Note: Descriptions are shown in the official language in which they were submitted.
~ PA~5284-0-VC-IJS~
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"MICROCOMPUTER CONTRO~ SYSTEM FOR A CANISTER VACUUM CLEANER"
This application is a division of application Serial
No. 525,609 filed December 17, 1986.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invsntion relates to vacuum cleaners and
more particularly to a microcomputer control system for a vacuum
cleaner.
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Description of_the Prior Art ~ ~
:~ , ~. . .
U.S. Patent No. 3,588,943 discloses a control circuit
: , :
for a vacuum cleaner, the vacuum cleaner having a motor fan
suction unit and a floor contacting motor brush unit. The
~control circuit includes a switch on the vacuum cleaner handle to ;~
control current flow to both of the motors.
U.S. Patent No. 3,579,706 discloses a vacuum cleaner
motor control comprising a first switch circuit including an -~
electric current varying means for varying the current to a -~
suction motor and a second switch circuit for energizing the
motor of the motor brush unit for cleaning the floor.
U.S. Patent No. 4,245,37Q discloses a control circuit
for protecting a vacuum cleaner motor from jammed beater brush ~-
damage. A Hall effect sensor is used to detect the rotational
speed of the beater brush. The control circuit effects
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1 1 3 3 0 2 3 1 PA-5284-0-VC~USA
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discontinuation of the energization of the motor in the event
that the rotational speed of the beatex brush drops below a
preselected speed.
U.S. Patent No. 4,357,729 discloses a vacuum cleaner
control which reduces the total current delivery to the vacuum
cleaner when both a suction motor and a brush motor are being ~;~
operated concurrently where the full load currents of the suction
and brush motors cumulatively total an amount greater than a -~
preselected safe current deliverable to the vacuum cleaner.
SUMMARY OF T~E INVENTION
The present invention consists of a canister-type
vacuum cleaner, comprising: a canister having a vacuum motor for
generating a vacuum air flow and a filter bag through which said ~-~
air flow is filtered; a power nozæle having a rotatable beater
bar driven by a beater bar motor; a handle portion having a
control and display panel and a hollow wand section connectable '
to said power nozzle: a suction hose being connectable between
said canister in communication with said filter bag and said
handle portion in communication with said hollow wand section; a ~ -
canister control circuit mounted in saîd canister and having a
first microcomputer: a power nozzle control circuit mounted in -
said power nozzle and having a second microcomputer a handle
portion control circuit mounted in said handle portion and having
a third microcomputer: first and second A.C. power leads being
connectable to an A.C. power source, said first and second A.C.
power leads along said suction hose and said wand section between
said canister control circuit and said handle portion control
circuit and said power nozzle control circuit: a first data lead
being connected between said canister control circuit and said
handle portion control oirouit along said ~uction hose; a eeoond
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] data lead being connected between said handle portion control
circuit and said power nozzle control circuit along said hollow
~ wand; a first means for transmitting and receiving data connected
i to said first data lead and said first microcomputer to -~
3, communicate serial data therebetween; and means at each of said
~ canister control circuit and said handle portion control circuit
j and said power nozzle control circuit ~or ge.nerating a cloak
q signal in synchronization with a signal from said A.C. power
source, said first and third microcomputers transmitting serial
data packets therebetween in synchronization with said clock
signal, said second and third microcomputers transmitting serial
data packets therebetween in synchronization with said clock
signal.
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BRIEF DESCRIPTION OF THE DR~WINGS
, FIG. 1 is a perspective view of a vacuum cleaner having
a canister, handle and a power nozæle floor cleaner embodying the
principles of the present invention.
FIG. 2 is a plan view of the handle con~rol panel and
display portion of the vacuum cleaner shown in FIG. 1.
FIG. 3 is an electrical schematic for the control ~
circuit in the canister. ~ ~ -
FIG. 4 is an electrical schematic for the control ~ ;
circuit in the handle.
FIG. 5 is an electrical schematic for the control in
the power noz~le floor cleaner.
FIG. 6 is a flow chart for the control circuit of the
canister.
FIG. 7 is a flow chart for the control circuit of the -~
handle. .
FIG. 8 is a flow chart for the control circuit of the
power floor cleaner.
FIG. 9 is a schematic drawing of the wiring connections
20 Of the three circuits.
,, ~
FIG. 10 is a diagramatic view of information
transmitted from the handle to the power nozzle floor cleaner. -~-
FIG. 11 is a diagramatic view of information
v transmitted from the power no2zle floor cleaner to the handle.
~ FIG. 12 is a diagramatic view of information
!~ transmitted from the handle to the canister.
~;` ~ FIG. 13 is a diagramatic view of information
transmitted from the canister to the handle.
FIG. 14 is a sectional view of the canister of Fig. 1
30 showing the interior thereof.
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~, FIG. 15 is a voltage-time diagram of one serially
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~,.7 transmitted code packet Eor transmission from the handle to the
~ canister.
j7~ FIG. 16 is an electrical circuit diagram of information
transmitting and receiving circuitry in the canister and the
handle.
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i~ ~ DE5CRIPTION OF THE PREFERRED EMBODIMENTS : ~
In FIG. 1 there is shown generally a vacuum cleaner at ~ ~-
~ 10 which includes a power nozzle floor cleaning device 12
,~0 sometimes referred to under the trademark "Powermate", having a
3''~ nozzle 14 provided with a rotating brush 16 driven by a brush
~, ~
motor 18 through a drive belt 20. The power no~zle floor cleaner
12 is provided with a hollow wand section 22 connected to a
suction hose 24 at a handle portion 26. The hose 24 is .
¢onventional and includes three spirally-wound electrical
conductors embeded in the hose which support the ho/se and conduct
current between the hose terminals at the ends of the hose 24. A
plurality of electrical controls and displays 28 are provided on
a control panel and display comprising a top face 30 of the ..
handle portion 26. ~ three wire cord 32 connects the electrical ~
circuitry in the handle portion 26 with the circuitry in the . :
power nozzle floor cleaner 12.
Suction is provided to the no~zle 14:through the
suction hose 24 which is attached to a suction inlet 33 of a
canister suction unit 34. The suction hose 24 connects at one .~
end to the circuitry in the handle 26, and via a plug 38 connects ` ~.
to the circuitry within the canister 34. ~s seen in FIG. 14, the
canister suction unit 34 includes a suction fan motor 40 mounted
within the canister 34, a power cord 42 and a conventional .~ . :
electrical plug 44. When the suction motor 40 is ener~ized to - ;
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operate the suction Ean, a vacuum is applied to the nozzle 14
through the wand 22 and the suction hose 24 to effect the desired
vacuum cleaning operation. As is conventional in such systems, a
suitable dirt-collecting filter bag 46 is provided within the
I canister 34 for collecting the dirt sucked from the surace being
cleaned such as the floor being cleaned by the nozzle 14.
FIG. 2 is a plan view of the handle portion 26 showing -
.
the various controls and indicators 28. At the bottom of the
handle control panel there is provided a switch 48 labeled "Power
o On/Off" which a user would operate to energize both the suction
motor 40 as well as the power cleaner motor 18. Just above the -~
main power switch 48 are provided two laterally spaced touch- ~:
actuated switches 50, 52 which, respectively, permit the user to
decrease or increase the speed of the suction motor 40. As will -~
be described in greater detail below, the speed of the suction
motor 40 can be stepped through a series of five discreet
speeds. Just above the speed switches 50, 52 are provided five ;~
LEDs 54 which provide a visual indication to the user as to the
speed level selected. Once a speed level has been selected, it
0 i5 "remembered" by the vacuum cleaner control, even if the power
is turned off and later turned on. That is, when the power is ~;-
later turned on, the control will operate the suction motor 40 at
the speed last selected.
Just above the speed indicating LEDs, there are
provided two laterally spaced touch-actuated switches 56, 58.
The first switch 56 can be operated to cause a sensed pile height
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~ to be displayed on a plurality of LEDs 60 positioned just above
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Y the pile height switch S6. The second switch 58 allows the user
to selectively deenergize and reenergize the motor 18 in the
~30 power nozzle device 12 independently of the main on/off switch
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At the top of the handle there are three separa~e
indicator LEDs, a top indicator 62 indicates a detected fault in
~.,
the power floor cleaner 12, a second indicator 64 indicates a
full dirt filter bag 46 and a third indicator 66 indicates a
~ blocked suction hose 24 -~
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, To more fully explain the controls and indicators shown ~
~ .
~' in FIG. 2, FIGS. 3, 4 and 5 show the electrical schematics for
the control circuitry in the canister 34, the handle 26 and the
power nozzle 12, respectively.
~ ........
0 Firstly, the handle control circuitry is shown in FIG.
4. This portion of the control contains a four-bit microcomputer --
72 such as a National Semiconductor, Inc. COPS 420, and
associated electronics ~o control the system as well to provide
an interface to the user. Input from the user is accomplished --~
via five touch-actuated switches identified above with the
'~ following functions~
Switch Label Switch Function
: ~:
Power On/Off 48 Turns entire system on or
~20 Increase Speed S2 Increases canister motor
;3, speed until reaching
maximum speed.
Decrease Speed 50 Decreases canister motor
speed until reaching
minimum speed. -
, ~ . ,,
Powermate On/Off 58 Turns power cleaner motor
~, on or off regardless of
main on/off function.
Display Pile Height 56 Initiates a pile height
,30 reading to be made in the
power cleaner de~ice and
displays the reading on -~
the handle on LEDs 60.
`~ Display to the user is accomplished via 12 LEDs with
`¦ the following functions:
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LED Label LED Function
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Motor Speed 54 (S LEDs) Displays the selected
suction motor speed in a
bar-graph format ~1 LED
on at a time),
Pile Height 60 (4 LEDs) Displays the pile height
sensed in a bar-graph
format (1 LED on at a : .
time).
~0 Check Powermate 62 Indicates a system shut
down due to broken belt
or obstructed beater bar
via a flashing light
format. ~-
Check hose 66 Indicates that pressure
sensorts) in canister
detected a plugged hose,
via a flashing light
display format. ;~
0 Check bag 64 Indica'ces that a pressure
sensor in the canister
detected a full bag via a
flashing light displ y
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The handle control circuitry of Fig. 4 in¢ludes a D.C.
power supply portion 300,a 60 Hz. clock signal generator 302, a
clock oscillator 304, a power-up reset portion 306, a keyboard
308 for user inputs, a display LED matrix 310, a transmit and
receive portion 312 for the canister 34, and a transmit and
, , - , .
0 receive portion 314 for the power nozzle 12. The D.C. power
supply portioZn 300 is connected to A.C. power leads 75 and 77
which are connected to standard A.C. power, such as at a wall
outlet. A transformer 320 provides a voltage reduction of from
~ :
120 volts to approximately 20-30 volts, depending upon the load
~; re~uirements. A full-wave rectifying bridge 322 is connected
across a secondary 324 of the transformer 320. At the output of
the rectifying bridge 322 'is a voltage regulator 326 and a pair
~7l of filtering capacitor9 328 and 330, which provides a 5 volt
'~;t
regulated voltage for the microprocessor 72.
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,`~ The 60 Hz. clock signal generator 302 is also connected
~i! to the transformer secondary 324 and includes a transistor 332
and biasing resistors 334 and 336. The 60 Hz. generator 302
.r~, generates a sguare wave timing signal in synchroni~ation with 60
~z. power line signal for use by the microprocessor 72. The
60Hæ. timing, or clock, signal is used to synchronize data
communications between the handle 26 control of Fig. 4 and the
canister 34 and power noz~le 12 controls. It is also foreseen to
use a 50 Hz. timing signal where applicable.
0 The clock oscillator 304 is an RC oscillator formed of
a resistor 338 and a capacitor 340 for providing a timing signal
for internal use by the microprocessor 72. The power-up reset
portion 306 has a resistor 342 connected to a capacitor 344 with
.~t an RC time constant long enough to hold the microprocessor 72 at
a reset level until the D.C. power supply has reached a steady
state voltage and for the clock oscillator 304 to achieve its
operating freguency. A diode 346 is connected to release, or
; dump, the charge stored in the capacitor 344 when power is
removed from the system so that the microprocessor 72 may be
0 reset quickly.
The keyboard 308 is connected directly to the
microcomputer 72 to provide means for inputting user
information. In a preferred embodiment, the keyboard 308
includes a plurality of touch sensitive dome switches. As ~;~
described above, the LEDs 54 and 60-66 display the outputs of ; -~
various sensing and protection circuitry. The LEDs are
multiplexed so that power supply requirements and heat build up
are lower; multiplexing is accomplished in synchroni2ation with
i the 60 HZ. signal at a 50g duty cycle with a l/60 second
0 period. A maximum of two LEDs are on during any half line
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cycle. Resistors 348, 350 and 352 are connected to set the LED
current.
The transmit and receive portion 312 provide serial
data communication to and from the canister 34 control. As will
be described more fully hereinafter, the maximum voltage on line
76 is held at l9 volts. A transistor 354 and resistor 356 level
shift and amplify signals on lead 76 frosn the canister 34 control
for use by the microcomputer 72. A transistor 358 is connected
to selectively pull the voltage on line 76 to zero (logic 0) for
~i o data transmission to the canister 34 control.
Transmission of data to the canister control is as
follows: a logic zero is transmitted when the microcomputer 72
supplies a logic one to the base of the transistor 358 at a
negative transition of the 60 Hz. clock signal, which results in
the line 76 being held at approx imately zero volts. For the
~ transmission of a logic one data bit, the base of the transistor ~ ~`
!~ 358 is placed at a logic zero so that a positive going signal is
allowed to occur on the line 76 at the negative clock transition. ~`
Data is received from the canister 34 as follows: when
20 a negative going transition of the 60 Hz. clock pulse occurs, the
microcomputer 72 monitors the collector of the transistor 354.
If a logic one is on line 76, the collector will be at logic 2ero
and, if a logic zert~ is received on line 76 from the canister 34,
the collector will be at logic one. Thus, transmission and
reception of data is in synchronization with the 60 H2. power
line freguency.
The data voltage level on line 76 is high enough to
insure that low cost dry c'onnectors can be used and still have
reliable data transmission. A 2ener diode 360 is connected at
30 the line 76 to protect the device from voltage spikes that may
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occur when the hose 24 is connected or disconnected from the ~ ~ -
canister unit 34 at the plug 38. ~ --
The transmit and receive portion 314 for serial data
transfer to and from the power nozz le 12 includes a resistor 362
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and a transistor 364 for amplifying received data and a --~
transistor 366 for transmitting data over lead 74, similar to the
circuit portion 312 described above< A zener diode 368 is
provided for over voltage protection.
.::
Although a 60 band data transfer rate has been
L0 described, it is also foreseen to transmit two or more data bits
;~ during each positive hal cycle of the clock signal.
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; ~hen the plug 44 is plugged in, the system is poweredup with the power no~z le floor cleaner motor 18 and the canister
suction motor 40 off and no LEDs on.
With power up, the handle control 26 begins to transmit
~ data packets shown in FIGS. 10 and 12 to the power ,nozzle 12 and
i~i!. ` canister control 34. This is done via the circuitry `~
schematically shown in FIG. 9 in whi~h there are the two
~,! electrical lines 75 and 77 representing the AC power line, the
third communications line 76 connecting the handle circuitry 26
with the canister circuitry 34 through the hose 24 and the third ;
communications line 74 connecting the handle 26 with the power
nozzle circul'cry 12 though the cord 32 as shown; one side o the ~`
AC lines is used as a ground for the communications circuit. The
data packets shown in FIGS. 10 and 12 show the informati~n sent ; ~ ~
from the handle 26 to the power nozzle 12 and canister 34, ~ -
respectively.
The data packetl to the power nozzle 12, FIG. 10,
contains a four-bit preamble, a bit 5 relating to the on or off
condition of switches 48 and 58, and bits 6, 7 and 8 relating to
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a test mode. The data packet to the canister, FIG. 12, includes
a four-bit preamble, bit 5 contains inEormation relating to the
on or off posi~ion of switch 48 and bits 6, 7 and 8 contain
information relating to the selected motor speed for the canister
motor 40. In both cases, the on/off bit (bit 5) is initially set
to the off level, thus, indicating to the slave, or outboad,
contol to remain off.
After receiving the above-described data packets, the
respective slave units will then transmit back to the handle data
~10 packets as shown in FIGS. 11 and 13 via the circuitry shown
schematically in FIG. 9. FIG. 11 shows the data packet from the
power no~zle 12 to the handle 26 which includes a four-bit
; preamble, a motion sensor fiag in a bit 5, and pile height
information in bits 6, 7 and 8. The canister 34 transmits a data
packet containing a four-bit preamble, filter bag and hose
condition data in bits 7 and 8, and bits 5 and 6 not used. If
the user wishes to change the canister motor speed via the
decrease or increase switches 50, 52, the handle control 26 will
send the appropriate data to the canister 34 in discrete steps or
20 a slew type signal.
Pile height data is con~inuously transmitted to the
handle 26 for either an instantaneous or time averaged display at
tHe handle control 26, if requested by the user.
Filter bag and hose pressure sensor data are
transmitted to the handle control 26 continuously. If the data
indicates a fault, the handle control 26 must see the same fault
indication for several seconds before the specific fault is
displayed to the user ~hose plugged or bag full). ~ ;~
If the power nozzle control circuitry 12 detects a
30 broken belt 20 or obstructed beater bar, it will turn off the
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power nozzle motor 18 and send the appropriate motion sensor flag ~ -
bit to the handle circuit over line 74. This causes the handle
-` circuitry 26 to display the trip-out via "check Powermaten LED 62,, : ,
",r and sends an appropriate code to the canister control via line 76
,, .
to turn the canister motor 40 off. If ~he power no~zle 12 has
been electrically disconnected before turning on the system or
during system operation, the handle circuitry 26 detects this ;~
situation since only "ones" will be read from the power nozzle
circuit 12 to the handle control 26. Under this condition, the
handle circuit 26 locks out the motion sensor trip and pile
` height display.
An important feature of this circuit is the voltage -
used to transmit data between control boards. The voltage is -
sufficiently high, in the range of 15 to 25 volts, to ensure
electrical continuity, or breakover potential, across the ~ ~
connectors used to tie sub-system controls together~, thus ~ ~;
allowing the use of low cost connectors while maintaining ~;~
communication reliability. In one embodiment, a 19 volt data
transmission level is used. `
The circuit diagram for the power nozzle 12, known as `;~ -
the "Powermate", is shown in FIG. 5. This portion of the control
contains a four-bit microcomputer 80 such as a COPS 411L and ~;
associated electronics to control the Powermate motor 18 and to
communicate to the handle 26 the pilè height and motion sensor
data. This communication is done in packet form over the line
74, as described above. ;~
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The power nozzle control circuitry of Fig. 5 includes a ~
D.C. power supply 400, a 60 hz. clock generator 402, a power-up l -
reset 404, a belt protector adjustment 406, a beater bar speed
30 detector 408, a pile height sensor 82, a triac driver circuit
,;
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~- 410, a triac power control circuit 412, and a transmit and ~ ;~
receive portion 414. The D.C. power supply 400 includes a
resistor 420, a diode 422, a zener diode 424 and a capacitor
426. The line voltage at the lead 75 is thereby reduced,
;~ rectified and filter to approximately 5.6 volts D.C. for supply
.
to the microcomputer 80. ;~
. .
The 60 H2. clock generator 402, as above, generates a ~
,.
square wave clock signal in synchroni2ation with the A.C. power
signal. The power no~zle control 12 utilizes the clock signal ~ -
L0 not only for communication synchronization but also for zero
crossing detect;on for phase control of the motor 18 speed. A
diode 428 halfwave rectifies the line voltage and a transistor
430 and biasing resistors 432 and 434 convert the rectified
signal into a sguare wave clock signal for transmission to the
microcomputer 80. The power-up reset 404, that includes a
resistor 436, a diode 438, and a capacitor 440, maintains a reset
signal at the microcomputer 80 during power-up, just as described
, in conjunction with Fig~ 4.
Pile height data of a carpet is sensed by the pile
height sensing device 82 and is input to the microcomputer 80 at
input ports 84 and 86 when strobed by the microcomputer via port;;~
90. When a user reguests a pile height information, the pile
height sensor 82 is activated by a logic zero signal at the port
90 being transmitted to a switch 442. The switch 442 includes a
transistor 444 and resistors 446 and 448 which operate to supply
power to the sensor 82 long enough to obtain a pile height
reading. Supplying pc>wer to the sensor 82 only when needed
reduces D.C. power supply~requirements and heat build up in the
power no2zle 12.
Although many different types of sensors may be used,
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the sensor 82 includes a spring loaded probe (not shown) to
penetrate into the carpet pile. Penetration depth is determined
` by probe diameter, spring force and carpet pile~ For a known
; probe diameter and spring tension, the carpet pile can be
determined. In one embodiment, the probe depth sensor is a pair
of Hall effect sensors 450 and 452 which sense the displacement
of two magnets (not shown) mounted on the probe for a one of four
possible range resolution. In range one, neither Hall effect
sensor is on~ while in range two the sensor 450 is on. In range
. D three both sensors 450 and 452 are on, while in range four only
sensor 452 is on. Increasing the number of sensors and magnets
can increase the resolution of the sensor 82. Once sensed, the
microcomputer 80 converts the pile height data input on pins 84
and 86 to a form for transmittal to the handle control 26 for
."
display to the user.
The triac driver circuit 410 is controlled by the
microcomputer 80 to turn on the Powermate motor 18 by pulsing a
gate 91 of a triac 92 in the triac power control 412 such that ~ -
~;; ~ full power is applied to the Powermate motor 18, thus reducing ;~
'0~ the DC power supply requirements of the control. The triac
driver circuit 410 includes a transistor 454 and resistors 456,
458 and 460. The microcomputer 80 monitors the output of the 60
Hz. clock generator 402 for positive-going and negative-going
transitions, and, when such transition occurs, applies a logic
zero to pin 462 to turn on the transistor 454. When the
transistor 454 is turned on, it supplies power through the
current limiting resistor 460 to the gate 91 of the triac 92.
After a time interval, a logic one is applied at the pin 462 to
turn of the transistor 454 and remove power from the triac gate ~ -
0 91. The microprocessor 82 is also programmed to phase fire the
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triac 92 for diagnostic testing of belt protector cutout RPM
during the manufacturing process.
The triac power control 412 includes a resistor 464 and
a capacitor 466 to protect the triac 92 from voltage change turn
on, a resistor 468 to load the gate 91, and a capacitor 470 to
filter out noise.
The beater bar 16 speed is monitored by the speed
detector 408 which has a reluctance pickup coil 94 and a magnet
(not shown) in the beater bar 16. As the Powermate beater bar 16
0 spins, the magnet rotates past the coil 94, generating an AC
pulse across the coil windings. The AC voltage generated is
placed across the base-emitter junction of a transistor 96 to
turn it on for a short period of time. As a result, a signal ~.
pulse is sent to pin 98 on tbe microcomputer 80 for counting.
The microcomputer 80 then counts the number of pulses generated
within a specific time period. The count is then cOmpared to a
trip-out, or cut-out, value stored in memory (ROM). If the count
is less than the stored value indicating a jammed beater bar 16,
the microcomputer 80 turns the triac 92 off, thus, turning off
O~ the Powermate motor and transmitting a fault condition to the
handle control.
An important feature of this control is the ability to ~ -~
modify the trip-out values stored in memory to accommodate for
different motor performance characteristics without the need to
`;s remask the microcomputer 80. This is accomplished using four
input lines to the microcomputer 100, 102, 104 and 106. By
grounding them in the proper order, one of sixteen possible
comblnations can be obtain'ed. If the expected mean value of cut-
out RPM is stored in ROM, it can be modified according to the bit
r., ~0 pattern input on pins 100, 102, 104 and 106. Assigning small RPM
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modification to each bit change, the base value can be modified
in plus seven or minus eight increments. We have found a
~, satisfactory base value of 2340 RPM with 60 RPM increments, which
results in a cut-out ~PM range oE 1920 to 2880 RPM. Another
embodiment utiliæes 20 RPM increments. This feature allows
maximum flexibility to the manufacturer to quickly compensate the
cut-out RPM, if required, for such as changes in horsepower
rating of motors used.
The transmit and receive portion 414 communicates data
to and from the handle control portion 26. A resistor 472 and a
diode 474 reduce the voltage level from the power line 75 and
half-wave rectify the 6Q Hz. signal for the data transmission
line 74. A zener diode 476 clamps the maximum voltage on the
lead 74 at approximately 19 volts. Data is transmitted by a
: ~:
transistor 478, the collector of which is tied to line 74, and a
~ resistor 480 connected between the base of the tran~istor 478 and
`~ the output of the D.C. power supply 400. The microcomputer 80
causes the transistor 478 to transmit data at the negative-going
transistions of the 60 Hæ. clock signal.
Data is received from the master control of the handle
12 by the microcomputer 80 through resistors 482 and 484, as well ~-~
as a transistor 486, by monitoring the collector of the
`~j transistor 486 a~ negative going transitions o the clock-
signals. The collector will be at a logic one Eor the
~i transmission of a logic zero, and at a logic æero for the
transmission of a logic one.
YI The circuitry for the canister control is shown in FIG.
3 a contains a four-bit mi'crocomputer 108 such as a COPS 410L and
j associated electronics to control the canister motor 40 and to
~30 communicate to the handle control circuitry fil~er bag peessure
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and hose pressure sensor data, as described above. As with the
handle control circuit and the power no2zle circuit, the canister
control circuit includes a D.C. power supply 500, a 60 Hz. clock
generator 502, a power-up reset 504, a clock oscillator circuit
506, and a transmit and receive circuit 508. More speciically,
the D.C. power supply 500 includes a resistor 510, a diode 512, a
~ener diode 514, and a capacitor 516 for providing an
~ approximately 5.6 volt D.C. supply to the microcomputer 108. The
i 60 Hz. clock generator 502 includes a diode 518, a zener diode -
'D, .0 520, resistors 522 and 524, and a transistor 526 for generating a
square wave in synchronization with the A.C. power signal. The
power-up reset 504 includes an RC circuit having a resistor 528,
~; a capacitor 530 and a diode 532 drain for holding the
microcomputer 108 at reset during power-up. The clock oscillator
506 generates a signal for microcomputer 108 timing control and
includes a ceramic resonator 534, in one embodiment having a
resonator freguency of 455 KH2., a pair of resistors 536 and 538
and a pair oE capacitors 540 and 542. ; 1
The transmit and receive circuit 508 is substantially
similar to that of the power nozzle control of Fig. 5 and
includes a diode 544 and resistor 546 for line power
rectification and reduction, a zener diode 548 for peak voltage
clamping, biasing resistors 550 and 552 and a transistor 554 for . ;~
amplifying received data, and a a resistor 556 and a transistor
558 for transmitting data. The control continuously receives and
transmits data packets from and to the handle control in the -~
Eormat previously described.
~r' The canister con~rol shown in Fig. 3 has a triac power
control 560 for controlling the canister motor 40 and a triac
... ~ . , ~
'~30 driver circuit 562 for operating the triac control 560. The
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triac driver 562 has a transistor 111 and three resistors 564,
566 and 568 while the triac control circuit 560 has a triac 112,
resistors 570 and 572, and a capacitor 574. Upon initial power
Pr that is, inserting the plug 44 into a wall outlet, the
control sets the output at pin 110 to the of level, keeping
transistor 111 and the triac 112 off, thus also keeping the
~ ~ ~ . - .
canister motor 40 off. Upon receipt of a data packet requiring -~
the canister motor 40 to be turned on, the system applies full
power to the canister motor 40. Full power is applied until the
master handle control 26 sends a data packet reguiring a lower ~ ;
speed setting. Speed changes are programmed to occur in steps at
a change rate that is slow enough for the user to easily discern ~ ~`
and use audible feedback to terminate the speed changing process
at the desired level. The canister microcomputer 108 stores the
selected motor speed in RAM. If the user turns the vacuum system ; ;~
off and then turns the system on sometime later, the canister `~
microcomputer 108 will use the speed last selected by the user.
Full power is applied, however, for a few line cycles to ensure
that the motor 40 starts under low line voltage conditions. This
aspect of the control is especially important if the canister
motor 40 must start at one of the lower speeds under low line
conditions. The control ensures that the canister motor 40 will
always start guickly and not stall out.
~5''`i ' ' .' ., , ~
~, As with the power nozzle control, the canister
microcomputer 108 turns on controls the speed of the motor 40 by
phase firing of the triac 112 by pulsing a gate 114, thus
,~ reducing the DC power supply reguirements and heat build up of
the control. The microcom~uter 108 monitors the 60 Hz. clock
input for positive-going or negative-going transitions. When a ~-
~30 transition occurs, the microcomputer 108 delays for a
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predetermined time lnterval, the duration of which depends upon
the motor speed selected, and then applies a logic 2ero at the
pin 110. The application of the logic ~ero causes current flow
through the resistors 564 and 566 which turns on the transistor
111 to supply power to the triac gate 1]4. Power is supplied to
the gate 114 just long enough to turn on the triac 112 before the
pin 110 is switched to a logic one and the triac 112 is turned
off. A thermal overload protector 576 is connected between the
motor 40 and the triac 112.
Motor speeds are derived by phased firing oE the triac
112 at the phase angles listed below with the resulting voltages
being delivered to the motor (assuming a line voltage is 117V
~ ' RMS) .
TA~LE 1
~eed ~ Motor Voltaqe ~RMS)
4 62 10~ ~ -
3 80 g3
104 73
`I A plugged hose 24 or a full filter bag 46 is sensed by
"
'~I the canister microcomputer 108 via hose and bag pressure
sensors. A hose sensor 116 is a digital switch that switches on
when the pressure differential from atmosphere to the inlet of
the canister reaches some predetermined value. A bag sensor 118
is a digital switch that switches on when the pressure
differential from atmosphere to the filter bag compartment
reaches some predetermined value. Under a plugged hose
~30 condition, only the ba~ sensor 118 will actuate. This
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information is input to the microcomputer via pins 120, 122 and
converted to a format to be transmitted to the handle control.
Because the values of pressure differential are preselected,
pressure sensor data is not monitored by the handle control
..
unless the canister motor 40 is running at full speed. As
mentioned above, the handle control microcomputer 72 must be
advised of the same fault for several seconds before displaying
the fault to the user, thus, eliminating false indications
occuring due to normal variations in pressure levels when moving
the power nozzle 12 over work surfaces.
A transient absorber circuit 578 is connected across
the A.C. power lines 75 and 77 to prevent line transients from
destroying the control circuitry. The transient absorber 578 ~;
includes a pair of zener diodes 580 and 582 mounted back-to-back.
Functionality testing of the control circuitry is also
~ . :::
provided. In a first test mode, three switches labeled ~increase
speed" 52, "Powermate on/off" 58 and "display pile height" 56 are `
; .: .:, .. .
pushed at the same time. When this is done, the canister motor
40 phase fires at the highest speed. The Powermate motor 18
~20 phase fires at a phase angle which gives approximately 90 VAC
~ RMS. A normal thirty second delay due to the activation of the
.- , .;
pressure transducers 116, 118 in the canister 34 is eliminated. ~ -
The full-bag sensor flashes the n full-bag" indicator LED 64 on
the handle 26. The hose sensor flashes the "check hose" LED 66
, :, : .
on the handle. If both sensors are activated, then both the
"check hose" and "check bag" LEDs on the handle flash. The lock
out function for the pile-height is eliminated. The pile height
probe may be moved and read at the same time on the handle. To
return the unit to the initial off state, the on/off canister
~I ,, .
~30 switch 48 must be pushed. ~ `
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A ~econd tes~ involves pushing the three switche~
marked ~Powermate on/of" 58, ~'increase speed" 52, and 'tdec~ea~e
Spee~" SO at the same tim..~. The "ch~ck bag" 64, "çheck ho.qe" 66
and "check Powermate" 62 LEDs all Elash, This i~ to ~eci~y that
t~e h3ndle control can control th~ L~Ds and that all IJEDs are
working. To return the un;t to the ;nitial off state, the ; ;~
"on/oEf canlster" sw;t~h" 48 must he puslle~. Activation oE the
¦~ second test ca~cels the ~irs~ test and aCtiv~tion o~ the fi~st
test cancels the second test.
0 With the provisions o thesc diagno,stic unctions, the
: assembly and testing p~sonnel can more quickly test ~he
operation~1ity of t~l~ control without waiting or the vario~s
.built in time delays to pass. This provides a high Leliability
in testing ~hich can be performe~ in a short time period.
An example o a da~a packet ~or transmlsslon ~rom the .
han~le control to the canister control is shown in Fig. 15. Data
,~, . .
bits are transmitted at each nega~ive-going transition oE the
~`r clock signal such that the data transmissi~n ;s in
~, synchconization ~ith the clo~k. ~or ~ logic zero to be ~
0 transmitted, the lea~ 7~ is ~eld to "~ero" a~ a negative-going :~ ;
~; ; :transition oE the clock slgn11, and, Eor a logic one, the lead 76
is raised to a 1091c one leval at a ncgative-going clock
t~ansitio~. Re~erring to Fig. 12 in conjunction wlth Fig. 15,
the fi~st four bits tran.smit:ed, comprising the p~eamble which is
"1010"; while the on/of bit is high indicatlng that the canl5ter
motoc 40 is to be on. The l~st three "motor speed" bits a~e eaoh ;~ :
logic one, thereby controllilg the motor 40 to lts hlghest speed.
In Fig. 16 is shown the signal transmitting ~nd
receiving circuitry connecte~ bet~een the handle control and the
30 canister control over which :he serial blt pattern o~ Pig. 15 is
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transmitted. For the sake of clarity, only the microcomputers 72
and 108, the D.C. power supplies, the 60 Hz. clock generators and
the pertiment transmit and receive circuits are shown. A.C.
power is connected at leads 75 and 77 and is half-wave rectified
so that the clock generator transistors 332 and 526 generate a
synchronized sguare wave signal, as can be seen in the upper ;
diagram of Fig. 15. The rectified signals are further regulated ~- ;
~. and fi~ltered to supply power to the respective microcomputers 72
'3~ and 108. The microcomputer 72 transmits an eight bit data packet
over lead 76 to the microcomputer 108 by transmitting an inverted ~ ;
form of the data to the base of the transistor 358 in
synchronization with the clock signal. The transistor 358 either
holds the line 76 to a logic zero or raises it to a logic one,
depending on the bit transmitted. The lead 76 is controlled at a
relatively high date voltage level, preferably about 19 volts, by
the resistor 546 in conjunction with the diode 544 ~nd zener
diode 548 for breakover at the connectors 600, 602, 604, 606, 608
and 610. The signals on the third lead 76 are received at the
base of the transistor 554 through the resistor 55D, where they
~c . ~ ,
20 are amplified. The microcomputer 108 monitors the amplified data
signals in synchronization with the clock signals. In this way
data is serially transmitted between the control circuits in data
packets of eight bits~ Synchronization is derived from the A.C.
power signal and the voltage level for the data transmission is
sufficiently high to overcome inhibiting factors present at the
connectors.
Flow charts showing the operation of the controls are
presented in FIGS. 6, 7, ~A and 8B.
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FIG. 6 shows a general Elow chart for the canister
control. Control begins in control unit 130 in which a inquiry
is continuously made as to whether there is a first 60 Hz line
crossing. When such a crossing has occurred, control is passed
to control unit 132 which inquires whether there should be an
,
i initial motor start up. If the answer is affirmative, control
.~
; passes to control unit 134 which causes the triac 112 to be
fired. If the answer is negative, or after the triac has been
fired, control is passed to control unit 136 which inquires if it
~ is time to receive data.
! j
If the answer to the inquiry in control unit 136 is
yes, control is passed to control unit 138 in which data is
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received. If the answer to the inquiry is no or after the data
j has been received, control is passed to control unit 140 which
. ..
33 inquires whether the motor 40 should be on. If the answer to the
inguiry is yes, control is passed to control unit 14~2 where the
; ~ . ..
appropriate delay is chosen and then control passes to control
¦ unit 144 to fire the triac 112. If the answer in control unit
-~ 140 is negative or after the triac 112 has been fired, control is ~ -
20 passed to control unit 146 to inquire if there has been a first ~ ;
line crossing. If the answer is no, control is passed back to
control unit 130 to repeat the procedure described above.
,
If the answer to the inquiry in control unit 146 is
affirmative, control is passed to control unit 148 where a
continuous inquiry is made as to whether a second 60 H~. line -~
crossing has occurred. Once the answer to this inquiry is
affirmative, control is passed to control unit 150 which inquires
whether there should be a~ initial motor start up. If the answer
to this inquiry is affirmative, control is passed to control unit
~30 152 to fire the triac 112. If the answer to inquiry in control
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unit 150 is negative oc after the triac ].12 is ired, control is
passed to control unit 154 in which the keyboard is read.
Control is then passed to control unit 156 which inquires whether
it is time to send data. If the answer to this inquiry is yes,
control is passed to control unit 158 to send the data. I~ the
answer to inguiry in control unit 156 is negative or after the `-
data is sent by control unit 158, control is passed back to ;
control unit 140 to repeat the procedure described above. !
FIG. 7 shows a general flow chart for the handle
circuit. Control begins in control unit 160 where a continuous ;
inguiry is made as to whether a first 60 ~2. line crossing has
occurred. Once the answer to that inquiry is affirmative,
control passes to control unit 162 which sends an output to the ;
bag full and hose plugged LEDs 64, 66. Control is then passed to
control unit 164 where an inquiry is made as to whether the
canister motor 40 should be on. If the answer to this inquiry is
negative, control passes to control unit 166 which turns off all
outputs. If the answer to the inquiry in control unit 164 is
affirmative or after the outputs have been turned off, control is
passed to control unit 168 which inquires whether it is time to
send data. ~;
If the answer to the inquiry in control unit 168 is
negative, control is passed to control unit 170 causing data to
be received. If the answer to inquiry in control unit 168 is
afirmative or af~er data has been received by control unit 170,
control is passed to control unit 172 in which the clocks are
updated and then control is passed to control unit 174 in which ;
~he keyboard is debounced~
Control then passes to control unit 176 which inquires
whether there is a first line crossing. If the answer to this
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to repeat the procedure described above. If the answer to the
inguiry in control unit 176 is affirmative, control is passed to
control unit 178 which continuously inquires whether there has
been a second line crossing. Once an affirmative answer is
received to this inquiry, control is passed to control unit 180
in which output for the pile height and check power brush lights
is sent.
ii Control then passes to control unit 182 which inquires
: ,
`i ~ whether the canister should be on. If the answer to this inquiry
is negative, control passes to control unit 184 to turn off all
outputs. If the answer to the inquiry in control unit 182 is
affirmative or after all outputs have been turned off, control is
passed to control unit 186 where inquiry is made as to whether it
is time to send data. If the answer to this inquiry is
affirmative, control is passed to control unit 188 t~o send the
data. If the answer to the inquiry in control unit 186 is
negative or after the data has been sent by control unit 188,
~n, control is passed back to control unit 172 to repeat the above
' ' procedure.
~j
FIGS. 8A and 8B show a general flow chart for the power -
nozzle control circuitry. Control first passes to control unit - --
190 which continuously inquires whether there is a first 60 H~. -.. ,' '':i", :i,'~,-
line crossing. Once the answer to this inQuiry is affirmative,
control passes to control unit 192 which inquires whether the
power brush motor 18 should be on. If the answer to this inquiry
is affirmative, control passes to control unit 194 which inquires
whether the motion sensor'has tripped. If the answer to this
¦ inqùixy is negative, control is passed to control unit 196 which
~ 30 causes the triac 92 to be fired. ~ `~
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If the answer to the inquiry in control unit 192 is
negative, or the answer to the inquiry in control unit 194 is
affirmative, or after the triac has been fired by control u~it
196, control is passed to control unit 198 which inquires whether
it is time to send data. If the answer to this inquiry is
negative control passes to control unit 200 in which data is
received. Control then passes to control unit 202 which inguires
whether there should be an initial start up. If the answer to
;.~
this inquiry is afirmative, control passes to control unit 204
s~ which sets a delay-finished flag and makes a turn-on delay
~S! active.
If the answer to inquiry in control unit 198 is
afirmative, or the answer to inquiry in control unit 202 is
~; ~ negative or after the delays are set and made active by control
unit 204, control is passed to control unit 206 which inquires
whether the power brush motor 18 is on. If the answ,er to this
inquiry is negative, control is passed to control unit 208 which
resets the motion sensor trip-out and then control is passed to -~
control unit 210 in which the pile height input switches are
20 read.
If the answer to the inquiry in control unit 206 is
affirmative, control passes to control unit 212 which inquires
whether the turn-on delay is active. If the answer to this
inquiry is negative, control is passed to control unit 214 which
inquires whether the delay-finished flag is set. If the answer
to this inquiry is affirmative, control is passed to control unit
216 to reset the delay-finished 1ag. If the answer to inquiry
~0 in control unit 214 i9 negative or after the delay-finished 1ag
is reset by control unit 216, control is passed to control unit
~ 30 218 which stores the belt protector RPM. Control is then passed
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to control unit 210 to read the pile-height input switches.
If the inquiry in control unit 212 is affirmative,
control is passed to control unit 220 to inquire whether th~
delay-finished flag is set. If the answer to this inguiry is
negative, control is passed to control unit 222 to compare the
belt protector RPM, to turn off the motor 18 if the RPM is too
low, to set the delay-finished flag and to make the turn-on delay
inactive. If the answer to the inquiry in control unit 220 is
affirmative or after all of the steps of control unit 222 have
been performed, control passes to control unit 210 to read the
pile-height input switches.
Control then passes to control unit 224 which inquires
whether there is first line crossing. If the answer to this
inquiry is negative, control passes back to control unit 190 to
repeat the procedure described above. If the answer to this
inquiry is affirmative, control passes to control unit 226 which
continuously inquires whether there has been a second 60 Hz line
crossing. When the answer to this inquiry is affirmative, ~ `-
control passes to control unit 228 which inquires whether the ~ -
0 power-brush motor 18 should be on. If the answer to this inquiry ~ ~
is yes, control passes to control unit 230 which inquires whether `
the motion sensor has tripped. If the answer to this inquiry is
negative, control passes to control unit 232 which causes the
triac 92 to be fired.
If the answer to inquiry in control unit 228 is
negative, or the answer to inquiry in control unit 230 is
afirmative, or after the triac has been fired by control unit i~
232, control passes to co~trol unit 234 which updates the
cloc~s. Control then passes to control unit 236 which inquires
30 whether the time delay has expired. If the answer to this -
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~ inquiry is affirmative, control passes to con~rol unit 238 which
.~ .
toggles the turn-on delay. If the answer to inquiry in control
unit 236 is negative or after the turn-on delay has been toggled
by control unit 238, control passes to control unit 240 in which
the belt pr~tector reference RPM is read. Control then passes to
!~ control unit 242 which in~uires whether it is time to send
data. If the answer to this inquiry is affirmative, control
passes to control unit 244 to send the data. If the answer to
the inguiry in control unit 242 is negative or after the data has
been sent by a control unit 244, control passes back to control
unit 206 to repeat the procedure described above.
From the foregoing description of a preferred
embodiment of the invention it is seen that the present invention -
provides a control for vacuum cleaner having three separate ~ ~ -
~! . .- .: .
circuits to control various functions in the canister and power
floor cleaner and to permit the user to control these functions
through the handle on the suction hose. A1so, indicator lights
are provided on the control to alert the user and to apprise the -
~ user of various sensed and selected parameters. Further,
; 20 diagnostics testing is built into the circuits to assist in the
manufacturing and testing processes.
As is apparent from the foregoing specification, the -
~ invention is susceptible of being embodied with various
t alterations and modifications which may differ particularly from
those that have been described in the preceeding specification
;~ and description. It should be understood that we wish to embody
within the scope of the patent warranted hereon all such
modifications as reasona~ly and properly come within the scope of
our contribution to the art.
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