Vacuum Cleaner Full Bag Detection Using Motor Temperature Thresholds
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Solution Overview
Problem
Existing vacuum cleaners face increased costs and potential motor overheating due to the use of pressure sensors to monitor debris bag fullness, which can lead to excessive temperature increases when the bag is nearly full.
Innovation Solution
A vacuum cleaner system that includes a controller with a voltage sensor to detect input voltage, a temperature sensor to monitor the motor temperature, and a processor to determine a threshold temperature based on the input voltage, outputting a warning when the motor temperature exceeds the threshold, indicating a full filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are used to monitor airflow and determine debris bag fullness, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical pressure sensor system with an electrical monitoring system that measures input voltage to the motor. The controller monitors voltage drops across the motor circuit, which change as airflow restriction increases the motor's electrical load. This substitution eliminates the need for physical pressure sensors while maintaining the ability to detect debris bag fullness through electrical parameter changes.
2Measurement precision
If pressure sensors are used to monitor airflow, then debris bag fullness detection is improved, but motor temperature increases excessively when bag is approaching full condition
Solution Approach 1:
The system performs preliminary detection of airflow restriction by monitoring input voltage changes before the motor temperature rises excessively. By detecting voltage drops that indicate increasing airflow restriction, the system can alert users to empty the debris bag before the motor overheats, preventing temperature-related damage while maintaining accurate fullness detection.
3Reliability
If voltage sensor and temperature sensor are used to monitor motor conditions, then motor protection is improved, but device complexity increases
Solution Approach 1:
The patent combines the functions of voltage sensing, temperature monitoring, and fullness detection into a single integrated controller system. The controller processes signals from both the voltage sensor and temperature sensor, correlating voltage changes with temperature data to determine debris bag fullness and provide comprehensive motor protection. This merging reduces overall system complexity compared to having separate dedicated systems for each function.
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 solution reduces costs by eliminating the need for pressure sensors and prevents motor overheating by providing an accurate warning of a full filter before it restricts airflow and causes temperature increases.
Implementation Method 1
a voltage sensor positioned to detect an input voltage applied to the motor
Implementation Method 2
a temperature sensor positioned to detect a temperature associated with the motor
Implementation Method 3
a motor assembly including a motor and an impeller connected to the housing and operable to generate airflow through the debris chamber and filter
Data Source
AI summary
A vacuum cleaner includes a housing, a debris chamber defined within the housing, a filter disposed within the debris chamber, a motor assembly including a motor and an impeller connected to the housing and operable to generate airflow through the debris chamber and filter, a voltage sensor positioned to detect an input voltage applied to the motor, a temperature sensor positioned to detect a temperature associated with the motor and a controller communicatively coupled to the voltage sensor, temperature sensor, and motor. The controller includes a processor and memory having instructions that program the processor to determine a threshold temperature based at least in part on the input voltage detected by the voltage sensor, compare the temperature associated with the motor to the threshold temperature, and output a warning that the filter is full of debris when the temperature associated with the motor exceeds the threshold temperature.