Method and system of detecting a blockage in a vacuum cleaner

Abstract

A vacuum cleaner with a blockage sensor and methods of identifying an obstructed airway in a vacuum are described. The vacuum cleaner has a motor and a circuit board to provide electrical current to the motor including an amperage flow sensor to determine the electrical current draw of the motor, and a blockage determiner to sample the electrical current draw and count the number of times the sampled electrical current draw exceeds a threshold amperage within a window of time. The blockage determiner can sense a blockage within the airflow path or the beater bar, and can optionally shut down the motor prior to motor failure.

1 . A vacuum comprising;
 a motor; and   a power supply to provide electrical current to the motor;   an amperage flow sensor to determine the electrical current draw of the motor; and   a blockage determiner to sample the electrical current draw and count the number of times the sampled electrical current draw exceeds a threshold amperage within a window of time.   
     
     
         2 . The vacuum of  claim 1 , wherein the blockage determiner signals that vacuum is experiencing blockage when the count during the window of time exceeds a desired percentage of samples sampled in the window of time. 
     
     
         3 . The vacuum of  claim 2 , wherein the desired percentage is at least 30% of the samples sampled in the window of time. 
     
     
         4 . The vacuum of  claim 2 , wherein the desired percentage at least 50% of the samples sampled in the window of time. 
     
     
         5 . The vacuum of  claim 1 , where the blockage determiner samples the amperage draw 60 times a second or more. 
     
     
         6 . The vacuum of  claim 1 , where the sliding window of time is greater than or equal to 10 seconds. 
     
     
         7 . The vacuum of  claim 1 , where the sliding window of time is greater than or equal to 60 seconds. 
     
     
         8 . The vacuum of  claim 1 , further comprising a reset switch connected to the control board. 
     
     
         9 . The vacuum of  claim 1 , wherein the electrical current to the motor is stopped when the blockage determiner signals that vacuum is experiencing blockage. 
     
     
         10 . The vacuum of  claim 9 , wherein the blockage being experienced is an obstructed air flow conduit. 
     
     
         11 . The vacuum of  claim 9 , wherein the blockage being experienced is an obstructed beater bar. 
     
     
         12 . The vacuum of  claim 1 , wherein the circuit board further comprises a variable speed control for the motor. 
     
     
         13 . The vacuum of  claim 1 , wherein the circuit board further comprises a LED power supply. 
     
     
         14 . The vacuum of  claim 1 , wherein the circuit board further comprises a control circuit to actuate a diverter valve. 
     
     
         15 . A method of detecting blockage along an airpath, the method comprising:
 providing a vacuum comprising a motor;   providing electrical current to the motor;   determining the amperage flow of the electrical current; and   detecting blockage along an airpath by sampling the amperage flow of the electrical current and counting how many times the sampled amperage draw exceeds a threshold amperage within a window of time.   
     
     
         16 . The method of  claim 15 , wherein the detecting comprises counting the number of times the amperage draw exceeds a desired percentage of samples sampled within the window of time. 
     
     
         17 . The method of  claim 15 , further comprising enabling a blockage indicator when a blockage is detected. 
     
     
         18 . The method of  claim 15 , further comprising:
 receiving a reset signal; and   enabling the current flow to the motor.