Integrated cleaning apparatus and methods

Abstract

Apparatus and method providing efficient cleaning of various surfaces. The apparatus including a collector and a controller. The collector having an inlet conduit, a vacuum pump, a first valve, a second valve, a tank, and a separator. The inlet conduit connects to an inlet aperture of the separator, the vacuum pump connects to an outlet aperture of the separator, the first valve regulates flow between a drain aperture of the separator and an inlet aperture of the tank, and the second valve regulates flow through a drain aperture of the tank. One or more filters may filter flow between the separator and the vacuum pump. The controller may be programmed to, upon sensing a full tank, selectively close the first valve and open the second valve and, after the passage of a selected period of time, selectively close the second valve and open the first valve. The collector and controller may provide an integrated, compact cleaning system that supports continuous operation.

1 . A cleaning system, comprising: 
 a collector comprising an inlet conduit, a vacuum pump, a first valve, a second valve, a tank, and a separator;    the separator having an inlet aperture, an outlet aperture, and a drain aperture;    the tank having an inlet aperture and a drain aperture;    the inlet conduit configured to connect to the inlet aperture of the separator;    the vacuum pump configured to connect to the outlet aperture of the separator;    the first valve positioned to regulate flow between the drain aperture of the separator and the inlet aperture of the tank;    the second valve positioned to regulate flow through the drain aperture of the tank; and    a controller programmed to, upon sensing a first tank condition, selectively close the first valve and open the second valve.    
   
   
       2 . The cleaning system as defined in  claim 1 , wherein the controller is further programmed to selectively close the second valve and open the first valve upon sensing a second tank condition.  
   
   
       3 . The cleaning system as defined in  claim 2 , wherein the first tank condition occurs when fluid within the tank rises above a first level and the second tank condition occurs when fluid within the tank falls below a second level, distinct from the first level.  
   
   
       4 . The cleaning system as defined in  claim 2 , wherein the second tank condition occurs at the expiration of a selected period of time measured from an event selected from the group consisting of when the first tank condition was detected, when the first valve was closed, and when the second valve was opened.  
   
   
       5 . The cleaning system as defined in  claim 1 , wherein the separator comprises an upper cylinder.  
   
   
       6 . The cleaning system as defined in  claim 5 , wherein the inlet aperture of the separator introduces flow into the upper cylinder in a substantially tangential direction.  
   
   
       7 . The cleaning system as defined in  claim 1 , wherein the collector further comprises an outlet conduit configured to provide a connection between the outlet aperture of the separator and the vacuum pump.  
   
   
       8 . The cleaning system as defined in  claim 7 , wherein the outlet conduit comprises a first filter.  
   
   
       9 . The cleaning system as defined in  claim 8 , wherein the outlet conduit further comprises a second filter positioned between the first filter and the vacuum pump.  
   
   
       10 . The cleaning system as defined in  claim 9 , wherein the first filter is configured to be removed, cleaned, and reused substantially indefinitely without significant degradation in filtering ability.  
   
   
       11 . The cleaning system as defined in  claim 1 , wherein the collector further comprises at least one delivery wand, the inlet conduit connecting the delivery wand to the inlet aperture of the separator.  
   
   
       12 . The cleaning system as defined in  claim 11 , further comprising a carrier subsystem comprising a water source, a heater, and at least one carrier conduit, the carrier conduit delivering water from the water source to the heater and from the heater to the delivery wand of the collector.  
   
   
       13 . The cleaning system as defined in  claim 11 , wherein the carrier subsystem continuously delivers water to the delivery wand of the collector at temperature in the range of between about 48° C. and about 121° C.  
   
   
       14 . The cleaning system as defined in  claim 12 , wherein the carrier subsystem further comprises a pump to increase the pressure of the water within the carrier conduit.  
   
   
       15 . The cleaning system as defined in  claim 14 , wherein the carrier conduit forms a recirculation path through the heater.  
   
   
       16 . The cleaning system as defined in  claim 15 , wherein the carrier subsystem further comprises a storage tank to store heated water.  
   
   
       17 . The cleaning system as defined in  claim 11 , further comprising a detergent subsystem comprising a detergent source, a mixer, and at least one detergent conduit, the mixer educing detergent from the detergent source and into the detergent conduit.  
   
   
       18 . The cleaning system as defined in  claim 17 , wherein the mixer selectively mixes detergent from the detergent source with heated water from the carrier subsystem.  
   
   
       19 . The cleaning system as defined in  claim 1 , wherein the controller comprises a processor coupled to a memory device, at least one sensor connected to the tank of the collector, and at least one actuator connected to each of the first and second valves of the collector.  
   
   
       20 . The cleaning system as defined in  claim 1 , wherein the collector further comprises a balancing conduit and a balance valve, the balancing conduit connecting the tank to the vacuum pump, the balance valve positioned to regulate flow through the balancing conduit.  
   
   
       21 . A cleaning system, comprising: 
 a separator having an inlet aperture, an outlet aperture, and a drain aperture;    a tank having an inlet aperture and a drain aperture;    a first valve positioned to regulate flow between the drain aperture of the separator and the inlet aperture of the tank;    a second valve positioned to regulate flow through the drain aperture of the tank; and    a controller programmed to selectively close the first valve and open the second valve upon sensing a first condition and selectively close the second valve and open the first valve upon sensing a second condition.    
   
   
       22 . The cleaning system as defined in  claim 21 , further comprising: 
 a vacuum pump providing positive displacement of air;    an outlet conduit configured to provide a connection between the outlet aperture of the separator and the vacuum pump;    a first filter positioned within the outlet conduit and configured to be removed, cleaned, and reused without significant degradation in filtering ability; and    a second filter positioned within the outlet conduit between the first filter and the vacuum pump.    
   
   
       23 . A method for cleaning a surface, the method comprising the steps of: 
 selecting a collector comprising a vacuum pump, a separator, and a tank;    employing the collector to collect a mixture of liquid and gas;    employing the collector to separate the liquid from the gas and store the liquid in the tank;    emptying the tank, while continuing to employ the collector to collect the mixture, by isolating the separator from the tank and opening the drain on the tank; and    returning the tank to storage duty, while continuing to employ the collector to collect the mixture, by closing the drain on the tank and reestablishing fluid communication between the separator and the tank.    
   
   
       24 . The method for cleaning a surface as defined in  claim 23 , wherein the vacuum pump is a positive displacement pump providing a vacuum of at least 25.4 cm Hg.  
   
   
       25 . The method for cleaning a surface as defined in  claim 24 , wherein the step of employing the collector to separate the liquid from the gas further comprises the step of applying an acceleration greater than gravitational acceleration to the mixture.