Electronic control system for a vacuum system

Abstract

A programmable control unit for a vacuum cleaning system, such as central vacuum cleaning system. A control unit is programmed after manufacture to execute a particular control program for performing various diagnostic and operational functions including user interface, voltage level detecting, voltage monitoring, current monitoring, user interface, power supply control, temperature monitoring, AC line frequency detection, operation data recording, speed control program selection, expansion bus interface and service tool interface. Power control to the vacuum motor is facilitated by the control unit directly through a triode for alternating current (TRIAC). Manufacturing costs are reduced by producing a single programmable control unit that can be programmed with a control program corresponding to a variety of different vacuum cleaning devices across a manufacturer's product line.

1 . A vacuum cleaner system comprising:
 a line power input;   a dirt collection unit;   at least one dirty air intake conduit defining an airflow path to the vacuum unit and terminating in a dirt collection unit;   a vacuum motor adapted to generate a working airflow from the dirty air intake to conduit to the dirt collection unit; and   a programmable control unit having a power conditioning module and adapted to be programmed with one or more of a plurality of different control programs that control the power conditioning module to provide power from the line power input to drive the vacuum motor.   
   
   
       2 . The vacuum cleaner system according to  claim 1 , wherein the programmable control unit comprises a microprocessor-based printed circuit board (PCB). 
   
   
       3 . The vacuum cleaner system according to  claim 1 , wherein the power conditioning module is controlled by the programmable control unit to deliver power to the vacuum motor. 
   
   
       4 . The vacuum cleaner system according to  claim 1 , wherein the dirt collection unit, at least one dirty air intake, vacuum motor, and programmable control unit are located in a power unit of a central vacuum system. 
   
   
       5 . The vacuum cleaner system according to  claim 1 , wherein one of the plurality of different control programs is stored in memory structure in the control unit. 
   
   
       6 . The vacuum cleaner according to  claim 1 , wherein each of the plurality of different control programs is correlated to a particular feature set. 
   
   
       7 . The vacuum cleaner system according to  claim 6 , wherein each feature set comprises at least a maximum air watt output level for the vacuum motor. 
   
   
       8 . The vacuum cleaner system according to  claim 1 , wherein the control unit is adapted to detect a voltage level of the line power input. 
   
   
       9 . The vacuum cleaner system according to  claim 6 , wherein detecting a voltage level comprises measuring the voltage across a fly back transformer supplying power to the control unit. 
   
   
       10 . The vacuum cleaner system according to  claim 1 , wherein the control unit further comprises an expansion interface. 
   
   
       11 . The vacuum cleaner system according to  claim 10 , wherein the expansion interface comprises an electrical connector adapted to interface with at least one expansion boards utilizing a reciprocal connector interface. 
   
   
       12 . The vacuum cleaner system according to  claim 1 , wherein the control unit comprises a memory structure and the control unit is adapted to record operational data relating to operation of the vacuum system in the memory structure. 
   
   
       13 . The vacuum cleaner system according to  claim 12 , wherein operational data consists of information selected from the group consisting of measured motor current levels, line voltage levels, faults, motor operation hours, on/off cycles, filter changes and combinations thereof. 
   
   
       14 . The vacuum cleaner system according to  claim 1 , wherein the control unit further comprises a service tool interface. 
   
   
       15 . The vacuum cleaner system according to  claim 14 , wherein the service tool interface comprises an interface selected from the group consisting of a connector, a wireless interface and combinations thereof. 
   
   
       16 . The vacuum cleaner system according to  claim 1 , further comprising a user interface in electrical communication with the control unit and adapted to receive user inputs and output status information. 
   
   
       17 . The vacuum cleaner system according to  claim 16 , wherein the user interface comprises an indicator panel with one or more status indicators. 
   
   
       18 . The vacuum cleaner system according to  claim 1 , wherein the control unit is further adapted to execute a power shut off if at least one error condition is detected from the group consisting of a detected locked motor rotor, a detected line voltage exceeding a predetermined threshold, a detected current level exceeding a predetermined threshold, a detected temperature exceeding a predetermined threshold, a period of continuous vacuum motor operation exceeding a predetermined threshold, filter missing, filter not completely attached, dirt collection reservoir missing, dirt collection reservoir not complete attached, and combinations thereof. 
   
   
       19 . The vacuum cleaner system according to  claim 18 , further comprising a remote user interface in electrical communication with the control unit and adapted to permit a user of the system to restart the vacuum system after a power shut off event. 
   
   
       20 . The vacuum cleaner system according to  claim 1 , wherein the control unit is adapted to perform harmonic emissions reduction. 
   
   
       21 . The vacuum cleaner system according to  claim 20 , wherein performing harmonic emissions reduction comprises reducing harmonic emissions in compliance with European Norm EN61000-3-2. 
   
   
       22 . The vacuum cleaner system according to  claim 1 , wherein the control unit is further adapted to detect an AC line frequency connected to the vacuum system and to control the power conditioning module based on the detected frequency. 
   
   
       23 . The vacuum cleaner system according to  claim 1 , wherein the programmable control unit is adapted to be programmed with a serial number of a vacuum cleaner during vacuum cleaner system assembly. 
   
   
       24 . A product line of distinct central vacuums, each central vacuum in the product line comprising:
 an integral power unit, comprising:
 a line power input; 
 a dirty air intake; 
 a dirt reservoir; 
 a particulate barrier; 
 an air outlet; 
 a vacuum motor configured on a side of the particulate barrier fluidly opposite the dirt reservoir and adapted to generate a working airflow from the dirty air intake to the particulate barrier, and expect the working airflow out of the air outlet; and 
 a programmable control unit, including a power conditioning unit adapted to condition a line power, wherein the programmable control unit is programmed with a control program specific to one of the distinct central vacuums for controlling the power conditioning unit, wherein the control program comprises a feature set including a maximum power watt output level for the vacuum motor. 
   
   
   
       25 . A vacuum cleaner system comprising:
 a line power input;   an air intake;   a dirt collection reservoir;   a vacuum motor adapted to generate a working airflow from the dirty air intake to conduit to the dirt collection unit; and   a programmable control unit including a power conditioning module and adapted to be programmed with one or more of a plurality of different control programs, wherein each control program corresponds to a different product in a vacuum manufacturer's product line and specifies a maximum current level for the power conditioning module to deliver to the vacuum motor thereby providing each different product in the product line with at least one different operational characteristic.