Vacuum Cleaner Floor Detection Using Fan Motor Load Signals
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Solution Overview
Problem
Existing vacuum cleaners face challenges in reliably identifying floor coverings due to difficulties in classifying hard floors with weak ultrasound reflection and heavily damping carpets, which lead to incorrect evaluations and susceptibility to malfunctions and soiling of sensors.
Innovation Solution
A method utilizing an electronically commutated fan motor with a control unit that compares current parameters, such as rotational speed and pressure, with stored reference values to identify floor coverings without sensors, allowing for sensorless detection and automatic adjustment of suction settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical sensors or vacuum sensors are used to identify the floor covering, then the floor covering can be detected, but the sensors are susceptible to soiling and malfunctions
Solution Approach 1:
The patent extracts the detection function from traditional optical or vacuum sensors and relocates it to the electronically commutated motor itself. The motor's current parameters and rotational speed become the detection basis, eliminating the need for separate sensors that are prone to soiling and malfunctions.
Solution Approach 2:
The electronically commutated motor is given a dual function: it serves both as the driving force for the vacuum cleaner and as the sensor for floor covering detection. By analyzing the motor's current parameters and rotational speed during operation, the system can identify floor covering types without requiring additional detection components.
2Measurement precision
If ultrasonic transducers are used to determine surface properties of floor coverings, then hard floors and carpets can be classified, but different floor coverings are difficult to classify due to varying reflection and absorption behaviors
Solution Approach 1:
The patent changes the detection parameter from ultrasonic wave reflection/absorption to motor electrical parameters (current, rotational speed). This parameter change provides more consistent and reliable detection data, as the motor's electrical characteristics respond predictably to varying load conditions caused by different floor coverings.
Solution Approach 2:
The patent replaces the mechanical/acoustic ultrasonic transducer system with an electrical detection system based on motor current and rotational speed analysis. This substitution eliminates the classification problems associated with ultrasonic methods while maintaining the ability to distinguish between different floor covering types.
3Measurement precision
If complex sensor systems and control mechanisms are implemented for floor covering detection, then detection capability is improved, but implementation costs increase and device complexity increases
Solution Approach 1:
The control unit that already exists for managing the electronically commutated motor is extended to perform floor covering detection functions. No additional control mechanisms or sensors are required, as the existing motor control infrastructure is utilized for both motor management and floor covering identification.
Solution Approach 2:
The system performs self-detection using its own motor's operational parameters. The vacuum cleaner detects floor coverings by analyzing data from its own motor without requiring external sensors or complex additional control systems, thereby reducing overall device complexity and implementation costs.
Data Source
Figure 1~2
AI summary
The method involves providing a storage unit (5), and containing two floor coverings with reference parameters in the unit. An inspection procedure for a sensor-less floor covering detection is started by a control unit (4). An electronically commutating motor (3) is brought by a number of revolutions in an operating point into another operating point with another number of revolutions. Actual characteristics of the motor are determined by the control unit during the procedure, and are compared with the parameters. An identification of the floor covering is obtained. An independent claim is also included for a vacuum cleaner.