Floor Cleaning Machine Fault Detection Using Liquid Flow Comparison
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Solution Overview
Problem
Floor cleaning machines often fail to reliably detect malfunctions in the dirty-liquid take-up system, leading to safety risks and incomplete cleaning due to unreliable detection of blockages or excessive liquid levels, which cannot be differentiated by motor current measurements alone.
Innovation Solution
A method for operating floor cleaning machines that involves sensing the amount of cleaning liquid applied and dirty liquid removed within specific time intervals, comparing these against threshold values, and outputting fault signals if the applied cleaning liquid exceeds thresholds while the removed dirty liquid does not, thereby detecting unreliable operation of the dirty-liquid take-up means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If motor current measurement alone is used to detect faults, then the detection method is simple, but it cannot differentiate between blockages and liquid-filled conditions
Solution Approach 1:
The fault detection method is segmented into multiple independent measurement components: motor current measurement, cleaning liquid consumption measurement, and dirty liquid removal measurement. Each component provides specific information, and their combination enables accurate fault differentiation. The cleaning liquid consumption sensor and dirty liquid removal sensor are separate from the motor current sensor, allowing independent measurement of each parameter.
Solution Approach 2:
The control unit serves multiple functions: it monitors motor current, processes cleaning liquid consumption data, processes dirty liquid removal data, compares all three parameters, and determines fault conditions. This multi-functional approach allows a single control unit to perform comprehensive fault detection by integrating information from multiple measurement sources.
2Reliability
If the dirty-liquid take-up means is not working reliably, then cleaning liquid loaded with dirt remains on the floor surface, but the fault cannot be detected
Solution Approach 1:
The system implements feedback by continuously measuring cleaning liquid consumption, dirty liquid removal, and motor current, then comparing these measurements to expected values. When the dirty-liquid take-up means fails, the feedback loop detects the discrepancy between cleaning liquid applied and dirty liquid removed, triggering a fault signal that alerts the operator to the reliability issue.
Solution Approach 2:
The system performs preliminary fault detection by continuously monitoring the relationship between cleaning liquid consumption and dirty liquid removal before complete failure occurs. The control unit compares measurements in real-time to identify when the dirty-liquid take-up means is not working reliably, allowing preventive action before safety hazards or incomplete cleaning develop.
3Productivity
If cleaning liquid is continuously applied but dirty liquid is not removed, then the floor surface becomes unsafe, but the machine continues operating
Solution Approach 1:
The feedback mechanism monitors the balance between cleaning liquid application and dirty liquid removal. When dirty liquid removal falls below the second threshold value while cleaning liquid consumption remains above the first threshold, the control unit detects this imbalance and generates a fault signal, preventing continued operation under unsafe conditions.
Solution Approach 2:
The system takes preliminary anti-action by detecting fault conditions before they lead to safety hazards. By continuously comparing cleaning liquid consumption with dirty liquid removal, the system identifies when the dirty-liquid take-up means is failing and issues a fault signal to stop operation, preventing the accumulation of dirty liquid on the floor surface that would create slipping hazards.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for reliable automatic detection of malfunctions in the dirty-liquid take-up system, preventing safety hazards and ensuring effective cleaning by distinguishing between blockages and liquid-filled conditions, even in autonomous machines.
Implementation Method 1
the suction-extraction means which, in operation, generates negative pressure
Implementation Method 2
a suction-extraction means such as a suction turbine, which is driven by an electric motor. This generates an air flow from the dirty-liquid take-up means
Data Source
AI summary
A method for operating a floor cleaning machine on a floor surface. The floor cleaning machine includes a cleaning-liquid container, a dirty-liquid container, a chassis for moving the floor cleaning machine over the floor surface, a cleaning means and a dirty-liquid take-up means. The method includes: sensing an amount of cleaning liquid supplied from the cleaning-liquid tank to the cleaning means within a first time interval while moving the floor cleaning machine; sensing an amount of dirty liquid being removed from the dirty-liquid take-up means to the dirty-liquid container within a second time interval while moving the floor cleaning machine; comparing the sensed amount of cleaning liquid against a first threshold value; comparing the sensed amount of dirty liquid against a second threshold value; outputting a first fault signal if the sensed amount of cleaning liquid is greater than the first threshold value and the sensed amount of dirty liquid is less than the second threshold value.