FLOOR CLEANER

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/701,330, filed Sep. 30, 2024, the entire content of which is hereby incorporated by reference.

TECHNICAL FIELD

Embodiments relate to floor cleaners and control of floor cleaners.

SUMMARY

Floor cleaners may include a recovery tank configured to store fluid and/or debris drawn up from a surface being cleaned. Upon the recovery tank reaching a storage capacity it is desirable to limit additional fluid and/or debris from being drawn into the recovery tank and limit liquid from traveling near a motor that power a suction source of the floor cleaner. Some motors are limited in how much liquid can be in the airflow that pass through the motor. Liquid in the airflow (liquid-laden air) passing through the motor can reduce the motor's lifespan, lead to costly repairs, and/or electric shock of the user.

One embodiment provides a floor cleaner including: a suction inlet; a recovery tank configured to store liquid drawn through the suction inlet from a surface to be cleaned, the recovery tank having a tank inlet, a tank outlet, and a tank volume configured to store the liquid; a fluid flow path; a suction motor operable to generate a suction airflow to draw liquid-laden air along the fluid flow path and into the recovery tank, wherein the fluid flow path extends from the suction inlet to an exhaust of the suction motor and directs the suction airflow through the recovery tank toward the suction motor from the suction inlet; a sensor disposed upstream of the suction motor, the sensor configured to detect liquid in the suction airflow in the fluid flow path and generate a signal corresponding to the detected liquid, wherein the suction airflow extends from the suction inlet to the suction motor; and a controller having an electronic processor, the controller configured to: determine the presence of liquid in the suction airflow in the fluid flow path based on the signal of the sensor, and control operation of the floor cleaner based on the sensor signal exceeding a first threshold value.

Another embodiment provides a floor cleaner including: a supply tank configured to store a dispensing liquid; a distribution nozzle in fluid communication with the supply tank, the distribution nozzle configured to dispense the dispensing liquid; a pump in fluid communication with the supply tank and the distribution nozzle, the pump operable to control the flow of the dispensing liquid from the supply tank to the distribution nozzle; a suction inlet; a recovery tank configured to store liquid drawn through the suction inlet from a surface to be cleaned, the recovery tank having a tank inlet, a tank outlet, and a tank volume configured to store the liquid; a fluid flow path; a suction motor operable to generate a suction airflow to draw liquid-laden air along the fluid flow path and into the recovery tank, wherein the fluid flow path extends at least in part from the tank volume to an exhaust of the suction motor and directs the suction airflow from the recovery tank toward the suction motor; a sensor positioned upstream of the suction motor, the sensor configured to detect liquid in the suction airflow in the fluid flow path and generate a signal corresponding to the detected liquid, wherein the suction airflow extends from the suction inlet to the suction motor; and a controller having an electronic processor, the controller configured to: determine the presence of liquid in the suction airflow in the fluid flow path based on the signal of the sensor, and control the suction motor or the pump based on the sensor signal reaching a first threshold value.

Another embodiment provides a floor cleaner including: a supply tank configured to store a dispensing liquid; a distribution nozzle in fluid communication with the supply tank, the distribution nozzle configured to dispense the dispensing liquid; a pump in fluid communication with the supply tank and the distribution nozzle, the pump operable to control the flow of the dispensing liquid from the supply tank to the distribution nozzle; a suction inlet; a recovery tank configured to store liquid drawn through the suction inlet from a surface to be cleaned, the recovery tank having a tank inlet, a tank outlet, and a tank volume configured to store the liquid; a fluid flow path; a suction motor operable to generate a suction airflow to draw liquid-laden air along the fluid flow path and into the recovery tank, wherein the fluid flow path extends at least in part from the suction inlet to an exhaust of the suction motor; a sensor positioned upstream of the suction motor, the sensor configured to detect liquid in the suction airflow in the fluid flow path and generate a signal corresponding to the detected liquid, wherein the suction airflow extends from the suction inlet to the suction motor; and a controller having an electronic processor, the controller configured to: determine the presence of liquid in the suction airflow in the fluid flow path based on the signal of the sensor, and control the suction motor and the pump based on the sensor signal reaching a first threshold value.

Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a floor cleaner according to some embodiments.

FIG. 2 is a side view of the floor cleaner of FIG. 1.

FIG. 3 is a rear view of the floor cleaner of FIG. 1.

FIG. 4 is a first perspective view of a recovery tank of the floor cleaner of FIG. 1.

FIG. 5A is a cross-sectional view of the body of the floor cleaner of FIG. 1.

FIG. 5B is a cross-sectional view of an alternative embodiment of the body of the floor cleaner of FIG. 1.

FIG. 6 is a perspective view of an alternative embodiment of a sensor configuration of the floor cleaner of FIG. 1.

FIG. 7 is a perspective view of an alternative embodiment of a sensor configuration of the floor cleaner of FIG. 1.

FIG. 8 is a front view of an alternative embodiment of the sensor of the floor cleaner of FIG. 1.

FIG. 9 is a block diagram of the control system of the floor cleaner of FIG. 1.

FIG. 10 is a flowchart illustrating the process or operation of the floor cleaner of FIG. 1.

Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components.

Also, the functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not listed.

Furthermore, some embodiments described herein may include one or more electronic processors configured to perform the described functionality by executing instructions stored in non-transitory, computer-readable medium. Similarly, embodiments described herein may be implemented as non-transitory, computer-readable medium storing instructions executable by one or more electronic processors to perform the described functionality. As used in the present application, “non-transitory computer-readable medium” comprises all computer-readable media but does not consist of a transitory, propagating signal. Accordingly, non-transitory computer-readable medium may include, for example, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (Read Only Memory), a RAM (Random Access Memory), register memory, a processor cache, or any combination thereof.

Many of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application specific integrated circuits (“ASICs”). Terms like “controller” and “module” may include or refer to both hardware and/or software. Capitalized terms conform to common practices and help correlate the description with the coding examples, equations, and/or drawings. However, no specific meaning is implied or should be inferred simply due to the use of capitalization. Thus, the claims should not be limited to the specific examples or terminology or to any specific hardware or software implementation or combination of software or hardware. Also, if an apparatus, method, or system is claimed, for example, as including a controller, module, logic, electronic processor, or other element configured in a certain manner, for example, to perform multiple functions, the claim or claim element should be interpreted as meaning one or more controllers, modules, logic elements, electronic processors other elements where any one of the one or more elements is configured as claimed, for example, to perform any one or more of the recited multiple functions.

Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value.

It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and/or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings.

DETAILED DESCRIPTION

FIGS. 1-3 illustrate a floor cleaner 100 according to some embodiments. The illustrated floor cleaner 100 includes a base 112 and a body 114 pivotably coupled to the base 112. In the illustrated embodiment, the body 114 is pivotable relative the base 112 between the upright storage position (FIG. 1) and an inclined operating position. The illustrated floor cleaner 100 further includes a supply tank 116, a distribution nozzle 117, a recovery tank 118, a suction source 120, and a sensor 123. The supply tank 116 is configured to store a cleaning liquid or dispensing liquid, and the floor cleaner 100 is operable to dispense the cleaning liquid through the distribution nozzle 117, such as by a control device, for example, a pump 122, a valve 125, or other fluid distribution system in communication with the distribution nozzle 117. The pump 122 is configured to pump cleaning liquid from the supply tank 116 to the distribution nozzle 117. The valve 125 is configured to control a flow and pressure of cleaning liquid from the supply tank 116 to the distribution nozzle 117. In some embodiments, the floor cleaner 100 includes the pump 122 and the valve 125, the valve 125 in fluid communication with and downstream of the pump 122. In some embodiments, the floor cleaner 100 includes either the pump 122 or the valve 125. In some embodiments, the floor cleaner 100 is operable to dispense the cleaning liquid onto a surface 121 to be cleaned through the distribution nozzle 117, as shown in FIG. 1. In some embodiments, the floor cleaner 100 is operable to dispense the cleaning liquid of the supply tank 116 onto or adjacent to a component of the floor cleaner (e.g., onto or adjacent to a brushroll and/or other agitator via a distributor bar or distribution nozzle). In some embodiments, the fluid distribution system is omitted and the floor cleaner 100 is configured to recover liquids from the surface 121, such as a wet/dry vacuum.

The suction source 120 includes a suction motor and a fan. The motor and the fan are operable to draw, via a generated airflow, liquid (e.g., the cleaning liquid, spilled drinks, water, or the like) and/or debris from the surface 121 into the recovery tank 118.

Referring to FIG. 2, the sensor 123 is configured to detect a change in an operating environment. For example, the sensor 123 detects changes in electrical properties, such as conductivity, resistivity, or the like of the sensor 123 caused by a change in an operating environment of the sensor 123. Electrical signals corresponding to these detected changes are generated by the sensor 123. The sensor 123 is disposed upstream of the suction source 120. The sensor 123 is configured to detect liquid in a suction airflow. The sensor 123 is positioned in the suction airflow such that liquid in the suction airflow contacts the sensor 123. The sensor 123 provides an electrical signal based on the detected liquid in the suction airflow upstream of the motor. In some instances, liquid may be drawn out of the recovery tank 118 when the liquid in the recovery tank 118 reaches or is near a defined level (e.g., operating capacity, fill limit, storage capacity, or the like). In these instances, the sensor 123 is configured to generate an electrical signal to indicate when liquid in the recovery tank 118 reaches the defined level, includes an excessive amount of foam (e.g., foam exceeds the defined level), and/or liquid splashing or sloshing above the defined level of the recovery tank 118. In one embodiment, the floor cleaner 100 uses the electrical signal of the sensor 123 to alert the user to check the recovery tank 118, indicate the defined level of the recovery tank 118 is reached, reduce or stop the suction airflow, and/or various other control operations discussed herein.

The sensor 123 includes a sensing portion configured to respond to a change in the operating environment. The sensing portion of the sensor 123 may include one or more electrodes composed of a conductive metal, graphite, or the like, or a combination thereof. In some embodiments, the sensor 123 may be coated in a carbon-based material, a noble metal, or a combination thereof. For example, the sensor 123 may include one or more electrodes (i.e., a sensing portion) composed of a conductive copper and coated with gold or stainless steel such that the electrode(s) is/are protected from corrosive elements in the operating environment. In another example, the sensor 123 may include one or more electrodes coated with carbon or nickel such that the electrode(s) is/are protected from corrosive elements. In some embodiments, the sensor 123 includes a sensing portion having a solid surface such that liquid and air contacts the solid surface and flows off the sensor 123 when drawn in the direction of the suction airflow generated by the suction source 120. In some embodiments, the sensor 123 includes a sensing portion having a mesh surface composed of interlaced electrodes such that liquid and air contact the sensing portion when passing through the mesh surface.

Referring again to FIG. 1, the base 112 is movable over the surface 121 to be cleaned. In the illustrated embodiment, the base 112 includes wheels 124 to facilitate moving the base 112 over the surface 121 to be cleaned. The base 112 includes a suction inlet 126 in fluid communication with the suction source 120 and the recovery tank 118. The liquid is drawn from the surface 121 to be cleaned through the suction inlet 126 and into the recovery tank 118. The distribution nozzle 117 is disposed in the base 112 in fluid communication with the supply tank 116. The distribution nozzle 117 dispenses the cleaning liquid toward the surface 121 to be cleaned.

As shown in FIGS. 1-3, the floor cleaner 100 includes a handle assembly 130. The handle assembly 130 includes a grip 132 and a user interface 133 adjacent the grip 132. The grip 132 is grabbed by the user to move the floor cleaner 100 along the surface 121 and to pivot the body 114 relative to the base 112. In some embodiments, the user interface 133 includes one or more indicators 134 to provide operating information to the user. In some embodiments, the user interface 133 includes an actuator 135. The actuator 135 may be operable to control the flow of cleaning liquid from the supply tank 116 through the distribution nozzle 117. The handle assembly 130 may further include an extension 136 that extends from the body 114. The extension 136 includes a first end 138 and a second end 140. The first end 138 is coupled to and adjacent the body 114. The second end 140 may be adjacent the grip 132.

Referring again to FIG. 1, the base 112 may further include a brushroll and/or other agitator adjacent the suction inlet 126. The brushroll and/or other agitator may be positioned and configured to contact the surface 121 being cleaned such that it may agitate, wipe, scrub, etc. the surface 121 being cleaned. The floor cleaner 100 may further include an agitator motor 137 (FIG. 3) that rotates the brushroll and/or other agitator. The brushroll and/or other agitator may be operably connected to the agitator motor 137 by a transmission, which may include a belt, gears, or other transmission. In one embodiment, the brushroll and/or other agitator and suction inlet 126 cooperate to ingest air and debris from the surface 121 being cleaned. In some embodiments, the floor cleaner 100 includes a single brushroll. In other embodiments, the floor cleaner 100 may include additional brushrolls and/or agitators that are positioned in parallel to the brushroll and formed from the same or different materials.

In the illustrated embodiment, the floor cleaner 100 further includes a rechargeable battery pack 142 that provides power to the suction source 120 and/or other components of the floor cleaner 100. In some embodiments, the rechargeable battery pack 142 provides a constant voltage (for example, 12 volts) to the suction source 120. The rechargeable battery pack 142 may be stored in a battery receptacle, the battery receptacle having an opening through which the rechargeable battery pack 142 may be removed or replaced within the battery receptacle. A battery door 146 (FIG. 2) may be coupled to an edge of the opening of the battery receptacle, the battery door 146 being configured to cover and provide access to an interior of the battery receptacle. In other embodiments, the floor cleaner 100 receives power from an AC power source (for example, an AC power outlet).

Referring to FIG. 4, the recovery tank 118 includes a tank body 230 and a lid 232 (for example, tank cover) attached to the tank body 230. The lid 232 may include a filter 315 (FIG. 5A) forming a recovery tank air outlet. In some embodiments, the lid 232 also includes a recovery tank outlet aperture forming the recovery tank air outlet, the recovery tank outlet aperture upstream of and in fluid communication with the filter 315. For example, the filter 315 is a pre-motor filter. The tank body 230 has a lower end wall 234 and a sidewall 236 that extends upwardly from the lower end wall 234 to an upper end 238 of the tank body 230. The lid 232, the lower end wall 234, and the upper end 238 forming the tank volume of the recovery tank 118. The lid 232 is configured to cover the tank volume of the recovery tank 118. The lower end wall 234 includes a recovery tank inlet aperture 305 supporting an inlet duct. For example, the inlet duct extends vertically upwards from the lower end wall 234 and includes an inlet aperture and an outlet aperture (e.g., exhaust). In this example, the inlet aperture is in fluid communication with the suction inlet 126 shown in FIG. 1, and the outlet aperture opens facing upwards towards the upper end 238 of the tank body 230. The recovery tank 118 includes a baffle 240 disposed over the outlet aperture of the inlet duct. The baffle 240 having a baffle wall positioned around the outlet aperture of the inlet duct. The baffle 240 is in fluid communication with the outlet aperture and is positioned in the path of the suction airflow between the outlet aperture of the inlet duct and the sensor 123. Air and liquid entering the recovery tank 118 through the recovery tank inlet travel upwards through the outlet aperture. In some instances, the baffle 240 deflects the air and liquid exiting the outlet aperture into the recovery tank 118. Liquid suctioned by the suction source 120 fills the recovery tank volume. Air suctioned by the suction source 120 exits the recovery tank 118 by flowing through a portion of a fluid flow path, which directs the air to exit through the recovery tank air outlet in the lid 232. The recovery tank air outlet is in fluid communication with the filter 315, the recovery tank outlet aperture, and recovery tank air outlet.

As shown in FIG. 5A, the body 114 includes a recovery tank inlet aperture 305, a recovery tank outlet aperture 310, the filter 315, a fluid flow path 320, and a suction airflow 330 according to some embodiments. The recovery tank inlet aperture 305 is in fluid communication with the suction inlet 126. The recovery tank inlet aperture 305 is downstream of the suction inlet 126 receiving liquid. Liquid is drawn through the suction inlet 126 and the recovery tank inlet aperture 305 into recovery tank 118 along the fluid flow path 320. A portion of the fluid flow path 320 extends from the suction inlet 126 to the tank volume of the recovery tank 118 and is the portion through which debris and/or liquid are suctioned into the recovery tank 118. A portion of the fluid flow path 320 also extends from the tank volume of the recovery tank 118 to the exhaust of the suction source 120. The recovery tank outlet aperture 310 is in fluid communication with the lid 232, the filter 315, and the suction source 120. The recovery tank outlet aperture 310 is downstream of the recovery tank 118. The recovery tank outlet aperture 310 is upstream of the sensor 123, the filter 315, and the suction source 120. The lid 232 includes the filter 315. The filter 315 is downstream of the recovery tank outlet aperture 310 and upstream of the suction source 120. The filter 315 limits debris and/or liquid in the fluid flow path 320 from entering the suction source 120.

The fluid flow path 320 is a path for air of the suction airflow 330 to travel. The fluid flow path 320 extends from the suction inlet 126 to an exhaust of the suction source 120. The fluid flow path 320 may include a path through the suction inlet 126, the recovery tank inlet aperture 305, the recovery tank 118, the recovery tank outlet aperture 310, the lid 232, and the suction motor 120. The fluid flow path 320 directs the suction airflow 330 through the tank volume of the recovery tank 118 toward the suction motor 120. The suction source 120 generates the suction airflow 330 using a suction motor and fan. The suction airflow 330 is drawn through the suction inlet 126, the recovery tank inlet aperture 305, the recovery tank outlet aperture 310, and the suction source 120. The suction airflow 330 is drawn through the floor cleaner 100 along the fluid flow path 320. Liquid entrained in the suction airflow 330 in the fluid flow path 320 upstream of the suction source 120 can be correlated to a recovery tank event such as, for example the recovery tank 118 being filled to its operating capacity, the recovery tank 118 containing excess foam, excessive splashing, or other recovery tank event. In some instances, during a recovery tank event, the suction airflow 330 may become entrained with liquid such that the suction airflow 330 may include liquid-laden air that resultantly contacts the sensor 123.

The sensor 123 is configured to detect liquid in the suction airflow 330 drawn along the fluid flow path 320. For example, the sensor 123 detects liquid drawn from the recovery tank 118 in the fluid flow path 320, via the suction airflow 330, contacting the surface of the sensor 123. In this example, the sensor 123 generates a first signal corresponding to a change in conductivity caused by detecting an amount of liquid when the recovery tank 118 reaches a storage capacity (e.g., defined level). In this example, the sensor 123 also detects liquid drawn from the recovery tank 118, via the suction airflow 330, contacting the surface of the sensor 123 and generates a second signal corresponding to a change in conductivity caused by foam in the recovery tank 118. The first signal corresponds to a change in conductivity greater than the change in conductivity corresponding to the second signal when foam results in less liquid contacting the sensor 123.

In the embodiment illustrated in FIG. 5A, the sensor 123 is downstream of the recovery tank 118 and upstream of the suction source 120. The sensor 123 is coupled to a surface of the lid 232 such that liquid in the suction airflow 330 impinges a sensing portion of the sensor 123. The sensor 123 is disposed within the lid 232 and positioned downstream of the recovery tank outlet aperture 310 in the fluid flow path 320. The baffle 240′ shown in FIG. 5A is another embodiment of the baffle wall positioned in the fluid flow path 320 between the outlet aperture of the inlet duct and the sensor 123. The sensor 123 is oriented at a non-zero angle relative to the recovery tank outlet aperture 310, the fluid flow path 320, or the suction airflow 330. The sensor 123 can be removed from the floor cleaner 100 when the recovery tank 118 is removed from the floor cleaner 100 in the illustrated embodiment but may be removed from the floor cleaner 100 when the lid 232 is removed from the floor cleaner 100 in other embodiments. The sensor 123 is upstream of the filter 315 in the illustrated embodiment but may be downstream of the filter 315 in other embodiments. In some embodiment, the sensing portion of the sensor 123 may be disposed in the recovery tank 118. In some embodiment, the sensor 123 may be disposed in the fluid flow path 320 at a non-zero angle relative to a direction the suction airflow 330 in the fluid flow path 320. Accordingly, the sensor 123 illustrated in FIG. 5A is provided as one example configuration and should not be construed as limiting.

In some embodiments, the sensor 123 is positioned downstream of the recovery tank 118 and upstream of the suction source 120 and in a portion of the fluid flow path 320 extending through the lid 232. In those embodiments, the sensor 123 is not removed from the floor cleaner 100 when the recovery tank 118 and/or the lid 232 are removed from the floor cleaner 100.

In an alternative embodiment illustrated in FIG. 5B, the floor cleaner 100 includes the recovery tank outlet aperture 310, the fluid flow path 320, and the suction airflow 330 according to some embodiments. The suction source 120 is disposed below the recovery tank 118 in the illustrated embodiment but may be disposed above the recovery tank 118 in other embodiments. Liquid is drawn through the suction inlet 126 (FIG. 1) into recovery tank 118. The recovery tank outlet aperture 310 is in fluid communication with the recovery tank 118 and the suction source 120. The recovery tank outlet aperture 310 is downstream of the recovery tank 118. The recovery tank outlet aperture 310 is upstream of the sensor 123 and the suction source 120. The fluid flow path 320 extends from the tank volume of the recovery tank 118 to the suction source 120. The suction source 120 generates the suction airflow 330 using a suction motor and fan. The suction airflow 330 is drawn through the suction inlet 126, the recovery tank outlet aperture 310, and the suction source 120. Liquid entrained in the suction airflow 330 in the fluid flow path 320 upstream of the suction source 120 can be sensed by the sensor 123 and correlated to a recovery tank event such as the recovery tank 118 being filled to its operating capacity, the recovery tank 118 containing excess foam, excessive splashing, or another recovery tank event.

Referring to FIG. 5B, the sensor 123 detects liquid in the suction airflow 330 drawn along the fluid flow path 320. The sensor 123 is downstream of the recovery tank 118 and upstream of the suction source 120. The sensor 123 is also downstream of the recovery tank outlet aperture 310. The sensor 123 is positioned in the suction airflow 330 in the fluid flow path 320 such that liquid in the suction airflow 330 impinges a sensing portion of the sensor 123. The sensor 123 is downstream of the recovery tank 118 in the illustrated embodiment but may be disposed at other locations as appropriate in other embodiments. In some embodiment, the sensor 123 may be disposed in the fluid flow path 320 at a non-zero angle relative to a direction of the suction airflow 330 in the fluid flow path 320. Accordingly, the sensor 123 illustrated in FIG. 5B is provided as one example configuration and should not be construed as limiting.

The sensor 123 being configured to detect liquid in the suction airflow 330 may replace the use of a mechanical float in the recovery tank 118, meaning, in examples where the sensor 123 replaces the mechanical float, that the tank is free from a float that rises due to increasing fluid levels to indicate the liquid level. The sensor 123 increases the usable tank volume of the recovery tank 118 compared to a traditional mechanical float. In addition, the output signal of the sensor 123 can be utilized to identify recovery tank events (e.g., sloshing water inside the recovery tank 118, the orientation of the floor cleaner 100 in operation causing an indication that the recovery tank 118 is full, or other recovery tank events) such that the floor cleaner 100 can avoid inadvertent indications that liquid has reached a defined level of in the recovery tank 118 can be avoided. Furthermore, the sensor 123 can account for foam, which if undetected can cause damage to a motor when the foam is drawn into the suction airflow 330 in the recovery tank 118.

FIG. 6 shows a sensor configuration 400 of the sensor 123 of the floor cleaner 100 according to an alternative embodiment. The sensor configuration 400 includes a conduit 405. The conduit 405 is a channel in the floor cleaner 100 for conveying air, such as, for example, a duct, a pipe, a tube or the like. The fluid flow path 320 runs through the conduit 405. As shown, the sensor 123 is positioned at an angle in the conduit 405 causing liquid-laden air drawn through the conduit 405 in a direction of the suction airflow 330 (FIGS. 5A and 5B) generated by the suction source 120 of FIGS. 5A and 5B, as indicated by the arrow of the fluid flow path 320, to impinge on a surface of the sensor 123. The surface of the sensor 123 including a sensing portion (e.g., electrode). In some instances, the effects of the angle of the sensor 123, the airflow direction, and gravity on the liquid-laden air results in the sensor 123 shedding water from the surface of the sensor 123. In some embodiments, the sensor 123 is coupled to the conduit 405. In some embodiments, the sensor 123 includes a plurality of electrodes arranged in a mesh array, such that liquid and air in the fluid flow path 320 may flow through the mesh array. In some embodiments, the sensor 123 includes a plurality of electrodes arranged in a linear array, such that liquid and air in the fluid flow path 320 may flow through the linear array. Referring now to FIGS. 5A and 5B, in some embodiments, the conduit 405 may be connected to or extend from the recovery tank outlet aperture 310 into the tank volume of the recovery tank 118. Accordingly, the sensor 123 and configuration illustrated in FIG. 6 is provided as an example configuration and should not be construed as limiting.

FIG. 7 shows a sensor configuration 500 of the sensor 123 of the floor cleaner 100 according to another alternative embodiment. The sensor configuration 500 includes a conduit 505. The conduit 505 is a channel for conveying air, such as, for example, a duct, a pipe, a tube or the like. The conduit 505 including a bend. The fluid flow path 320 runs through the conduit 505. Referring now to FIGS. 5A and 5B, in some embodiments, the conduit 505 may be connected to or extend from the recovery tank outlet aperture 310 into the tank volume of the recovery tank 118 or into the lid 232. In some embodiments, the motor housing of the suction motor 210 as illustrated in FIG. 5B forms the conduit 505.

Returning to FIG. 7, the sensor 123 is positioned at an angle in the bend of the conduit 505. The sensor 123 is positioned at the bend of the conduit 505 such that when liquid-laden air drawn in an airflow direction in the suction airflow 330 (FIG. 5A), as indicated by the arrow of the fluid flow path 320, impinges on a surface of the sensor 123. The surface of the sensor 123 including a sensing portion (e.g., electrode). In some embodiments, the sensor 123 is positioned such that the angle of the sensor 123 is relative to the airflow direction and gravity enables liquid collecting on the sensor 123 to flow off of, or shed from, the surface of the sensor 123. In some embodiments, the sensor 123 is coupled to a wall of the conduit 505 and extends from the wall or surface of the conduit 505 into the fluid flow path 320. In some embodiments, the sensor 123 includes a plurality of electrodes arranged in a mesh array, such that liquid and air in the fluid flow path 320 flows through the mesh array. In some embodiments, the sensor 123 includes a plurality of electrodes arranged in a linear array, such that liquid and air in the fluid flow path 320 flows through the linear array. In some embodiments, the sensor 123 includes a plurality of electrodes arranged in a linear array or a mesh array disposed on a solid surface, such that liquid and air in the fluid flow path 320 flow over the surface in contact with the mesh array or linear array. In some embodiments, the sensor 123 is integrated into the conduit 505 such that there is no gap between the sensor 123 in the bend and a wall of the conduit 505. Accordingly, the sensor 123 and configuration illustrated in FIG. 7 is provided as one example configuration and should not be construed as limiting.

FIG. 8 is an example illustration of a mesh configuration 600 of the sensor 123 according to some embodiments. The sensor 123 includes a sensing portion 605 having a plurality of electrodes. The plurality of electrodes of the sensing portion 605 forming a mesh surface composed of interlaced electrodes where liquid and air pass through or over the mesh surface. In some instances, the sensor outputs a signal indicating a conductivity level of the sensing portion 605 of the sensor 123 when liquid impinges an electrode of the plurality of electrodes.

FIG. 9 is a block diagram of a control system 700 of the floor cleaner 100 according to some embodiments. The control system 700 includes a controller 705. The controller 705 is electrically and/or communicatively connected to a variety of modules or operating elements of the floor cleaner 100. For example, the controller 705 is connected to the suction source 120, the pump 122, the valve 125, the user interface 133 (which includes indicator 134), and one or more sensors (which includes the sensor 123). In some embodiments, the one or more sensors 123 are sensors that sense the presence of liquid, such as liquid droplets, splashes, foam, or the like. In some embodiments, the controller 705 is operable to control the one or more operating elements of the floor cleaner 100, such as the suction source 120, the pump 122, the valve 125, and the user interface 133, based on determined characteristics of the floor cleaner 100.

In some embodiments, the controller 705 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 705 and/or the floor cleaner 100. For example, the controller 705 includes, among other things, an electronic processor 720 (for example, a microprocessor or another suitable programmable device) and a memory 725.

The memory 725 includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (ROM) and random access memory (RAM). Various non-transitory computer readable media, for example, magnetic, optical, physical, or electronic memory may be used. The electronic processor 720 is communicatively coupled to the memory 725 and executes software instructions that are stored in the memory 725, or stored in another non-transitory computer readable medium such as another memory or a disc. The software may include one or more applications, program data, filters, rules, one or more program modules, and other executable instructions.

The battery 142 is configured to supply power to the controller 705 and/or other components of the floor cleaner 100. As illustrated, in some embodiments, the rechargeable battery pack 142 provides power to the controller 705 and/or other components of the floor cleaner 100. In other embodiments, the controller 705 and/or other components of the floor cleaner 100 can receive power from an AC power source (for example, an AC power outlet).

The user interface 133 is configured to receive input from a user and/or output information to the user concerning the floor cleaner 100. Although illustrated as including indicator 134 and actuator 135, in other embodiments, the user interface 133 may further include, in addition to or in lieu of indicator 134 and actuator 135, a display (for example, a primary display, a secondary display, etc.), output devices (for example, speakers), and/or input devices (for example, touch-screen displays, a plurality of knobs, dials, switches, buttons, etc.).

Referring to FIGS. 3-8, as liquid enters the recovery tank 118, along the fluid flow path 320, through the inlet duct in fluid communication with the recovery tank inlet aperture 305, the liquid level within the recovery tank 118 rises. As the liquid enters the fluid flow path 320 along with the suction airflow 330, it is drawn toward the recovery tank 118. In operation, the controller 705 monitors the signal generated by the sensor 123. The sensor signal may indicate a change in conductivity of the sensing portion of the sensor 123 when an electrode is impinged with the liquid in the suction airflow 330. The controller 705 compares the signal of the sensor 123 to one or more thresholds stored in the memory 725. In some embodiments, a first threshold is selected to indicate a small amount of liquid is present in the suction airflow 330 when the first threshold is reached. For example, the small amount of liquid may correspond to foam, liquid droplets, and/or liquid sloshing in the recovery tank 118 or the suction airflow 330. In some embodiments, a second threshold is selected to indicate a large amount of liquid is present in the suction airflow 330 when the second threshold is reached or exceeded. For example, the large amount of liquid corresponds to liquid in the suction airflow 330 causes the sensor 123 to produce a conductivity level that is greater than a conductivity level produced when the first threshold is reached. In this example, the large amount of liquid corresponds to a predetermined desired maximum liquid level of the recovery tank 118 being exceeded when the second threshold is reached. In some embodiments, the controller 705 repeatedly samples the signal of the sensor 123 according to a predetermined time. For example, the controller 705 may sample the signal of the sensor 123 every millisecond. In other embodiments, the controller 705 may sample the signal of the sensor 123 every second(s) or every predetermined fraction of a second as appropriate (e.g., 0.2 s, 0.3 s, 0.4 s, 0.5 s, 0.75 s, and the like).

The controller 705 determines the signal of the sensor 123 reaches one or more thresholds stored in the memory 725. The controller 705 may control the operation of the suction source 120 and/or other operating elements of the floor cleaner 100. In some embodiments, the controller 705 reduces a speed of the suction motor of the suction source 120 when the signal of the sensor 123 reaches a first threshold, such that the airflow of the suction airflow 330 generated by the suction source 120 is reduced. In some embodiments, the controller 705 stops the suction motor of the suction source 120 when the signal of the sensor 123 reaches a second threshold, such that the airflow of the suction airflow 330 generated by the suction source 120 is stopped.

In some embodiments, the controller 705 controls the pump 122, the valve 125, or other distribution system upon determining the signal of the sensor 123 reaches one or more thresholds stored in the memory 725. In some embodiments, the controller 705 controls the pump 122 and/or the valve 125 to limit the flow of liquid out of the supply tank 116 when the signal of the sensor 123 reaches a first threshold. In some embodiments, the controller 705 reduces a flow rate of the pump 122 by reducing a speed of the pump 122 when the signal of the sensor 123 reaches a first threshold, such that flow of liquid out of the supply tank 116 is limited. In some embodiments, the controller 705 inhibits a flow of liquid through the pump 122 by stopping the pump 122 when the signal of the sensor 123 reaches a second threshold. In some embodiments, the controller 705 reduces a flow rate of liquid out of the supply tank 116 by closing the valve 125 in the fluid distribution line when the signal of the sensor 123 reaches a first threshold, such that the liquid passing through the distribution nozzle 117 is limited. In some embodiments, the controller 705 inhibits a flow of liquid out of the supply tank 116 by shutting off the valve 125 in the fluid distribution line when the signal of the sensor 123 reaches a second threshold, such that the liquid is prohibited from passing through the distribution nozzle 117.

In some embodiments, the controller 705 controls the user interface 133 upon determining the signal of the sensor 123 has reached either a first threshold or second threshold. The controller 705 may be configured to activate the indicator(s) 134 of user interface 133 upon determining the signal of the sensor 123 has reached either a first threshold or a second threshold. For example, the controller 705 may activate the indicator(s) 134 by illuminating the indicator(s) 134 in an always-on state or pulsing the indicator(s) 134.

In some embodiments, the sensor 123 may include one or more electrodes disposed in a conduit the suction airflow 330 flows through. The controller 705 monitors the signal generated by the sensor 123. The controller 705 compares the signal of the sensor 123 to one or more thresholds stored in the memory 725. In some embodiments, a first threshold is selected to indicate a small amount of liquid is present in the recovery tank 118 when the first threshold is reached. For example, the small amount of liquid may correspond to a liquid level within a defined distance of the predetermined desired maximum liquid level (e.g., defined level of the recovery tank 118) or foam, liquid droplets, and/or sloshing in the recovery tank 118 or the suction airflow 330. In some embodiments, a second threshold is selected to indicate a large amount of liquid is present in the suction airflow 330 or the predetermined desired maximum liquid level of the recovery tank 118 is exceeded when the second threshold is reached or exceeded. For example, the large amount of liquid corresponds to liquid in the suction airflow 330 causing the sensor 123 to produce a conductivity level that is greater than a conductivity level produced when the first threshold is reached or exceeded. In this example, the second threshold may be selected to correspond to the predetermined desired maximum liquid level of the recovery tank 118 being reached. The predetermined desired maximum liquid level of the recovery tank 118 may be selected to be below the outlet aperture of the inlet duct (FIG. 4) in fluid communication with the suction inlet 126 (FIG. 1). Therefore, when the liquid in the recovery tank 118 reaches the first threshold and not the second threshold corresponding to the desired maximum liquid level, the controller 705 reduces operation of the floor cleaner 100. Requiring the sensor signal of the sensor 123 to reach the first threshold and the second threshold prevents the floor cleaner 100 from being inadvertently shutoff due to waves, foam, or splashing of liquid in the recovery tank 118 or other movement causing liquid to be drawn into the suction airflow 330 in the fluid flow path 320 or from errantly signaling to the controller 705 that the desired maximum liquid level within the recovery tank 118 has been reached.

In some embodiments, when the controller 705 determines that the desired maximum liquid level within the recovery tank 118 has been reached based on a second threshold, the controller 705 may control the operation of the suction source 120 and/or other operating elements of the floor cleaner 100. In some embodiments, the controller 705 controls the pump 122, the valve 125, and/or the suction source 120 of the floor cleaner 100 to reduce the suction airflow 330 and distribution of liquid from the supply tank 116 when a first threshold has been reached but the second threshold has not been reached. In other embodiments, the controller 705 controls the pump 122, the valve 125, and/or the suction source 120 of the floor cleaner 100 to stop the suction airflow 330 and distribution of liquid from the supply tank 116 when the second threshold has been reached. In some embodiments, the floor cleaner 100 is no longer operational when the recovery tank 118 is full.

In some embodiments, the controller 705 controls the pump 122, the valve 125, and/or, other distribution system upon determining the liquid within the recovery tank 118 has reached the desired maximum liquid level. The controller 705 controls the pump by prohibiting power provided by the power supply 710 to the pump 122 or closing the valve 125 to limit or stop distribution of liquid. Prohibiting power to the pump 122 prevents the pump 122 from drawing cleaning liquid out of the supply tank 116. Similarly, closing the valve 125 in the fluid distribution line inhibits or prevents liquid from passing through the distribution nozzle 117.

In some embodiments, the controller 705 controls the user interface 133 upon determining the liquid within the recovery tank 118 has reached the desired maximum liquid level. The controller 705 may be configured to activate the indicator(s) 134 of user interface 133 upon determining the liquid within the recovery tank 118 has reached the desired maximum liquid level. For example, the controller 705 may activate the indicator(s) 134 by illuminating the indicator(s) 134 in a constantly lit state or pulsing the indicator(s) 134.

FIG. 10 is a flowchart illustrating a process, or operation, 800 for operating the floor cleaner 100. It should be understood that additional steps may be added and not all of the steps may be required. The floor cleaner 100 draws liquid into the recovery tank 118 via suction inlet 126 (block 805). The controller 705 receives, from the sensor 123, a signal indicative of the presence of liquid in the suction airflow 330 in the fluid flow path 320 (block 810). The controller 705 determines the presence of liquid in the suction airflow 330 in the fluid flow path 320 based on the signal of the sensor 123 and a first threshold (block 815). If the signal of the sensor 123 has not reached the first threshold (block 815 “NO” branch), the controller 705 returns to block 810 and continues to receive the signal of the sensor 123. If the signal of the sensor 123 has reached the first threshold (block 815 “YES” branch), the controller 705 proceeds to block 820. The controller 705 determines the presence of liquid in the suction airflow 330 in the fluid flow path 320 based on the signal of the sensor 123 and a second threshold (block 820). If the signal of the sensor 123 has not reached the second threshold (block 820 “NO” branch), the controller 705 reduces operation of the floor cleaner 100 by controlling one or more operating components of the floor cleaner 100 (block 825). In some embodiments, subsequent to the controller 705 reducing operation of the floor cleaner 100, the controller 705 continues receiving the signal of the sensor 123 (block 810) and continues to control operation of the floor cleaner based on the steps of the process, or operation 800. If the signal of the sensor 123 has reached the second threshold (block 820 “YES” branch), the controller 705 stops operation of the floor cleaner 100 by controlling one or more operating components of the floor cleaner 100 (block 830). The controller 705 provides a notification to a user via the user interface 133 indicating the operation of the floor cleaner 100 in block 825 or block 830 (block 835). In some embodiments, the user interface 133 provides an indication of the operating status of the floor cleaner 100. In some embodiments, the user interface 133 changes an indication of the operating status of the floor cleaner 100 in response to the signal of the sensor 123 reaching the first threshold or the second threshold. Accordingly, the controller 705 may continuously perform the steps of the process, or operation, to control one or more operating components of the floor cleaner 100.

Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present disclosure. Embodiments of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure. It should thus be noted that the matter contained in the above description or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.