Vacuum cleaner with brushroll control

Abstract

A vacuum cleaner includes a base having a floor nozzle that defines a suction chamber, a brushroll driven by a brushroll motor, and a brushroll motor sensor configured to measure an electrical current used by the brushroll motor. The vacuum cleaner further includes a pressure sensor configured to measure an internal pressure within the vacuum cleaner, and a controller in communication with the brushroll motor sensor and the pressure sensor. The controller is operable to control an operating speed of the brushroll motor based on feedback received from the pressure sensor and the brushroll motor sensor.

1 . A vacuum cleaner comprising:
 a base including a floor nozzle, the floor nozzle defining a suction chamber;   a brushroll driven by a brushroll motor;   a brushroll motor sensor configured to measure an electrical current used by the brushroll motor;   a pressure sensor configured to measure an internal pressure within the vacuum cleaner; and   a controller in communication with the brushroll motor sensor and the pressure sensor,   wherein the controller is operable to control an operating speed of the brushroll motor based on feedback received from the pressure sensor and the brushroll motor sensor.   
     
     
         2 . The vacuum cleaner of  claim 1 , further comprising a dirt cup, wherein the controller is operable to determine a fullness level of the dirt cup based on feedback received from the pressure sensor. 
     
     
         3 . The vacuum cleaner of  claim 1 , further comprising a filter, wherein the controller is operable to determine if the filter is present based on feedback received from the pressure sensor. 
     
     
         4 . The vacuum cleaner of  claim 1 , further comprising a filter, wherein the controller is operable to determine if the filter is clogged based on feedback received from the pressure sensor. 
     
     
         5 . The vacuum cleaner of  claim 1 , further comprising a filter housing and a filter received within the filter housing, wherein the pressure sensor is located within the filter housing. 
     
     
         6 . The vacuum cleaner of  claim 1 , wherein the pressure sensor is located within the floor nozzle. 
     
     
         7 . The vacuum cleaner of  claim 1 , wherein the pressure sensor includes
 a housing defining a chamber,   a hall-effect sensor, and   a magnet moveable within the chamber relative to the hall-effect sensor in response to changes in the internal pressure.   
     
     
         8 . The vacuum cleaner of  claim 1 , wherein the pressure sensor includes
 a housing including a cap portion connected to a base portion,   a diaphragm supporting a magnet in the housing, the diaphragm and base portion defining a chamber arranged in fluid communication with an airflow path of the vacuum cleaner, the diaphragm moveable within the chamber in response to changes in the internal pressure of the vacuum cleaner, and   a hall-effect sensor configured to measure a relative distance between the magnet and the hall-effect sensor.   
     
     
         9 . The vacuum cleaner of  claim 8 , wherein the diaphragm is sandwiched between the cap portion and the base portion. 
     
     
         10 . The vacuum cleaner of  claim 1 , wherein at least a portion of the pressure sensor is formed integrally with the base or the handle of the vacuum cleaner. 
     
     
         11 . The vacuum cleaner of  claim 1 , wherein the pressure sensor is positioned in fluid communication with an air path of the vacuum cleaner to provide two or more indications of system performance selected from a group consisting of system clogged, filter bag full, dirt bin full, no filter present, no filter bag present, dirt bin empty, filter bag empty, and normal operation. 
     
     
         12 . The vacuum cleaner of  claim 1 , further comprising a tachometer configured to measure a speed of the brushroll motor or the brushroll to help maintain the speed of the brushroll motor or brushroll, the speed based on the sensed motor current and the sensed pressure. 
     
     
         13 . A method of controlling a brushroll motor in a vacuum cleaner, the method comprising:
 sensing a pressure within the vacuum cleaner;   sensing a motor current of the brushroll motor used to drive a brushroll;   comparing the sensed pressure with one or more reference pressure values;   comparing the sensed motor current with one or more reference current values; and   controlling operation of the brushroll motor based on the sensed pressure and the sensed motor current,   wherein controlling operation of the brushroll motor includes turning the brushroll motor on based on the sensed pressure.   
     
     
         14 . The method of  claim 13 , wherein controlling operation of the brushroll motor further includes altering an operating speed of the brushroll motor based on at least one of the sensed pressure or sensed motor current. 
     
     
         15 . The method of  claim 13 , wherein controlling operation of the brushroll motor further includes turning the brushroll motor off based on at least one of the sensed pressure or the sensed motor current. 
     
     
         16 . The method of  claim 15 , wherein turning the brushroll motor off is based on the sensed pressure. 
     
     
         17 . The method of  claim 15 , wherein turning the brushroll motor off is based on the sensed motor current. 
     
     
         18 . The method of  claim 15 , wherein turning the brushroll motor off is based on both the sensed pressure and the sensed motor current. 
     
     
         19 . The method of  claim 13 , further comprising
 providing a first mode in which controlling operation of the brushroll motor further includes altering an operating speed of the brushroll motor based on at least one of the sensed pressure or the sensed motor current;   providing a second mode in which controlling operation of the brushroll motor further includes turning the brushroll motor off based on at least one of the sensed pressure or the sensed motor current; and   providing a switch to selectively choose the first mode or the second mode.   
     
     
         20 . The method of  claim 13 , further comprising measuring an operating speed of the brushroll motor or the brushroll to help maintain the operating speed of the brushroll motor or brushroll, the speed of the brushroll motor or brushroll being based on the sensed motor current or the sensed pressure. 
     
     
         21 - 43 . (canceled)