system using the power management system, the power management system having a primary energy storage means comprising at least one removable energy storage device, and a secondary energy storage means;powering the surface treatment system, the control system and the secondary energy storage means using the primary energy storage means; and selectively powering the control system using the secondaryenergy storage means on removal of the energy storage device(s) of the primary energy storage means.Amendments to the claims have been filed aas follow:26 08 25Claims1. A surface treatment machine comprising:a powered surface treatment system;5 a control system configured to at least partially control operationof the surface treatment system;a power management system associated with the control system for managing the power requirements of the surface treatment system and the control system, the power management system comprising a primary energy storage means10 and a secondary energy storage means;wherein the primary energy storage means provide power for the surface treatment system, the control system and the secondary energy storage means, and wherein the primary energy storage means comprises at least one removable energy storage device; and15 wherein the secondary energy storage means is configured toselectively power the control system on removal of the energy storage device(s) of the primary energy storage means.

2. A surface treatment machine according to claim 1, wherein the primary energy storage 20 means provide power for the secondary energy storage means such that the secondary energy storage means is chargeable by the primary energy storage means and wherein recharging of the secondary energy storage means by the primary storage means is controlled by the power management system.25 3. A surface treatment machine according to claim 1 or claim 2, wherein the powermanagement system is configured to monitor the state of charge of the primary and secondary energy storage means.

4. A surface treatment machine according to claim 3, wherein the power management 30 system is configured such that the secondary energy storage means automatically provides power to the control system when the state of charge of the primary energy storage means is below a predetermined threshold.

5. A surface treatment machine according to claim 3 or claim 4, wherein the power26 08 25management system is configured such that the primary energy storage means automatically recharges the secondary energy storage means when the state of charge of the primary energy storage means exceeds a predetermined threshold.5 6. A surface treatment machine according to any one of claims 3 to 5, wherein thecontrol system comprises at least one of a visual display and / or a remote communication means, and wherein the control system alerts an operator via the visual display and / or the remote communication means when the state of charge of the primary energy storage means passes below a pre-determined threshold.

107. A surface treatment machine according to any preceding claim, wherein the energy storage device(s) are detachable from the machine to enable the primary energy storage means to be removed, allowing replacement of the primary energy storage device(s) when the state of charge of the primary energy storage device(s) decreases 15 below a predetermined threshold.

8. A surface treatment machine according to any one of claims 3 to 7, wherein the power management system is configured to initiate a programmed shut down of the control system when the state of charge of the secondary energy storage means passes below 20 a predetermined threshold.

9. A surface treatment machine according to any preceding claim, wherein the power management system comprises a detection mechanism for detecting the presence and / or absence of the energy storage device(s) of the primary energy storage means, 25 such that on detection of the absence of the primary energy storage device(s), the secondary energy storage means is configured to power the control system.

10. A surface treatment machine according to any preceding claim, wherein the primary and secondary energy storage means have different voltage ratings.

11. A surface treatment machine according to claim 10, wherein the secondary energy storage means has a voltage rating that is lower than a voltage rating of the primary energy storage means.26 08 2512. A surface treatment machine according to any preceding claim, wherein the secondary energy storage means has a watt hour rating that is lower than a watt hour rating of the primary energy storage means.5 13. A surface treatment machine according to any preceding claim, wherein thesecondary energy storage means is fully chargeable by the primary energy storage means using less than 20% of the capacity of a fully charged primary energy storage means.10 14. A kit of parts comprising a surface treatment machine according to anypreceding claim.

15. A method of managing the power requirements of a surface treatment machine, the method comprising the steps of:15 providing a powered surface treatment system, a control systemand a power management system;at least partially controlling operation of the surface treatment system using the control system;managing the power requirements of the surface treatment20 system and the control system using the power management system, the power management system having a primary energy storage means comprising at least one removable energy storage device, and a secondary energy storage means;powering the surface treatment system, the control system and the secondary energy storage means using the primary energy storage means; and25 selectively powering the control system using the secondaryenergy storage means on removal of the energy storage device(s) of the primary energy storage means.

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