Abstract:
A floor care appliance is provided with a microprocessor based control arrangement having a communications port for connection to a computer. Once connected to a computer, software updates for the microprocessor may be downloaded or diagnostic information stored in the microprocessor&#39;s memory may be uploaded for diagnostic purposes. In one embodiment of the invention, the communication port is configured to be connected to a local computer for possible further connection to a remote computer over a computer or telephone network. In an alternate embodiment of the invention, the communication port is configured to connect to and dial up a remote computer over a telephone network.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to floor care, and more specifically, to a floor care appliance having a port for connecting the microprocessor control system to a computer. 
     2. Summary of the Prior Art 
     Floor care appliances are well known in the art. Typical floor care appliances include upright vacuum cleaners, canister vacuum cleaners, hard floor cleaners, and extractors. More recently floor care appliances have been provided with increasingly sophisticated microprocessor based control systems for controlling one or more features including, for example, a suction motor, agitator motor, bag full indicators, and the like. Typically, such microprocessors are permanently pre-programmed at the factory with instructions for controlling the features. The microprocessors are not connected to any electronic hardware which would enable programming to be updated if required. It would be desirable to have the flexibility of updating the programming of the microprocessor as more sophisticated programming becomes available. Also, with the addition of hardware to connect the microprocessor to a computer, the microprocessor becomes more useful. For example, the microprocessor could be programmed to store real time operational data in a log that could be read by a computer for diagnostics purposes. The computer could be a local personal computer or a remote computer. 
     U.S. Pat. No. 6,637,546 discloses a carpet cleaning machine provided with a microprocessor which controls various components. The microprocessor is software controlled and can provide sequential operating instructions to the operator, enforce start-up and shut down sequences, store an electronic record of operating parameters for future use, provide auto- and remote diagnostics, and provide remote control. The software is updated via a modem. 
     However, updating the microprocessor software via a modem is not the only way to update microprocessor software and may not be the most desired means. With the adaptation of readily available access to high speed computer network services, such as the Internet, and most homes having a personal computer connected to the Internet, it may be more desirable to update microprocessor software from a personal computer connected to a remote computer through a computer network such as the Internet. Accordingly, there is a need in the art for a floor care appliance having a microprocessor based control system that can be connected to a personal computer. 
     Accordingly, it is an object of the invention to provide a floor care appliance having a microprocessor based control system that can be connected to a computer. 
     It is a further object of this invention to provide a floor care appliance having a microprocessor based control system that can be connected to a personal computer. 
     It is a further object of this invention to provide a floor care appliance having a microprocessor based control system that can be connected to a personal computer via a digital pathway. 
     It is a further object of this invention to provide a floor care appliance having a microprocessor based control system that can be connected to a personal computer via a wireless connection. 
     It is a further object of this invention to provide a vacuum cleaner having a microprocessor based control system that can be connected to a remote computer via a modem. 
     SUMMARY OF THE INVENTION 
     In the preferred embodiment of the invention, a floor care appliance having a programmable microprocessor is provided wherein the microprocessor is programmed to store operational parameters of the appliance as well as real time performance data. The microprocessor is capable of being connected to a computer wherein the programmed operational parameters may be changed and the real time performance data uploaded to the computer. The performance data can then be evaluated to determine the operating condition of the cleaner for repair and maintenance purposes. The performance data may also be used to determine adjustments to be made to the operating parameters of the appliance which are downloaded to the microprocessor from the computer. 
     In one embodiment of the invention, the computer is a personal computer and the floor care appliance is connected via a digital pathway. The digital pathway could use any one of a number of computer protocols including RS-232, ethernet, Firewire, Blue Tooth, X 10 , infrared or the newer RS-485. The personal computer can then be used to update the microprocessor software provided on a removable storage media or retrieve it from a remote computer via the Internet or a dial-up connection through a modem. 
     In an alternate embodiment of the invention, the digital pathway between the floor care appliance and the personal computer is replaced with a wireless connection utilizing a radio frequency. 
     In another embodiment of the invention, the microprocessor is configured to be a modem so that the floor care appliance can be connected directly to a telephone network for dialing up and connecting to a remote computer for software updates and diagnostics. The microprocessor could be pre-programmed with a toll free or other number of a customer service center of the appliance&#39;s manufacturer. 
     In the instant invention, the subject microprocessor is part of an improved power management system for controlling the total amount of current provided to at least a first and a second load device of an appliance. The power management system is comprised of a microprocessor, an alternating current voltage source, a voltage regulating circuit, a clamping circuit, at least two load devices, and a MOC and a triac for each of the at least two load devices. The clamping circuit outputs a fixed voltage during the portion of the ac cycle which is greater than or less than zero and provides a zero or negligible voltage while the ac cycle is at zero voltage. The fixed voltage and the zero or negligible voltage are input to a microprocessor. The microprocessor utilizes these inputs to control the amount of time the current is turned on to each of the at least first and second load devices. The current is turned on to each of the at least first and second load devices by an output from the microprocessor provided to the associated MOC which in turn controls the associated triac for turning the current on to the associated load. One of the at least first and second loads has a sensing circuit which monitors the current drawn by the load. A surge or rise in the current drawn will cause an output from the sensing circuit which is input to the microprocessor. The microprocessor will adjust according to pre-programmed instructions the amount of time the current is turned on to each of the at least first and second loads so that the total current drawn by all of the at least first and second loads does not exceed a predetermined value. This requires that the microprocessor reduce the current provided to the at least second load to account for the increased amount of current used by the first load. 
     In one embodiment of the power management system, the at least first and second loads are a motor-fan assembly and an agitator drive motor. The pre-determined level or total current that may be drawn by both motors is 12 amps with the agitator drive motor initially programmed to draw 2 amps. This means that the motor-fan assembly can initially draw 10 amps. An increase in the load placed on the agitator drive motor will cause the amount of current drawn by the agitator drive motor to exceed 2 amps. Necessarily, the microprocessor will adjust the current provided to the motor-fan assembly to less than ten amps. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference may now be had to the accompanying drawings for a better understanding of the invention, both as to its organization and function, with the illustration being only exemplary and in which: 
         FIG. 1  is a perspective view of a floor care appliance having a port for connection to a computer, according to the preferred embodiment of the present invention; 
         FIG. 2  is an exploded view of a floor care appliance having a microprocessor controlled power management system having a port for connection to a personal computer, according to the preferred embodiment of the present invention; 
         FIG. 3  is an electrical schematic of a microprocessor controlled power management system having a port for connection to a computer, according to the preferred embodiment of the present invention; 
         FIG. 4  is an electrical schematic of an improved power management system having a port for connection to a remote computer through a telephone network, according to an alternate embodiment of the present invention; 
         FIG. 4A  is an electrical schematic of an RS-232 transceiver connected to the microprocessor shown in  FIG. 4  for converting data from said microprocessor into RS-232 protocols for connecting the power management system to a remote computer through a telephone network, according to the alternate embodiment of the invention; 
         FIG. 4B  is an electrical schematic of an isolation circuit for isolating the RS-232 transceiver from the telephone network, according to the alternate embodiment of the present invention; 
         FIG. 4C  is a switching circuit for signaling the microprocessor shown in  FIG. 4  to connect the RS-232 transceiver shown in  FIG. 4A  with a remote computer through a telephone network, according to the alternate embodiment of the present invention; 
         FIG. 4D  is a circuit for connecting the microprocessor to ground, according to the alternate embodiment of the present invention; and 
         FIG. 4E  is a circuit for timing data for the modem of  FIG. 4C , according to the alternate embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to  FIGS. 1 and 2 , shown is an upright vacuum cleaner  10  having a microprocessor based control system having a port  700  for connection to a computer. Upright vacuum cleaner  10  includes a foot  100  and an upper housing assembly  200  pivotally connected to foot  100 . Foot  100  is similar to those known in the art and includes a nozzle opening (not shown) for receiving a stream of dirt-laden air and an agitator (not shown) for agitating and loosening dust and debris from a floor surface when upright vacuum cleaner  10  is in the floorcare mode. Foot  100  further includes a pair of front wheels (not shown), rotatably mounted on a wheel carriage (not shown), and a pair of rear wheels  130 . 
     Located in foot  100  or upper housing  200  is a motor-fan assembly M 2  which creates the suction necessary to remove the loosened dust and debris from the floor surface. The motor-fan assembly M 2  fluidly connects to foot or suction nozzle  100  by a dirt duct (not shown). The upper housing assembly  200  houses a particle filtration and collecting system  300  for receiving and filtering the dirt-laden airstream which is created by the motor-fan assembly  400 . The particle filtration and collecting system  300  may be interposed in the dirt-laden airstream between the suction nozzle  100  and the motor-fan assembly M 2  as in an “indirect air” system seen in  FIG. 1 , or the motor-fan assembly M 2  may be interposed between the suction nozzle  100  and the particle filtration and collecting system  300  as in a “direct air” system. An independent electric agitator drive motor M 1  is provided for providing rotary power for at least one rotary agitator (not shown). Motor-fan assembly M 2  and agitator drive motor M 1  are controlled by a power management system  800  located in the upper housing  200 . Although power management system  800  may be located anywhere on the floor care appliance  10 , including foot  100 , it is desirable to have power management system  800  located in a moving airstream, such as the exhaust for motor-fan assembly M 2 , for cooling purposes. Power management system  800  is shown in  FIG. 1  in the form of a snap-in module but may be constructed in numerous other ways. A detailed description of the composition and operation of power management system  800  is given below. 
     Referring now to  FIG. 2 , shown is an exploded view of a floor care appliance  10  with a preferred embodiment dirt collecting system  300 . Dirt collecting system  300  generally includes a translucent dirt cup  350 , a filter assembly  380  removably mounted within the dirt cup  350  and a dirt cup lid  382  which encloses the dirt cup  350 . Filter assembly  380  generally includes an apertured wall  312 , a filter support  314  extending from the apertured wall  312  and a primary filter member  381  which removably mounts on the filter support  314 . The filter assembly  380 , and particularly the apertured wall  312  thereof, along with the partition wall  310 , separate the dirt cup chamber  394  into a first dirt collecting chamber  316  and a second dirt collecting chamber  318 . The apertured wall  312  is positioned between rear wall  386  and front wall  392  and is formed with a plurality of apertures or holes  320 . The holes  320  provide for fluid communication between the first dirt collecting chamber  316  and the second dirt collecting chamber  318 . The apertured wall  312  functions as a coarse particle separator or pre-filter and could include any number of holes having various shapes (circular, square, elliptical, etc.), sizes and angles. To maximize airflow through the holes while still preventing large debris from passing therethrough, it is desirable to form the holes as large as 0.0036 square inches and as small as a 600 mesh screen. In the present embodiment, the holes  320  are circular with a hole diameter of approximately 0.030 inches. Further, the apertured wall  312  should be formed with enough total opening area to maintain airflow through the dirt cup  350 . It is desirable to form apertured wall  312  with a total opening area of between approximately 2.5 square inches to approximately 4 square inches. Complete details of the dirt collecting system  300  can be found in U.S. Pat. No. 6,596,044, owned by a common assignee and incorporated fully herein by reference. 
     On the lower portion of upper housing  200  is a data port  700  for connecting floor care appliance  10  to a network. A microprocessor  810  located in floor care appliance  10  may be used to control various features of floor care appliance  10 . The microprocessor  810  may be part of power management system  800  or otherwise. A microprocessor  810  used for this purpose usually is pre-programmed at the factory with the operational parameters of the floor care appliance  10 . Upon connection of floor care appliance  10  to a computer, the operational parameters may be changed through the computer. The microprocessor  810  could also be programmed to collect and store real time performance data which may also be uploaded to the computer. The performance data can be evaluated to determine the operating condition of the floor care appliance  10  for repair and maintenance purposes. The performance data, which is downloaded to the microprocessor  810  by the computer, may also be used to determine adjustments that should be made to the operating parameters of the appliance  10  to improve performance. Examples of such performance data could include a log of the running time of motors, cleaner suction, agitator brush life, and airflow in the various parts of the appliance  10 . 
     Referring now to  FIG. 3 , shown is an electrical schematic of the preferred embodiment of the power management system  800  having the capability of being connected to a computer  891 . Power management system  800  is comprised of a microprocessor  810 , an alternating current voltage source X 1 , a voltage regulating circuit  820 , a clamping or “zero cross detecting circuit”  830 , at least two load devices M 1  and M 2 , at least a first load driver circuit  860  and a second load driver circuit  880 , a sensing circuit  870  for sensing the current drawn by one of the at least two load devices M 1  and M 2 , a plurality of switches SW 1  to SW n  ( 840 ) for controlling various floor care appliance  10  features, and a plurality of light emitting diodes L 1  to L n  ( 805 ) whereon one light emitting diode L x  is associated with one of said plurality of switches SW 1  to SW n  ( 805 ). The clamping or zero cross circuit  830  outputs a fixed voltage during the portion of the ac cycle which is greater than or less than zero and outputs a zero or negligible voltage while the ac cycle is crossing the zero voltage threshold. Thus, clamping circuit  830  acts as a “zero cross detector” at any given time as either the fixed voltage or the zero or negligible voltage is input to a microprocessor  810  so the microprocessor  810  knows when the ac cycle is crossing the zero voltage threshold. In the preferred embodiment of the invention, the fixed voltage is 5.7 volts, and the zero or negligible voltage is −0.7 volts. 
     The microprocessor  810  is programmed to utilize these inputs to control the amount of time the current is turned on to each of the at least first and second load devices M 1  and M 2 . The microprocessor  810  essentially has timers for each of the at least two load devices M 1  and M 2  that start timing the amount of time the current is turned on to each of the at least two load devices M 1  and M 2  each time the ac current crosses past the zero voltage threshold. The current is turned on to each of the at least first and second load devices M 1  and M 2  by an output from the microprocessor  810  provided to an associated triac driver device MOC 1  and MOC 2  known as a “MOC” which in turn controls an associated triac U 1  and U 2  which when activated turns the current on to an associated load device M 1  and M 2 . A triac drive device or “MOC” model no. MOC3010-M made by Fairchild Semiconductor of South Portland, Me. has been found to be suitable for this purpose. 
     One of the at least first and second loads M 1  and M 2  has a sensing circuit  870  associated with it which monitors the current drawn by the load device M 1  and M 2 . In the preferred embodiment, the current sensing circuit  870  is associated with M 1 . A surge or rise in the current drawn by the load device M 1  will cause an output from the sensing circuit  870  which is input to the microprocessor  810 . The microprocessor  810  will adjust according to pre-programmed instructions the amount of time the current is turned on to each of the at least first and second loads M 1  and M 2  so that the total current drawn by all of the at least first and second loads M 1  and M 2  does not exceed a predetermined value. This requires that the microprocessor  810  reduce the current provided to the at least second load device M 2  to account for the increased amount of current used by the first load device M 1 . When the increased load on the second load device M 2  is reduced, the programming of microprocessor  810  programming will reduce the amount of time that current is turned on to the first load M 1  while increasing the amount of time the current is turned on to the second load M 2  such that the total current used by both the first and second load M 1  and M 2  does not exceed the predetermined value. 
     In one embodiment of the power management system  800 , the at least first and second loads M 1  and M 2 , respectively, comprise an agitator drive motor and a motor-fan assembly. The predetermined level or total current that may be drawn by both motors is 12 amps with the agitator drive motor M 1  initially programmed to draw 2 amps. This means that the motor-fan assembly M 2  can initially draw 10 amps. An increase in the load placed on the agitator drive motor M 1  will cause the amount of current drawn by the agitator drive motor M 1  to exceed 2 amps. Necessarily, the microprocessor  810  will adjust the current provided to the motor-fan assembly M 2  to less than 10 amps. Note that this is only one possible configuration, as additional loads M 3  through Mn may be added, and the microprocessor  810  can be programmed to adjust the current to each of the loads M 1  through Mn as the current increases in one of the M 1  through Mn loads so that the sum total current used by all loads M 1  through Mn does not exceed a predetermined value. With the use of switches SW 1  to SW n  ( 840 ) to turn various features on and off, the microprocessor  810  can control the current to each of the loads M 1  through Mn that remain on so that the total current drawn by the loads M 1  through Mn does not exceed a predetermined level. The entire power management system  800  could be embedded on a plug in module which simplifies assembly of floor care appliance  10  and replacement and/or upgrade of power management system  800 . 
     Power is supplied to power management system  800  by an ac voltage source X 1  which is typically 120 vac at 60 hz. The 120 vac line voltage is reduced through a resistor R 1  and capacitor C 1  and then the Zener diode D 1  which clamps the voltage to around 30 vac. The 30 vac voltage is half-wave rectified to direct current through the diode D 2  and smoothed through a capacitor C 2 . The smoothed direct current is fed into a voltage regulator V 1  that outputs a regulated 5 vdc voltage from the 10-35 vdc input. This 5 vdc power is then supplied to the microprocessor and the other low voltage devices and controls discussed above. 
     The 120 vac voltage source X 1  also has its voltage dropped through the resistive divider R 3  and R 4 . On the positive half of the AC wave, the upper diode D 4  conducts and the output signal is clamped to 5.7 vdc. On the negative half of the AC wave, the lower diode D 3  conducts and the output signal is clamped to 0 vdc. The square wave pulse train coincides with the zero crossing of the main 120 vac line. The signal is fed into the microprocessor  810  and used to sequence the firing of motors M 1  and M 2  (or other load devices M 3  through Mn) with the main ac voltage line based upon the zero crossing. 
     The switches SW 1  through SW n  ( 840 ) look for a transition from 0 vdc to 5 vdc or vice versa to recognize a valid press. Each switch SW 1  to SW n  ( 840 ) corresponds with a different mode, feature or speed selection. The LEDs L 1  through L n  ( 805 ) and associated resistors R 4  through Rn are used for indication of which mode, feature or speed is currently selected. 
     Each of the load driver circuits  860  and  880  is comprised of a MOC  1  and MOC  2 , respectively, used for firing triacs U 1  and U 2 , respectively. MOC  1  and MOC  2  are devices that are used to either block or pass a portion of the 120 vac power to load devices M 1  and M 2 . When a valid zero cross is determined, timers internal to microprocessor  810  start timing. When the preset time is reached, the input signal to MOC  1  and MOC  2  is toggled, and the device will allow a portion of the 120 vac wave to pass. The preset times can range from 0 to 7 miliseconds, depending on the average voltage that needs to be passed to M 1  and M 2 . Triacs U 1  and U 2  are devices that switch on and off, allowing current to flow to M 1  and M 2  based upon MOC  1  and MOC  2  and the timing signal coming through the microprocessor  810 . 
     Current sensing circuit  870  is a low ohm power resistor that generates a voltage with respect to the current through the agitator motor M 1 . That low voltage AC signal is half-wave rectified through a diode, filtered and smoothed through a resistive/capacitive network. That signal is then fed into an A/D pin on the microprocessor  810  where it is used to determine the load on M 1 . Based upon the load on M 1 , decisions can be made to change the speeds of M 1  and M 2  based upon the surface being cleaned, stall detection, etc. 
     In the preferred embodiment of the invention, a microprocessor  810  such as the one in power management system  800  or other microprocessor could be configured and programmed to collect and store data related to the operating parameters of the floor care appliance  10  such as was heretofore described related to the control of the current supplied to the at least first and second loads M 1  and M 2 . However, there could be an infinite number of possibilities as to what may be programmed into the microprocessor  810  or other microprocessor as various known and heretofore unknown features are added to floor care appliance  10 . The microprocessor  810  or other microprocessor could also be programmed to collect and store real time performance data related to the performance and operation of floor care appliance  10 . The performance data can then be evaluated to determine the operating condition of the floor care appliance  10  for repair and maintenance purposes. The performance data may also be used to determine adjustments to be made to the operating parameters of the floor care appliance  10  which are downloaded to the microprocessor  810  or other microprocessor over a network connected to a remote interface. Other possibilities of information that can be programmed into microprocessor  810  include date of purchase, warranty, serial number, production run number and date, model no., parts lists, etc. The data port  700  connected to the microprocessor  810  or other microprocessor is provided on floor care appliance  10  for this purpose. Data port  700  may be one of several types of data ports such as USB, serial, parallel, RJ-11 or other known or unknown data ports described hereinbelow. 
     In the preferred embodiment of the connection arrangement, as seen in  FIG. 3 , a floor care appliance  10  (not shown) is connected via a digital pathway  898 , such as a USB cable, to a personal type computer  891  which is further connected to a computer network, such as the Internet, through an ethernet connection  893  or a modem  892 . The microprocessor  810  is connected to a RS-232 converter  890  which converts RS-232 serial signals to other protocols such as the heretofore described Universal Serial Bus (USB). The digital pathway  898  is connected to the RS-232 converter through the port  700 . Alternate protocols that can be used over the digital pathway include RS-232, ethernet, Firewire, Blue Tooth, X 10 , infrared or the newer RS-485. The digital pathway  898  can also be replaced with a wireless connection that uses a radio frequency, including a wireless modem. These signals are input to the appropriate port on a personal computer  891 . The personal computer user may upload or retrieve performance data over the digital pathway  898  from the microprocessor  810  and then upload the data to a remote site  894  via the Internet. The remote site  894  will typically be an appliance repair facility which will analyze the data for the appliance&#39;s performance and possible malfunctions. The repair facility may also transmit new operational parameters to be downloaded to microprocessor  810  of appliance  10  based upon the analysis of the performance data. Upgrades to the operational parameters of the appliance  10  may also be provided by the repair facility or posted on a web site for retrieval by the end user at the personal computer site  891 . Upgrade or repair data could also be distributed on other computer storage media, such as a CD-ROM, for installation by the end user at the personal computer site  891 . 
     In an alternate embodiment of the connection arrangement, as seen in  FIG. 4 , a power management system X 1  is provided with a microprocessor  810  that is configured with an internal modem so that microprocessor  810  and floor care appliance  10  can be connected directly to a telephone network for further connection to a remote computer. To function as a modem, microprocessor  810  must be connected to an RS-232 transceiver ( FIG. 4A ) before being connected to an RJ-11 jack serving as port  705 . In addition, an isolation circuit  896  ( FIG. 4B ) is required to isolate the microprocessor  810  from the telephone line. The operation of the modem function can be commenced by the user through means such as a switch  895  ( FIG. 4C ). Once switch  895  is closed and port  705  is connected to a telephone network through a connection such as an RJ-11 jack connected to the RS-232 transceiver  897 , microprocessor  810  will dial a pre-programmed number. Preferably, the pre-programmed number will be a toll free number to a customer service center. Once connected, the microprocessor  810  can exchange data with a remote computer  894  at a location such as a customer service center for the reasons heretofore discussed. 
     It should be clear from the foregoing that the described structure clearly meets the objects of the invention set out in the description&#39;s beginning. It should now also be obvious that many changes could be made to the disclosed structure which would still fall within its spirit and purview.