Directionally-Aware Vacuum Cleaner

The present disclosure is generally directed to a vacuum cleaner, and more particularly to a directionally-aware vacuum cleaner.

The present disclosure is generally directed to vacuum cleaner with directional power control. In some embodiments described herein a cleaning head associated with the vacuum cleaner includes a powered cleaning roller and an articulating debris scraper. The articulating scraper is configured to move into a first position when the cleaning head is rolling in a forward direction, and a second position when the cleaning head is rolling in a reverse direction. The cleaning head includes sensors to determine the position of the articulating scraper. The vacuum cleaner also includes control circuitry to control a rotational speed of the cleaning roller based on the first or second position. For example, the cleaning roller may be controlled to reduce rotational speed (RPM) of the cleaning roller when the cleaning head is rolling in a reverse direction, and the cleaning roller may be controlled to increase the RPM of the cleaning roller when the cleaning head is rolling in a forward direction. In some embodiments, the control circuitry may adjust a vacuum suction force of the vacuum cleaner based on the first or second position of the scraper. By reducing the cleaning roller speed and/or vacuum suction force when the cleaning head is rolling in a reverse direction, more efficient cleaning is realized without sacrificing an overall “cleaning score” of the vacuum cleaner.

illustrates a block diagram of a vacuum cleaner systemaccording to embodiments of the present disclosure. The system generally includes a handle or base portion(“handle/base”) and a rollable cleaning head. The vacuum systemmay include, for example, an upright vacuum system, canister vacuum system, handheld vacuum system, battery powered vacuum system, central vacuum cleaner, etc. The cleaning headincludes a controllable cleaning rollerand controllable motor circuitryto control a rotational speed (e.g., revolutions per minute (RPM)) of the cleaning roller. In addition, the cleaning headincludes an articulating debris scrapergenerally configured to push and gather debris along a surface that is in contact with the cleaning head, as will be described in greater detail below. The scraper(also referred to herein as a “squeegee”) is pivotally coupled to the cleaning head, and may be deployed in a first (deployed) position and a second (retracted) position, depending on a rolling direction of the cleaning head, as described below. The cleaning head also includes position sensor circuitrygenerally configured to determine the first and second positions of the scraperand generate a control signal indicative of the first or second position of the scraper. The cleaning headis in fluid communication with the handle/base portionvia vacuum conduit. In addition, the cleaning head is configured to exchange commands, sensor data and power via electrical interface. The electrical interfacemay be embodied as, for example, male/female plugs, electrical contacts, locking pins/holes, etc., In some embodiments, the vacuum conduitand electrical interface are generally configured to removably couple the cleaning headto the handle or base portion.

The handle/baseincludes cleaning roller RPM control circuitrygenerally configured to control the controllable motor circuitry(and thus control the RPM of the cleaning roller) based on the control signal generated by the position sensor circuitry. As a general matter, when the cleaning headis moving in a forward direction (e.g., being pushed away from a user) the RPM of the cleaning rolleris controlled to have a first RPM, and when the cleaning headis moving in a reverse direction (e.g., being pulled toward a user), the RPM of the cleaning rolleris controlled to have a second RPM. To prevent dirt and debris from being “kicked” away from a footprint of the cleaning headwhen the cleaning head is moving in a reverse direction, according to some embodiments described herein, the second RPM is less than the first RPM, i.e., the cleaning rollerhas a reduced RPM when the cleaning headmoving in a reverse direction compared to a forward direction. By way of a non-limiting example, the rotational speed of the cleaning rollerin the forward direction may be on the order of 1000 RPM, and the rotational speed of the cleaning rollerin the reverse direction may be on the order of 500 RPM (or less). Of course, rotational speed of the cleaning rollermay also be selected based on, for example, the type of surface to be cleaned, nozzle configuration, etc.

The handle/base portionalso includes controllable vacuum motor circuitrygenerally configured to generate a suction force and supply the suction force to the cleaning head, via vacuum conduit. In some embodiments, the handle/base portionmay also include vacuum suction force control circuitrysupply generally configured to control a suction force generated by the vacuum motor circuitry, based on the control signal generated by the position sensor circuitry. For example, when the cleaning headis moving in a forward direction (e.g., being pushed away from a user) the suction force generated by the vacuum motor circuitryis controlled to have a first suction force, and when the cleaning headis moving in a reverse direction (e.g., being pulled toward a user), the suction force generated by the vacuum motor circuitryis controlled to have a second suction force. According to some embodiments described herein, the second suction force is less than the first suction force, i.e., suction force delivered to the cleaning headis reduced when moving in a reverse direction compared to a forward direction, as shown by pivoting arrow. As a general matter, reduction of suction force in a reverse direction may lessen a pulling force required to move the cleaning headacross a surface. By way of non-limiting example, the suction force in a forward direction may be on the order of 100% available force, while suction force in a reverse direction may be on the order of 70% of maximum suction force.

is a perspective view of an example cleaning headaccording to embodiments of the present disclosure. The cleaning head generally includes a vacuum interface regiongenerally configured to a receive handle and control assembly (not shown in this figure) associated with a vacuum system. The vacuum interface regiongenerally forms a vacuum conduitfor fluid communication between the cleaning headand a handle/base portion (not shown in this figure). In addition, the vacuum interface regionmay include an electrical interfaceto provide electrical and power coupling between the cleaning headand a handle/base portion (not shown in this figure). The cleaning headalso includes a surface cleaning regionthat includes a main bodygenerally configured to roll across an area to be cleaned, for example, carpet, flooring, etc. The cleaning headalso includes rollersto facilitate movement of the cleaning headacross a floor in both forward and reverse directions (as generally indicated by the F arrow and R arrow). The main bodyof the cleaning regionalso includes main controllable cleaning roller(cleaning roller) generally disposed within a vacuum regionof the main body, and generally configured to controllably rotate to lift dirt and debris into the vacuum region.

The cleaning rollergenerally extends across the width of the main body, and may include one or more bristle tracksto provide cleaning as the main bodypasses over flooring. In the view of, the cleaning rolleris generally controlled to rotate in a counter-clockwise direction. The one or more bristle tracksmay be formed of, for example, stiff bristles, flaps (e.g., rubber flaps), plush material (e.g., low-nap material), etc. The cleaning rollermay be coupled to controllable motor circuitry (not shown in this figure) to cause controllable rotation of the cleaning rollerand to enable a user to turn the roller“on” and “off”, depending on a given cleaning task. The vacuum orificeis illustrated as an elongated opening generally disposed near a leading edge or centrally to the main body, and the cleaning rollermay generally be disposed within and partially extending “below” the vacuum orificeto enable contact with a surface to be cleaned. In some embodiments, the main bodymay also include a “leading edge” rollerpositioned forward of the cleaning roller, and generally configured to maintain dirt and debris within the footprint of the main bodyas the main body moves across a floor.

The main bodyalso includes an articulating debris scraper assembly(“scraper”) generally extending across the width of the main body, and position “behind” the cleaning roller. The scraperis generally disposed parallel to the cleaning roller, and rotatably coupled at both ends to the main body. The scrapermay be formed of, for example, a pliable elastomeric material (e.g., soft plastic, rubber, etc.), stiff bristles, flaps (e.g., rubber flaps), plush material (e.g., low-nap material), etc.illustrates the scraperin a deployed position, i.e., so that the scrapercontacts the floor as the cleaning headmoves in the forward direction. As will be described below, the scraperis configured to pivot forward into a retracted position as the cleaning headmoves in reverse, thus eliminating “pile-up” of debris on the rear edge of the scrapper when the cleaning headmoves in reverse. Features of various embodiments of the cleaning headand scraper assemblyare described in greater detail below.

illustrates a perspective cross-sectional view of the cleaning head′ according to one embodiment of the present disclosure, taken along line X-X ofand partially zoomed in. The cleaning head′ of this embodiment includes a scraper assembly′ that includes an elongated, flexible strip portioncoupled to a rotatable head portion. The rotatable head portionis generally configured to pivot with slotformed in the main body′. As a general matter, the scraper assembly′ is configured to rotate into a first deployed position, as shown in, and a second retract position (not shown in the figure), as generally illustrated by pivot arrow.

As is also illustrated in, the cleaning head′ includes a controllable rollergenerally extends across the width of the main body, and may include one or more bristle tracksto provide cleaning as the main bodypasses over flooring. The one or more bristle tracksmay be formed of, for example, stiff bristles, flaps (e.g., rubber flaps), plush material (e.g., low-nap material), etc. The cleaning rolleris coupled to controllable motor circuitry′ to cause controllable rotation of the cleaning rollerand to enable a user to turn the roller“on” and “off”, depending on a given cleaning task. The vacuum orificeis illustrated as an elongated opening generally disposed near a leading edge or centrally to the main body, and the cleaning rollermay generally be disposed within and partially extending “below” the vacuum orificeto enable contact with a surface to be cleaned. In some embodiments, the main bodymay also include a “leading edge” rollerpositioned forward of the cleaning roller, and generally configured to maintain dirt and debris within the footprint of the main bodyas the main body moves across a floor. The main bodyalso includes wheels or rollersdisposed near the trailing edge of the main bodyto enable the main bodyto roll across a surface.

The cleaning head′ also includes hall sensor circuitrydisposed within the main bodyadjacent to the scraper assembly′ generally configured to determine a first position (deployed) and a second position (retracted) of the scraper assembly′. Details of the scrapper assembly′ and the hall sensor circuitryare described below with reference to.

illustrates a close-up view of the area of the main bodyaround the scraper assembly′ and the hall sensor circuitry. As illustrated, the rotatable head portionof the scrapper assembly′ includes a hemispherical memberremovably coupled to an inner housing member, and the rotatable head portionis generally configured to pivot within slot. The scraperincludes a T-flange portiongenerally dimensioned to fit within an anulus of the inner housing member. The inner housing member(and scrapper) may be removeably coupled to the hemispherical member(using, for example, tabs, interference fit, etc.) to enable removal of the inner housing memberand/or scrapperto replace and/or clean the scrapper assembly′.

To assist rotation of the scraper assembly′ when the main bodyis moving from a forward direction to a reverse direction, the present embodiment may also include at least one actuating foot assemblycoupled to the scrapper assembly′, and positioned generally behind the scraper assembly′. The actuating foot assemblygenerally includes a first portiondisposed generally parallel to the scraperand a curved second portionthat generally curves toward the rear of the main body. A lower edge of the first portionand the curved second portionextend beyond a lower edge of the scraper, in the deployed position shown in, so that when the main body transitions from a forward direction to a reverse direction, the curved second portion“catches” on the cleaning surface and causes a rotation of the actuating foot assembly, thus urging the scraper assembly′ to rotate into a retracted position (and thus avoiding debris build up along the rearward edge of the scraper). In some embodiments, a plurality of actuating foot assembliesmay be includes along the long axis of the scraper assembly′.

In this embodiment, the hemispherical memberincludes magnetic memberdisposed thereon (and/or disposed within). The magnetic memberis generally positioned to magnetically decouple from the hall sensor circuitrywhen the scraper assembly′ is in a first position, and to magnetically couple to the hall sensor circuitrywhen the scraper assembly′ is in a first position. By way of example,illustrates the scraper assembly′ in a first (deployed) position, and the magnetic memberis decoupled from the Hall sensor circuitry. When the cleaning head′ is moved in the reverse direction (R), the scraper assembly′ pivots into a retracted position (as described above), thus rotating the magnetic memberto magnetically couple to the Hall sensor circuitry.

The Hall sensor circuitryis configured to generate a first control signal indicative of (or proportional to) the condition where the magnetic memberis decoupled from the Hall sensor circuitry. This is illustrated in the position of the scraper assembly′ rotated away from the Hall sensor circuitry, as shown in. The Hall sensor circuitryis also configured to generate a second control signal indicative of (or proportional to) the condition where the magnetic memberis coupled from the Hall sensor circuitry. This occurs when the scraper assembly′ is rotated into the retracted position (not shown), and the magnetic memberis rotated to be approximately “facing” the Hall sensor circuitry.

The first and second control signals generated by the Hall sensor circuitryare communicated to the cleaning roller RPM control circuitry (,). If the first control signal indicates that the scraper assembly′ is in a deployed position, the cleaning roller RPM control circuitryis configured to control the controllable motor circuitry′ to cause the controllable cleaning rollerto rotate at a first RPM rate. This corresponds to a forward movement of the cleaning head′. If the second control signal indicates that the scraper assembly′ is in a retracted position, the cleaning roller RPM control circuitryis configured to control the controllable motor circuitry′ to cause the controllable cleaning rollerto rotate at a second RPM rate. This corresponds to a reverse movement of the cleaning head′. To prevent “kick-up” of dirt and debris when moving the cleaning head′ in a reverse direction, the first RPM is greater than the second RPM rate.

In some embodiments, in addition to (or alternatively to) controlling the controllable cleaning roller, the first and second control signals generated by the Hall sensor circuitrymay be communicated to the vacuum suction force control circuitry (,). If the first control signal indicates that the scraper assembly′ is in a deployed position, the vacuum suction force control circuitryis configured to control the controllable vacuum motor circuitry (,) to cause the controllable vacuum motor circuitryto generate a first vacuum suction force. This corresponds to a forward movement of the cleaning head′. If the second control signal indicates that the scraper assembly′ is in a retracted position, the vacuum suction force control circuitryis configured to control the controllable vacuum motor circuitry (,) to cause the controllable vacuum motor circuitryto generate a second vacuum suction force. This corresponds to a reverse movement of the cleaning head′.

illustrate cross-section views of the cleaning head′ operating in a forward direction () and a reverse direction (). As shown in, the scraper assembly′ is in the deployed, or downward, position, thus enabling dirt and debris to be pushed forward along the leading edge of the scraper. As illustrated in the deployed position, the bottom edge of the scraperis generally coplanar with the roller. As also shown in, the actuating foot assemblyis illustrated in the deployed position. As shown in, the scraper assembly′ is in the retracted position, thus preventing dirt and debris from being collected along the trailing edge of the scraper. As illustrated in the retracted position, the bottom edge of the scraperis “tucked” behind the roller, and the actuating foot assemblyis illustrated in the retracted position.

As is illustrated, the internal structure of the main bodyof the cleaning head′ includes various slots, channels and/or chambers to affix and/or house the scraper assembly′, cleaning roller, Hall sensor circuitry, controllable motor circuitry′, etc., within the main body. Of course, such slots, channels and/or chambers to affix and/or house components within the main bodymay be modified, for example, depending on dimensions of selected components, desired tolerances within the body and between components, etc.

illustrates a perspective cross-sectional view of a cleaning head″ according to another embodiment of the present disclosure, taken along line X-X ofand partially zoomed in. The cleaning head″ of this embodiment is similar to the embodiment of(described above), except this embodiment includes a spring contact sensor, as will be described below. The spring contact sensoris disposed within the main bodyadjacent to the scraper assembly″ generally configured to determine a first position (deployed) and a second position (retracted) of the scraper assembly″. Details of the spring contact sensorare described below with reference to.

illustrates a close-up view of the area of the main bodyaround the scraper assembly″ and the spring contact sensor. The scraper assembly″ of this embodiment is similar to the scraper assembly′ (described above), except that scraper assembly″ omits a magnetic member.

With reference to, the spring contact sensorincludes a housing memberhaving an electrical contact plungerdisposed within the housing member. A pinis disposed in contact with the plunger. A springis disposed within the housing memberand partially surrounding the pin. The springoperates to bias the pintoward the hemispherical memberof the scraper assembly″. The pinis generally positioned to contact the hemispherical member, and, when the scraper assembly″ is in a first position, to cause the plungerto be in a first electrical contact state, and when the scraper assembly″ is in a second position, to cause the plungerto be in a second electrical contact state. By way of example,illustrates the scraper assembly″ in a first (deployed) position, and the pinis extended and in contact with the hemispherical member. In this position, the plungeris in an extended position, as illustrated. When the cleaning head′ is moved in the reverse direction (R), the scraper assembly″ pivots into a retracted position (as described above), and the pinis urged upward into the plungercausing the plungerto move upward and engage or disengage an electrical contact within the housing member. Thus, the hemispherical memberoperates a cam and the pinfollows the contours of the hemispherical member.

The spring contact sensor circuitryis configured to generate a first control signal indicative of (or proportional to) the condition where the pinis extended. This is illustrated in the position of the scraper assembly″ shown in. The spring contact sensor circuitryis also configured to generate a second control signal indicative of (or proportional to) the condition where the pinis pushed upward into the plungercausing the plungerto move upward and engage or disengage an electrical contact within the housing member. This occurs when the scraper assembly″ is rotated into the retracted position (not shown).

The first and second control signals generated by the spring contact sensor circuitryare communicated to the cleaning roller RPM control circuitry (,). If the first control signal indicates that the scraper assembly″ is in a deployed position, the cleaning roller RPM control circuitryis configured to control the controllable motor circuitry″ to cause the controllable cleaning roller″ to rotate at a first RPM rate. This corresponds to a forward movement of the cleaning head″. If the second control signal indicates that the scraper assembly″ is in a retracted position, the cleaning roller RPM control circuitryis configured to control the controllable motor circuitry″ to cause the controllable cleaning roller″ to rotate at a second RPM rate. This corresponds to a reverse movement of the cleaning head″. To prevent “kick-up” of dirt and debris when moving the cleaning head″ in a reverse direction, the first RPM is greater than the second RPM rate.

In some embodiments, in addition to (or alternatively to) controlling the controllable cleaning roller″, the first and second control signals generated by the spring contact sensor circuitrymay be communicated to the vacuum suction force control circuitry (,). If the first control signal indicates that the scraper assembly″ is in a deployed position, the vacuum suction force control circuitryis configured to control the controllable vacuum motor circuitry (,) to cause the controllable vacuum motor circuitryto generate a first vacuum suction force. This corresponds to a forward movement of the cleaning head″. If the second control signal indicates that the scraper assembly″ is in a retracted position, the vacuum suction force control circuitryis configured to control the controllable vacuum motor circuitry (,) to cause the controllable vacuum motor circuitryto generate a second vacuum suction force. This corresponds to a reverse movement of the cleaning head″.

illustrate cross-section views of the cleaning head″ operating in a forward direction () and a reverse direction (). As shown in, the scraper assembly′ is in the deployed, or downward, position, thus enabling dirt and debris to be pushed forward along the leading edge of the scraper, and the bottom edge of the scraperis generally coplanar with the roller. As also shown in, the actuating foot assemblyis illustrated in the deployed position. In the deployed position, the pinis in a biased downward position to cause the plungerto be in the first electrical contact state. As shown in, the scraper assembly′ is in the retracted position, thus preventing dirt and debris from being collected along the trailing edge of the scraper. As illustrated in the retracted position, the bottom edge of the scraperis “tucked” behind the roller, and the actuating foot assemblyis illustrated in the retracted position. In the retracted position, the pinis in a biased upward position to cause the plungerto be in the second electrical contact state.

As is illustrated, the internal structure of the main bodyof the cleaning head″ includes various slots, channels and/or chambers to affix and/or house the scraper assembly″, cleaning roller″, spring contact sensor circuitry, controllable motor circuitry″, etc., within the main body. Of course, such slots, channels and/or chambers to affix and/or house components within the main bodymay be modified, for example, depending on dimensions of selected components, desired tolerances within the body and between components, etc.

In some embodiments, the cleaning head/′/″ described above may include other types of sensors. For example, electrical contacts may be positioned on the hemispherical memberand mating contacts positioned on a surface of the groovesuch that as the scraper assemblyis rotated, electrical coupling is connected or disconnected based on the position of the scraper assembly. Of course, these are only examples of the types of sensors that may be used to detect motion of the scraper assembly, and those skilled in the art will recognize may alternatives and/or modifications to the sensors described herein, and all such alternatives and/or modifications are deemed within the spirit and scope of the present disclosure. In still other embodiments, the cleaning headand/or handle/base portionmay include, for example, a motion sensor, image sensor, infrared sensor, etc., to determine a motion direction of the cleaning head independently of the scraper assembly, and in such embodiments the scraper assemblymay be omitted.

As used in this application and in the claims, a list of items joined by the term “and/or” can mean any combination of the listed items. For example, the phrase “A, B and/or C” can mean A; B; C; A and B; A and C; B and C; or A, B and C. As used in this application and in the claims, a list of items joined by the term “at least one of” can mean any combination of the listed terms. For example, the phrases “at least one of A, B or C” can mean A; B; C; A and B; A and C; B and C; or A, B and C.

Any of the operations described herein may be implemented in a system that includes one or more non-transitory storage devices having stored therein, individually or in combination, instructions that when executed by circuitry perform the operations. Such instructions may embodied as, for example, machine code, and/or “higher level” implementations such as software programing, application (app) programming, etc. “Circuitry”, as used in any embodiment herein, may comprise, for example, singly or in any combination, hardwired circuitry, programmable circuitry such as processors comprising one or more individual instruction processing cores, state machine circuitry, and/or firmware that stores instructions executed by programmable circuitry and/or future computing circuitry including, for example, massive parallelism, analog or quantum computing, hardware embodiments of accelerators such as neural net processors and non-silicon implementations of the above. The circuitry may, collectively or individually, be embodied as circuitry that forms part of a larger system, for example, an integrated circuit (IC), system on-chip (SoC), application-specific integrated circuit (ASIC), programmable logic devices (PLD), digital signal processors (DSP). field programmable gate array (FPGA), logic gates, registers, semiconductor device, chips, microchips, chip sets, etc.

The storage device includes any type of tangible medium, for example, any type of disk including hard disks, floppy disks, optical disks, compact disk read-only memories (CD-ROMs), compact disk rewritables (CD-RWs), and magneto-optical disks, semiconductor devices such as read-only memories (ROMs), random access memories (RAMs) such as dynamic and static RAMs, erasable programmable read-only memories (EPROMs), electrically erasable programmable read-only memories (EEPROMs), flash memories, Solid State Disks (SSDs), embedded multimedia cards (eMMCs), secure digital input/output (SDIO) cards, magnetic or optical cards, or any type of media suitable for storing electronic instructions. Other embodiments may be implemented as software executed by a programmable control device. Also, it is intended that operations described herein may be distributed across a plurality of physical devices, such as processing structures at more than one different physical location.

The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described (or portions thereof), and it is recognized that various modifications are possible within the scope of the claims. Accordingly, the claims are intended to cover all such equivalents. Various features, aspects, and embodiments have been described herein. The features, aspects, and embodiments are susceptible to combination with one another as well as to variation and modification, as will be understood by those having skill in the art. The present disclosure should, therefore, be considered to encompass such combinations, variations, and modifications.