Vacuum cleaner device

Abstract

A vacuum cleaner device 100 comprises a housing 102, a motor fan assembly 104 to generate an airflow along airflow path 106 extending between dirty air inlet 108 and clean air outlet 110, at least one

Description

Field The present disclosure relates to a vacuum cleaner device. In particular, the present disclosure relates to a vacuum cleaner device with a dust particle sensor assembly. Background Vacuum cleaner devices are most effective when all the components of the vacuum cleaner device are maintained and functional. Therefore, it is desirable for the user to understand whether the vacuum cleaner device has an operational fault. A user may wish to know whether the exhaust air from the vacuum cleaner device is clean or whether the filter is faulty. A known arrangement for detecting dust particles in an airflow is disclosed in US 2024 / 0074631 A1. US 2024 / 0074631 A1 discloses comparing sequential images of the airflow within the vacuum cleaner device and then determining a type of dust particle to provide a particular cleaning behaviour. A problem with this arrangement is that the arrangement requires significant computational processing power in order to detect dust particles. This means that the arrangement needs careful calibration and is prone to failure. Summary Examples of the present disclosure aim to address the aforementioned problems. According to an aspect of the present disclosure there is a vacuum cleaner device comprising a housing having a motor fan assembly configured to generate an airflow along an airflow path extending between a dirty air inlet and a clean air outlet; at least one dust particle sensor assembly mounted along the airflow path and downstream of the motor fan assembly wherein the at least one dust particle sensor assembly comprises a light source and a light detector wherein the light detector is configured to generate a detected light signal in response to backscattered light from dust particles in the airflow; and a controller connected to the at least one dust particle sensor assembly and configured to generate a signal indicative of the operational status of the vacuum cleaner device in response to the received detected light signal from the at least one dust particle sensor assembly . Optionally the controller is configured to generate a signal indicative of the operational status of the vacuum cleaner device in response to the received detected light signal indicating a detected intensity of backscattered light from dust particles in the airflow. Optionally the light source is a semiconductor laser diode. Optionally the controller is configured to generate the signal in response to the amount of detected backscattered light exceeding a predetermined threshold. Optionally the predetermined threshold corresponds to a particle concentration in the airflow greater than 0.1 mg / m3. Optionally the vacuum cleaner device comprises a filter mounted on the airflow path and the controller is configured to generate a signal indicative of the operational status of the vacuum cleaner device wherein signal indicative of the operational status comprises a notification signal that the filter is faulty in response to the received detected light signal from the at least one dust particular sensor assembly. Optionally the dust particle sensor assembly is mounted adjacent to the clean air outlet. Optionally the clean air outlet is an air vent in the housing and the at least one dust particle sensor assembly is mounted on the air vent. Optionally the motor fan assembly and the clean air outlet are in fluid communication via an exhaust pipe and the at least one dust particle sensor assembly is mounted in the exhaust pipe. Optionally the controller is configured to issue a stop control signal to the motor fan assembly in response to the received detected light signal from the at least one dust particle sensor assembly. Optionally the controller is configured to obtain information relating to the operational status of the motor fan assembly and the controller is configured to generate a signal indicative of the operational status of the vacuum cleaner device in response to the received detected light signal from the at least one dust particle sensor assembly and the obtained information relating to the operational status of the motor fan assembly. Optionally the operational status of the motor fan assembly is one or more of motor voltage, motor current, fan speed or air flow speed. Optionally the controller is configured generate a signal indicative of the operational status of the vacuum cleaner device based on obtaining information relating to the amount of dust particles in the airflow based on a look-up table or a calculating the amount of dust particles based on Mie scattering theory or Rayleigh scattering equations. Optionally the at least one dust particle sensor assembly is configured to detect along an axis perpendicular to the airflow path. Optionally the vacuum cleaner device is a workshop vac. Brief Description of the Drawings Various other aspects and further examples are also described in the following detailed description and in the attached claims with reference to the accompanying drawings, in which: Figure 1 shows a schematic view of the vacuum cleaner device; and Figure 2 shows another schematic view of the vacuum cleaner device. Detailed Description Figure 1 shows a schematic view of a vacuum cleaner device 100. In some examples, the vacuum cleaner device 100 is a workshop vac although the vacuum cleaner device 100 can be any suitable vacuum cleaner device. The vacuum cleaner device 100 as shown in Figure 1 is designed to facilitate efficient cleaning operations by generating an airflow that carries dirt and debris from a dirty air inlet 108 to a clean air outlet 110 along an airflow path 106. In one configuration, the vacuum cleaner device 100 comprises a housing 102 which encases and protects the internal components of the vacuum cleaner device 100. The housing 102 is also designed to facilitate the flow of air through the vacuum cleaner device 100, from the dirty air inlet 108 to the clean air exhaust 110. The housing 102 may be constructed from a durable material such as plastic or metal. In some implementations e.g. as shown in Figure 1, the housing 102 is box-shaped, providing a compact and robust structure for the vacuum cleaner device 100. The housing 102 may be compatible with other toolboxes and stackable and I or securable with the other toolboxes. Whilst the examples shown in the Figures illustrate a vacuum cleaner device 100 with a box-shaped form, the housing 102 can be any suitable shape, e.g. a cylindrical shape. Although not shown in Figures, in some examples, the vacuum cleaner device 100 comprises a dust collection portion (not shown). The dust collection portion is a volume of the vacuum cleaner device 100 located within the housing 102. The dust collection portion is designed to receive and store dirt, debris, or water contained in the airflow received at the dirty air inlet 108. The dust collection portion is in fluid communication with the motor fan assembly 104 and the dirty air inlet 108, and is positioned on the airflow path 106. The dust collection portion may be removable for easy disposal of collected debris by the user. The dust collection portion can be located at any point along the airflow path 106 upstream of the motor fan assembly 104. That is, between the dirty air inlet 108 and the motor fan assembly 104. The dirty air inlet 108 is designed to receive air carrying dirt and debris from a cleaning tool accessory, such as a hose (not shown) or other cleaning accessory (not shown). The dirty air inlet 108 is in fluid communication with the dust collection portion, allowing the airflow to pass from the dirty air inlet 108 to the dust collection portion. In one example, a filter 124 is optionally mounted in the vacuum cleaner device 100. The filter 124 is arranged to remove dirt and debris from the airflow in the vacuum cleaner device 100. The filter 124 can be located either upstream or downstream of the motor fan assembly 104. Preferably the filter 124 located upstream of the motor fan assembly 104 as shown in Figure 1. In some examples there can be a plurality of filters 124 located both upstream and downstream of the motor fan assembly 104. In some examples the filter 124 is upstream of the motor fan housing and removes particulates from the airflow before entering the motor fan assembly 104. In other examples, the vacuum cleaner device 100 comprises additional filters (not shown) which are located downstream of the motor fan assembly 104. The filter 124 may be made from a variety of materials suitable for trapping dirt and debris while allowing air to pass through. In some examples the filter 124 may be a pleated filter. In other examples, other types of filters can be used. The filter 124 may be designed to be easily removable and replaceable, facilitating regular maintenance of the vacuum cleaner device 100. The motor fan assembly 104 is responsible for generating airflow within the vacuum cleaner device 100. The motor fan assembly 104 includes a motor and a fan, which work together to draw air in through the dirty air inlet 108 and expel it out through the clean air outlet 110. The motor fan assembly 104 may be designed to provide a high level of suction power, enabling the vacuum cleaner device 100 to effectively pick up dirt and debris. In one configuration, the motor fan assembly 104 is housed within a motor fan assembly housing (not shown). The motor fan assembly housing is designed to protect the motor and the fan from damage and to facilitate the efficient flow of air through the motor fan assembly 104. The motor fan assembly housing may be constructed from a durable material such as plastic or metal. In some examples the motor fan assembly 104 is connected to a power source (not shown) which is selectively controlled by a user interface. The power source can be a battery and / or a mains power supply. The use of a battery or main power supply with a motor fan assembly 104 is known. Similarly, control of such a motor fan assembly 104 with a user interface is also known and will not be discussed in further detail. In some examples, the motor fan assembly 104 is in fluid communication with the clean air outlet 110 via an exhaust pipe 128. The exhaust pipe 128 guides the airflow path 106 through the housing 102. Whilst the exhaust pipe 128 is illustrated as straight in Figure 1, the exhaust pipe 128 can be curved and take any required route through the housing 102 to the clean air outlet 110. The clean air outlet 110 in some examples is integral with the housing 102. In this way, the clean air outlet 110 can be a plurality of apertures in the housing 102 forming an air vent 126. Turning to Figure 2, the vacuum cleaner device 100 will be discussed in further detail. Figure 2 shows a schematic arrangement of the components of the vacuum cleaner device 100. A controller 120 is mounted within the housing 102 and is electrically connected to at least one dust particle sensor assembly 112. The at least one dust particle sensor assembly 112 is arranged to detect dust particles 118 in the airflow along the airflow path 106 and generate a signal when dust particles 118 are detected. As shown in Figure 1, the dust particle sensor assembly 112 is mounted along the airflow path 106 downstream of the motor fan assembly 104. In some examples, the dust particle sensor assembly 112 is mounted in the exhaust pipe 128. Alternatively, the dust particle sensor assembly 112 is mounted in air vents 126 or adjacent to the clean air outlet 110. This means that the airflow under normal operating conditions will be free from dust particles 118 and the dust particle sensor assembly 112 will not detect any dust particles 118. However, in some circumstances, the exhaust air from the motor fan assembly 104 may be contaminated with dust particles 118. This may occur if the vacuum cleaner device 100 develops a fault or if a component needs replacement or maintenance. For example, dust particles 118 may enter the airflow downstream of the motor fan assembly 104 if the filter 124 is damaged or requires cleaning. A user of the vacuum cleaner device 100 may need to understand if the exhaust air from the vacuum cleaner device 100 comprises dust particles 118 if the user is operating in a clean environment. For example, the vacuum cleaner device 100 may be a L class, a M class or an H class vacuum cleaner device 100. In some examples the vacuum cleaner device 100 is rated for L-Class (light hazard). This means that the filter 124 comprises a filter efficiency of 99%. This may mean that the vacuum cleaner device 100 is suitable for home cleaning or for DIY home renovation jobs. This means that the vacuum cleaner device 100 can filter at least 99% of a micron 0.3 pm particle diameter size. In some examples the filter 124 is rated E12 Sub-HEPA (ISO 25E). In some examples, the vacuum cleaner device 100 is rated for M-Class (medium hazard). This means that the filter 124 comprises a filter efficiency of 99.9%. This means that the vacuum cleaner device 100 is suitable for a hobbyist workshop, or for plastering on-tool extraction. This means that the vacuum cleaner device 100 can filter at least 99.9% of a micron 0.3 pm in particle diameter size. In some examples the filter 124 is rated E13 HEPA (ISO 35H). In some examples, the number of particles 118 in the airflow is equal to or greater than 0.1 mg / m3 in an 8-hour Time Weighted Average. In some examples, the vacuum cleaner device 100 is rated for H-Class (high hazard). This means that the filter 124 comprises a filter efficiency of 99.995%. This means that the vacuum cleaner device 100 is suitable for working with hazardous materials like silica dust, asbestos, lead paint, dusts contaminated with carcinogens or pathogens, or respirable crystalline silica (RCS). This means that the vacuum cleaner device 100 can filter at least 99.995% of a micron 0.3 pm in particle diameter size. In some examples the filter 124 is rated E14 or E15 HEPA (ISO 45H, H15). In some examples, the number of dust particles 118 in the airflow is less than 0.1 mg / m3 in an 8-hour Time Weighted Average. Therefore, if the vacuum cleaner device 100 has a specific filter rating, the user may wish to monitor in real time that the vacuum cleaner device 100 continues to operate within a required filter performance. In the case where the vacuum cleaner device 100 is not removing the dust particles 118 correctly from the airflow, the amount of dust particles 118 will increase. The at least one dust particle sensor assembly 112 is configured to detect dust particles 118 in the airflow. Whilst the arrangement as shown in Figures 1 and 2 show a single dust particle sensor assembly 112, in some examples the vacuum cleaner device 100 can comprise a plurality of dust particle sensor assemblies 112. This may be advantageous to provide additional redundancy for detecting dust particles 118 in the air flow. However hereinafter reference will be made to a vacuum cleaner device 100 with a single dust particle sensor assembly 112. The dust particle sensor assembly 112 as shown in Figures 1 and 2 comprises a light source 114 and a light detector 116. In some examples, the light source 114 is a semiconductor laser diode arranged to emit a beam of light across the airflow. The semiconductor laser diode may be an advantageous light source 114 because the semiconductor laser diode emits a coherent beam of light. This means that backscattering of the beam of light is more likely due to dust particles 118 present in the exhaust air flow. In some examples, the light source 114 is arranged to emit a beam of light perpendicular to the airflow path 106. However, in other examples, the light source 114 is configured to emit a beam of light at an angle to the airflow path 106. This means preferable because the volume of exhaust air that the light source 114 emits a beam of light into may be increased per unit time. This may mean that the chances of detecting dust particles 118 in the exhaust air are increased. This may be useful if the concentrations of dust particles 118 in the airflow are very low. However as shown in Figure 1, the light source 114 emits a light of beam across the airflow path 106. Optionally, the dust particle sensor assembly 112 comprises a sampling chamber (not shown). The sampling chamber may be constructed to cause laminar flow of the exhaust air flow past the dust particle sensor assembly 112. The sampling chamber may be in fluid communication with the exhaust pipe 128 or any other part of the vacuum cleaner device 100 on the airflow path 106 downstream of the motor fan assembly 104. In some examples the light source 114 can be a semiconductor laser diode that operates in the visible or near-infrared spectrum. In some examples, the light source 114 emits light that is suitable for backscattering light off dust particles 118 with a particle size diameter 0.3 microns. In some examples the light source 114 is a GaN Laser Diode (Gallium Nitride) which is configured to operate in the blue range (typically 405-450 nm) which is small as 0.3 microns due to a shorter wavelength. Alternatively the light source 114 is a InGaN Laser Diode (Indium Gallium Nitride which is configured to operate in the blue to green range (405-520 nm). Alternatively the light source 114 is a AIGaAs Laser Diode (Aluminum Gallium Arsenide) which is configured to operate in a near-infrared range (780-850 nm). Alternatively, the light source 114 is a VCSEL (Vertical-Cavity Surface-Emitting Laser) which is configured to operate in wavelengths from 650 nm to 850 nm. Optionally, the dust particle sensor assembly 112 comprises a lens assembly for directing the scattered light towards the light detector 116. The lenses can also be optionally used to collect and focus the scattered light onto the light detector 116. In some examples the light detector 116 is configured to detect backscattered light from the light source 114. For example, the light detector 116 is one or more of a photodiode (Silicon or InGaAs), an avalanche photodiode (APD), a CMOS sensor, a phototransistor or a quadrant detector. As the amount of dust particles 118 in the exhaust air increases, the amount of light from the light source 114 backscattered to the light detector 116 will increase. Therefore, the intensity of the detected backscattered light by the light detector 116 will be proportional to the amount of dust particles 118 in the exhaust airflow. The controller 120 is arranged to receive from the light detector 116 the detected light signal in response to backscattered light from dust particles 118 in the airflow. The controller 120 is configured to generate a signal indicative of the operational status of the vacuum cleaner device 100 in response to the received detected light signal from the at least one dust particle sensor assembly 112. In some examples, the controller 120 or the dust particle sensor assembly 112 comprises an analogue-to-digital converter (ADC) to amplify and process the detected light signal. In some examples, the controller 120 receives the signal from the light detector 116 and obtains information about the concentration of the dust particles 118 in the airflow. In some examples, the controller 120 can determine the amount of dust particles 118 in the airflow by using a look-up table stored in memory 122. In some examples, the look-up tables can be pre-calibrated look-up tables which are used by the controller 120 to correlate received detected light signal intensity with particle size and or particle concentration. These tables are generated through calibration with known particle sizes. In some examples, the look-up tables can be formed using standard particles of known sizes to calibrate the controller 120 and the dust particle sensor assembly 112. Furthermore, during calibration, the controller 120 can measure the scattered light intensity and create a look-up table correlating intensity to particle size. The controller 120 can then test the dust particle sensor assembly 112 with air samples containing particles of known concentrations and sizes to validate accuracy and precision. Alternatively, the controller 120 can obtain information about the concentration of the dust particles 118 in the airflow by dynamically calculating the amount of dust particles 118 based on equations stored in memory 122. In some examples the equations stored in memory 122 are based on Mie scattering theory or Rayleigh scattering equations. The controller 120 then determines the amount of dust particles 118 in the exhaust airflow. The controller 120 can then determine if the amount of dust particles 118 in the exhaust airflow exceeds a predetermined threshold. The predetermined threshold in some examples corresponds to the rating of the filter 124. For example, if the vacuum cleaner device 100 is an H Class vacuum cleaner device 100, the predeterm ined threshold of dust particles 118 in the exhaust airflow corresponds to 0.1 mg / m3 in an 8-hour Time Weighted Average. In some examples, the controller 120 is configured to issue a warning notification to the user if the controller 120 determines that the predetermined threshold has been exceeded. Accordingly, the warning notification is a signal indicative of the operational status of the vacuum cleaner device 100 generated by the controller 120. The warning notification can be an audible noise, a warning light, a message on a display screen. Alternatively, the controller 120 can issue a message which is sent to a remote device e.g. a mobile phone. In some examples the controller 120 is connected to the motor fan assembly 104 and configured to selectively control the motor fan assembly 104. For example, the controller 120 is arranged to issue start and stop control signals to the motor fan assembly 104 in response to user input. However, in some examples, the controller 120 is configured to issue a control signal to the motor fan assembly 104 if the controller 120 determines that the amount of dust particles 118 exceeds the predetermined threshold. Accordingly, the controller 120 switches off the vacuum cleaner device 100 and prevents dust particles 118 being exhausted into the immediate vicinity of the vacuum cleaner device 100. This is particularly useful because this prevents the user from potentially breathing in harmful dust particles 118 if the filter 124 is not operating correctly. In some examples, the controller 120 is configured to obtain information relating to the operational status of the motor fan assembly 104. The controller 120 can then generate a signal indicative of the operational status of the vacuum cleaner device 100 in response to the received detected light signal from the at least one dust particle sensor assembly 112 and the obtained information relating to the operational status of the motor fan assembly 104. For example, the controller 120 can obtain information relating to the operational status of the motor fan assembly 104 such as motor voltage, motor current, fan speed or air flow speed. Accordingly, the controller 120 can obtain the airflow speed of the exhaust air. The volume of the exhaust air is dependent on the air speed of the airflow. Accordingly, the amount of dust particles 118 in the exhaust air depends on the air speed of the airflow. The controller 120 can then determine whether the detected amount of dust particles 118 from the received detected light signal exceeds the predetermined threshold also based on the air speed. In some examples, the controller 120 can dynamically adjust the predetermined threshold based on operational information of the vacuum cleaner device 100 e.g. the airflow speed. In another example, two or more examples are combined. Features of one example can be combined with features of other examples. The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including" when used herein specify the presence of stated features, integers, actions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and / or groups thereof. It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure. Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealised or overly formal sense unless expressly so defined herein. It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

1. A vacuum cleaner device (100) comprisinga housing (102) having a motor fan assembly (104) configured to generate an airflow along an airflow path (106) extending between a dirty air inlet (108) and a clean air outlet (110);at least one dust particle sensor assembly (112) mounted along the airflow path (106) and downstream of the motor fan assembly (104) wherein the at least one dust particle sensor assembly (112) comprises a light source (114) and a light detector (116) wherein the light detector (116) is configured to generate a detected light signal in response to backscattered light from dust particles (118) in the airflow; anda controller (120) connected to the at least one dust particle sensor assembly (112) and configured to generate a signal indicative of the operational status of the vacuum cleaner device (100) in response to the received detected light signal from the at least one dust particle sensor assembly (112).

2. The vacuum cleaner device (100) according to claim 1 wherein the controller(120) is configured to generate a signal indicative of the operational status of the vacuum cleaner device (100) in response to the received detected light signal indicating a detected intensity of backscattered light from dust particles (118) in the airflow.

3. The vacuum cleaner device (100) according to claim 2 wherein the light source (114) is a semiconductor laser diode.

4. The vacuum cleaner device (100) according to claims 2 or 3 wherein the controller (120) is configured to generate the signal in response to the amount of detected backscattered light exceeding a predetermined threshold.

5. The vacuum cleaner device (100) according to claim 4 wherein the predetermined threshold corresponds to a particle concentration in the airflow greater than 0.1 mg / m3.

6. The vacuum cleaner device (100) according any of the preceding claims wherein the vacuum cleaner device (100) comprises a filter (124) mounted on the airflow path (106) and the controller (120) is configured to generate a signal indicative of the operational status of the vacuum cleaner device (100) wherein signal indicative of the operational status comprises a notification signal that the filter (124) is faulty in response to the received detected light signal from the at least one dust particular sensor assembly (112).

7. The vacuum cleaner device (100) according to any of the preceding claims wherein the dust particle sensor assembly (112) is mounted adjacent to the clean air outlet (110).

8. The vacuum cleaner device (100) according to claim 7 wherein the clean air outlet (110) is an airvent (126) in the housing (102) and the at least one dust particle sensor assembly (112) is mounted on the air vent (126).

9. The vacuum cleaner device (100) according to any of claims 1 to 6 wherein the motor fan assembly (104) and the clean air outlet (110) are in fluid communication via an exhaust pipe (128) and the at least one dust particle sensor assembly (112) is mounted in the exhaust pipe (128).

10. The vacuum cleaner device (100) according to any of the preceding claims wherein the controller (120) is configured to issue a stop control signal to the motor fan assembly (104) in response to the received detected light signal from the at least one dust particle sensor assembly (112).

11. The vacuum cleaner device (100) according to any of the preceding claims wherein the controller (120) is configured to obtain information relating to the operational status of the motor fan assembly (104) and the controller (120) is configured to generate a signal indicative of the operational status of the vacuum cleaner device (100) in response to the received detected light signal from the at least one dust particle sensor assembly (112) and the obtained information relating to the operational status of the motor fan assembly (104).

12. The vacuum cleaner device (100) according to claim 11 wherein the operational status of the motor fan assembly (104) is one or more of motor voltage, motor current, fan speed or air flow speed.5 13. The vacuum cleaner device (100) according to any of the preceding claimswherein the controller (120) is configured generate a signal indicative of the operational status of the vacuum cleaner device (100) based on obtaining information relating to the amount of dust particles (118) in the airflow based on a look-up table or a calculating the amount of dust particles (118) based on Mie scattering theory or 10 Rayleigh scattering equations.

14. The vacuum cleaner device (100) according to any of the preceding claims wherein the at least one dust particle sensor assembly (112) is configured to detect along an axis perpendicular to the airflow path (106).1515. The vacuum cleaner device (100) according to any of the preceding claims wherein the vacuum cleaner device (100) is a workshop vac.s

Images