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.

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/557,211, filed on Mar. 29, 2004 for CYCLONE EXTRACTOR SYSTEM AND METHOD, which is incorporated herein by reference.

BACKGROUND

1. The Field of the Invention

This invention relates to cleaning systems and, more particularly, to novel systems and methods for cleaning carpets and upholstery using high vacuum, high temperature, continuously operating cleaning systems.

2. The Background Art

Currently, in the automotive detailing industry, dirty carpets and upholstery are treated with chemicals (e.g. surfactants) or chemical and water combinations to help lift grime and debris from the surface. The resulting mixture may then removed by a vacuum from the treated carpet or upholstery, which is then left to dry. Doors of the automobile are often left open to aid in drying. On occasion, heaters may be used to speed the drying process. However, even with these aids, several hours may be required for cleaning the treated carpet or upholstery. Additionally, prior art cleaning processes have a tendency to create an odor of mildew. Chemicals left within the carpet or upholstery attract dirt, whereby the treated carpet or upholstery may soon need to be re-cleaned.

In the self-serve carwash industry, current interior cleaning options are limited to wet-dry vacuums or vacuum and shampoo systems. Vacuums acting alone are only able to remove debris that is already loose and easily accessible from the surface of the carpet or upholstery. Accordingly, a vacuum acting alone is unable to provide a deep clean or remove adhered materials (e.g., grime trapped in soft drink spills, etc.).

In the vacuum and shampoo systems of the prior art, shampoo is usually introduced and worked into the dirty carpet or upholstery. A wet-dry vacuum may then be used to remove the dirty shampoo. In such situations, there is no rinse cycle. A large amount of dirty shampoo remains in the carpet or upholstery. This residual shampoo may leave a strong chemical smell and quickly attract new dirt.

Regardless of the industry were they are used, known carpet and upholstery cleaning systems are not generally optimized for deep cleaning and fast drying. For example, some current cleaning systems use large gravity settling tanks that are not easily included within an integrated package. Additionally, some current cleaning systems use residential water heaters. Such heaters are typically limited to a maximum of 60° C. Moreover, they lack the structures to maintain this temperature throughout the cleaning process. As appreciated, the water used in such systems cools significantly before it is ever applied to the carpet or upholstery, thereby reducing its cleaning potential and increasing drying time.

Cleaning systems of the prior art typically use vacuum pumps that are incapable of producing sufficient suction. Furthermore, known systems lack the structure necessary to implement more effective vacuum pumps. Current cleaning systems do not provide continuous operation. That is, they must be shut down before any tanks (e.g., settling tanks) can be emptied. In operations utilizing multiple cleaning stations, this downtime may be a significant nuisance and thereby reduce the overall efficiency of the cleaning operation.

In view of the forgoing failings of the current carpet and upholstery cleaning systems, what is needed is an integrated, compact cleaning system that supports continuous operation, enables water to be applied at near optimal temperatures, produces sufficient vacuum to remove more grime and reduce drying time, and eliminates or greatly reduces the need for chemicals.

BRIEF SUMMARY OF THE INVENTION

In view of the foregoing, in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed in one embodiment of the present invention as including an integrated cleaning system comprising a cleanser, collector, and controller. The cleanser may condition and distribute cleaning fluids such as detergents and heated water for dissolving, trapping in solution, or otherwise lifting grime (e.g. dirt, debris, oil, etc.) from the surface being cleaned. The collector may extract (e.g. vacuum) the soiled cleaning fluids from the surface. The controller may monitor and control the operation of the cleanser and collector.

In selected embodiments, a cleaner may include a heater for heating one or more cleaning fluids before they are transported to a wand for application to the surface being cleaned. Suitable heaters may include heat exchangers, electric heaters, gas heaters, and the like. In some embodiments, the cleanser may heat the cleaning fluids (e.g. water) under pressure to increase their boiling temperature. This may permit the cleaning fluids to have greater thermal energy when applied to the surface.

In general, the hotter the cleaning fluids, the better and faster the cleaning. For example, the hotter the water used, the less chemical detergents are needed. Certain embodiments in accordance with the present invention may apply water at temperatures range from about 48° C. and about 121° C., or even greater. To maintain the cleaning fluids at the desired temperature at distant locations, the cleaner may recirculate cleaning fluid through the heater. Moreover recirculation conduits and wand conduits may be insulated to reduce heat loss.

A collector in accordance with the present invention may utilize deep vacuum pumps. In general, deeper vacuums extract the cleaning fluids and dirt better than lower vacuums. As a result, a deeper vacuum generally shortens drying times. Additionally, cleaning fluids will evaporate at a lower temperature under vacuum. Selected collectors in accordance with the present invention may pull a vacuum of 25.4 cm Hg or greater.

In certain embodiments, a separator may remove the large majority of the liquid from the flow before it reaches the vacuum pump. In some embodiments, the separator may enforce a centrifugal acceleration greater than gravitational acceleration to effect the separation.

Deep vacuum pumps typically have close tolerances that must be protected from the debris and moisture picked up during the cleaning process. In certain embodiments, one or more filters may be positioned in the flow between the separator and the vacuum pump in order to mitigate the debris and moisture.

After being separated from the flow of air, waste (e.g., water, trash, dirt, foam, chemicals, and the like) may be stored in a storage tank. In certain embodiments, such storage may be contained within the separator itself. In other embodiments, an additional tank or tanks may be employed to store the waste as needed.

The novel systems in accordance with the present invention may further include a discharge system allowing for continuous operation. That is, removal of the waste liquids without shutting down the collector. By operating selected valves (manually, mechanically, or under computer control), one volume may be taken off-line and emptied while another continues to collect liquids.

Integrated cleaning systems in accordance with the present invention may be operated manually, mechanically, or by computer. In selected embodiments, a controller may facilitate computer control of the system. For example, a controller may include a programmable logic controller (PLC) programmed to facilitate the various valve openings and closings that may be needed to accomplish continuous operation of a collector. Swapping collection volumes may be programed or arranged to occur automatically when certain liquids levels are achieved. Moreover, various sensors and actuators may inform an operator of maintenance needs, low levels, low temperatures, high temperatures, low vacuum, high vacuum, and other system issues that may require attention.

In selected embodiments of the present invention, multiple cleaning stations (e.g. multiple wands) may be run with one integrated cleaning system in accordance with the novel concept of the present invention. Cleaning systems of the present invention may be applied to large and small detail shops, car dealers, semi-truck detail shops, gas stations, self-serve car washes, bus washes, rental car agencies, and large companies with an automobile fleet. Moreover, the present invention may be applied to cleaning applications unrelated to automobiles. For example, an integrated cleaning system may be used in furniture refurbishing, commercial carpet cleaning, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:

FIG. 1 is a schematic, block diagram of an integrated cleaning system in accordance with one presently preferred embodiment of the present invention;

FIG. 2 is a schematic diagram of one presently preferred embodiment of a cleanser in accordance with the present invention;

FIG. 3 is a schematic diagram of an alternative presently preferred embodiment of a cleanser in accordance with the present invention;

FIG. 4 is a schematic diagram of another alternative presently preferred embodiment of a cleanser in accordance with the present invention;

FIG. 5 is a schematic diagram of one presently preferred embodiment of a collector in accordance with the present invention;

FIG. 6 is a block diagram of one presently preferred embodiment of a method for operating the collector as shown in FIG. 5;

FIG. 7 is a top, cross-sectional view of one presently preferred embodiment of a separator in accordance with the present invention;

FIG. 8 is a side, cross-sectional elevation view of the separator as shown in FIG. 7;

FIG. 9 is a schematic diagram of an alternative presently preferred embodiment of a collector providing continuous operation in accordance with the present invention;

FIG. 10 is a block diagram of one presently preferred embodiment of a method of the present invention for operating the collector as shown in FIG. 9;

FIG. 11 is a schematic diagram of another alternative presently preferred embodiment of a collector providing continuous operation in accordance with the present invention;

FIG. 12 is a block diagram of one presently preferred embodiment of a method of the present invention for operating the collector as shown in FIG. 11;

FIG. 13 is a side elevation of one presently preferred embodiment of an integrated cleaning system secured to a skid in accordance with the present invention;

FIG. 14 is a schematic, block diagram of one presently preferred embodiment of a controller in accordance with the present invention;

FIG. 15 is a schematic, block diagram of one presently preferred embodiment of a sensor suite in accordance with the present invention;

FIG. 16 is a block diagram of one presently preferred embodiment of a method of the present invention for monitoring an integrated cleaning system in accordance with the present invention; and

FIG. 17 is a schematic, block diagram of one presently preferred embodiment of an actuator suite in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the presently preferred embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention. The presently preferred embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.

Referring to FIG. 1, an integrated cleaning system 10 in accordance with one presently preferred embodiment of the present invention may include a cleanser 12, a collector 14, and a controller 16. The cleanser 12 may condition and distribute cleaning fluids for dissolving, trapping in solution, or otherwise lifting grime (e.g., dirt, debris, oil, etc.) from the surface being cleaned. The collector 14 may extract the cleaning fluids and thereby dislodge grime from the surface and properly dispose of the same. The controller 16 may monitor and control the operation of the cleanser 12 and the collector 14 to promote safe, efficient operation of the overall cleaning system 10.

Referring now to FIGS. 1 and 2, in selected embodiments, a cleanser 12a in accordance with the present invention may include a carrier subsystem 18a. A carrier subsystem 18a may prepare and deliver a primary cleaning fluid. Due to cost, safety, and availability, the primary cleaning fluid of choice is often water. However, other fluids or combinations of fluids may be used. For example, and not by way of limitation, alcohol, dry cleaning chemicals, and the like may be used as the primary cleaning fluid.

In selected embodiments, a carrier subsystem 18a may include a heater 20 to increase the temperature of the primary cleaning fluid as it passes through various conduits 21 directing it from a source 22 to the surface 24 being cleaned. In general, the higher the temperature of the cleaning fluid, the greater its ability to lift grime from the treated surface 24. Additionally, in general, the hotter the cleaning fluid, the more rapidly it will evaporate from the surface 24 once the treatment or cleaning process is completed.

A source valve 26 may be positioned between the source 22 and the heater 20 to control the flow of the primary cleaning fluid into the carrier subsystem 18a. In certain presently preferred embodiments, the source valve 26 may be actuated by a solenoid 28. Accordingly, an operator of the cleaning system 10 desiring delivery of the cleaning fluid to the surface 24 may close an electrical circuit and thereby activate the solenoid 28. The solenoid 28, in turn, may open the source valve 26 permitting cleaning fluid to pass from the source 22, through the heater 20, to the point of application on the targeted surface 24, as selected by the operator.

A heater 20 in accordance with one presently preferred embodiment of the present invention, may be found in any suitable configuration or principal of operation. For example, the heater may use electric current passing through a heating element to generate the desired thermal energy to increase the temperature of the cleaning fluid passing through it. Alternatively, the heater may burn a combustible material to generate the desired thermal energy. In alternate other embodiments, a heat exchanger may be used which is contemplated herein.

In certain embodiments, a heater 20 may include an insulated tank. In such embodiments, the heater 20 may heat the primary cleaning fluid and store the same within the tank for future use. Such an arrangement may provide a quantity of heated cleaning fluid when desired. The size of the insulated tank and the heater's thermal energy generating capacity may be selected to match demand. Accordingly, the quantity may be sufficiently large to avoid excess depletion when considering the rate at which heated cleaning fluid is exiting and unheated cleaning fluid is entering.

In other embodiments, a heater 20 may adjust according to flow patterns of the primary cleaning fluid. For example, when the source valve 26 is closed, the heater 20 may cease operation. When the source valve 26 is opened and flow of the primary cleaning fluid resumes, the heater 20 may inject thermal energy into the flow. In such an embodiment, the source 22, the source valve 26, and the heater 20 may combine to create an “on demand” system delivering potentially unlimited quantities of primary cleaning fluid heated to a temperature selected for optimal or near optimal cleaning performance (i.e., grime lifting).

In selected embodiments, the primary cleaning fluid may be delivered to the surface 24 at or near the pressure of the source 22. For example, if the source 22 is a municipal water system, the primary cleaning fluid may be delivered to the surface 24 at or near the local pressure provided by the system supplying the source 22. Alternative, any arrangement of one or more pumps may increase (i.e., boost) the pressure within the cleanser 12 above that of the source 22. In still other embodiments, the source 22 may comprise a pump for extracting fluid from a reservoir. For example, the source 22 may comprise a pump that extracts water from an on-site well. In such situations, the pressure of the primary cleaning fluid within the carrier subsystem 18a may be substantially equal to the pressure generated by the pump, taking into consideration frictional losses.

A cleanser 12a, in accordance with one presently preferred embodiment of the present invention may also include a detergent subsystem 30a facilitating application of one or more detergents to the surface 24 being cleaned. Suitable detergents may include any suitable cleaning agents in either solid of liquid form. For example, a suitable detergent may be any water-soluble or liquid preparation that is able to emulsify oils and hold dirt in suspension.

The concentration of the ingredients with the detergent may be controlled in any suitable manner. For example, liquid detergent manufactured in a high concentration may be appropriately diluted. Similarly, detergent manufactured as a solid may be dissolved in an selected amount of an appropriate solvent. In certain embodiments, detergent may be dissolved in or diluted with a selected amount of the primary cleaning fluid.

Still referring to FIG. 2, in one presently preferred embodiment of the present invention, a detergent subsystem 20 may include a pump 32 for extracting detergent from a reservoir 34 and delivering the extracted detergent to the surface 24 being cleaning. In selected embodiments, the pump 32 may be manually operated. In one example, the pump 32 and reservoir 34 may be embodied as a hand-operated spray bottle. Alternatively, the reservoir 34 may be located some distance from the target treatment surface 24. In such embodiments, a pump 34 may transport detergent from the reservoir 34 to the surface 24 through appropriate conduits 35. If desired, at the point of application, a detergent subsystem 30 may include a nozzle generating a distributed flow pattern and producing an efficient application of the detergent to the surface 24.

Referring now to FIG. 3, a detergent subsystem 30b are suitable in accordance with one presently preferred embodiment of the present invention, may be formed having any suitable configuration or principles of operation to deliver detergent to the surface 24 being cleaned. In selected embodiments, the detergent and primary cleaning fluid may be mixed and simultaneously applied to the surface 24. For example, in certain embodiments, a carrier subsystem 18b may deliver the primary cleaning fluid to one or more delivery wands 36 (i.e., Wand A, Wand B, Wand C). Accordingly, a mixer 38, positioned along the length of a conduit 21 of the carrier subsystem 18b, may add detergent to the primary cleaning fluid before it reaches a corresponding delivery wand 36.

In selected embodiments, a mixer 38 may operate as a venturi, educing detergent from the reservoir 34 at a rate proportional to the flow of the primary cleaning fluid. In such an embodiment, a pump 32 may be unnecessary. In other embodiments, a mixer 38 may act as a pump 32. For example, a mixer 38 may include a paddle wheel extending into the flow of the primary cleaning fluid. So arranged, the paddle wheel may rotate with a speed proportional to the flow of the primary cleaning fluid. The rotation of the paddle wheel may be used to educe detergent from the reservoir 34 and meter the same into the flow of the primary cleaning fluid.

In one presently preferred embodiment of the present invention, a single meter 38 may be positioned “upstream” from all delivery wands 36. For example, in one embodiment, a single meter 38 may distribute detergent after the primary cleaning fluid has been heated, but before it is divided to service the one or more delivery wands 36. Alternatively, one meter 38 may distribute detergent at a location just after the source valve 26. In other embodiments, more than one meter 38 may be used. For example, a different meter 38 may be positioned “upstream” of each delivery wand 36. In such an embodiment, the various meters 38 may draw detergent from one reservoir 34 or any combination of multiple reservoirs 34, as desired.

A carrier subsystem 18, in accordance with one presently preferred embodiment of the present invention may include any components or arrangements for simplifying the operation, improving the efficiency, improving the safety, and reducing the initial and operating costs thereof. For example, in selected embodiments of the present invention, a source valve 26 may be a differential pressure regulator. In such an arrangement, the source valve 26 may permit fluid to enter the carrier subsystem 18b any time the pressure of the source 22 exceeds the pressure within the carrier subsystem 18b by a pre-determined selected amount. In other embodiments, a source valve 26 may a manually operated gate valve. If desired, a carrier subsystem 18b of the present invention may include a pressure relief valve 40 to avoid over pressurization of the system.

One presently preferred embodiment of the present invention, a tank 42 may be included within the carrier subsystem 18b. The tank 42 may be incorporated as part of the heater 20, as discussed hereinabove. In other embodiments, the tank 42 may be an independent component. If desired, the tank 42 may be insulated and form a buffer between the demand for heated cleaning fluid and the ability of the heater 20 to provide the same.

As shown in FIG. 4, in selected embodiments, it may be desirable to reduce the loss of thermal energy from the cleaning fluid as it travels in conduits 21 from the heater 20 to the appropriate delivery wand 36. For example, in certain embodiments, selected conduits 21 through which the heated cleaning fluid travels may be insulated, thereby reducing the rate at which thermal energy is lost to the surrounding environment. According to such design, the drop in temperature of the cleaning fluid between the heater 20 and the delivery wand 36 may be reduced.

Alternatively, or in combination with insulation, selected conduits 21 of the carrier subsystem 18c may be connected to form a recirculation loop 44. In such an embodiment, a pump 46 may recirculate unused cleaning fluid through the heater 20. Accordingly, the temperature of the cleaning fluid at the extremes of the carrier subsystem 18 may be maintained very near that of the cleaning fluid leaving the heater 20. The length 48 of the conduit 21 which extends between the recirculation loop 44 and the delivery wand 36 may be minimized, or even eliminated, to limit the drop in temperature of the cleaning fluid as it travels from the continuously heated recirculation loop 44 to the delivery wand 36.

In selected embodiments of the present invention, a pump 46 may be used to increase the pressure of the cleaning fluid within the carrier subsystem 18c. This increase in pressure may be in addition to that provided by the source 22, booster pump, reservoir pump, etc. The pump 46 responsible for pressurization may be the same pump 46 responsible for recirculation. Alternatively, multiple pumps 46 may be used to the perform the different functions. If desired or necessary, a throttling valve 50 may be incorporated with the carrier subsystem 18c to facilitate pressurization.

The primary cleaning fluid may be heated under pressure to increase the boiling temperature. For example, in some embodiments employing water as the primary cleaning fluid, the water may be heated to temperatures ranging from between about 48° C. and about 121° C., or even greater. By heating the water above the boiling temperature of water at the ambient pressure, part of the water may vaporize as it discharges from the delivery wand 36 into the relatively low pressure environment. This process may introduce the water deeper into the targeted surface 24, facilitating a deeper cleaning. Additionally, the extra heat from the vapor may speed the rate at which grime is dissolved and lifted from the surface 24 being treated. A portion of the extra heat from the vapor may also be transferred to the targeted surface 24 and thereby increase the rate of evaporation (drying) once the cleaning has been completed.

In general, the cleaning process may be visualized as a pie chart divided into three sections. The first section may represent the temperature of the primary cleaning fluid. The second section may represent the amount of detergent needed. The final section may represent the amount of agitation needed. An increase in one area of the pie chart will generally result in a reduction in one or both of the other two areas of the pie chart. Similarly, by increasing the thermal energy carried within the primary cleaning fluid, the amount of detergent and agitation needed may be significantly reduced. Such a configuration as contemplated and taught herein may provide fast cleaning (i.e., less agitation needed) and limit the use of detergents that attract dirt and leave unpleasant odors.

Other components may be incorporated within the carrier subsystem 18 as necessary. For example, as discussed hereinabove, a storage tank 42, which may or may not be insulated, may be employed. Additionally, sensors 52 may be incorporated into the overall cleaning system to monitor the carrier subsystem 18c and collect information regarding temperature, pressure, flow rate, detergent concentration, and the like.

Referring now generally to FIGS. 5-8, in selected embodiments, a delivery wand 36 in accordance with one presently preferred embodiment of the present invention may include a suction nozzle and a manually triggered spray jet. The suction nozzle may be connected to a collector 14a. The spray jet may be connected to a cleanser 12. Accordingly, cleaning fluids and detergents may be applied to the target surface 24 through the spray jet and be removed from the surface 24, together with the entrapped grime and debris, through the suction nozzle. Delivery wands 36 manufactured by HyDry® and others have been found to be suitable.

In operation, a delivery wand 36 may be moved across the treatable surface 24 while depressing the trigger on the spray jet. As the delivery wand 36 travels, cleaning fluid (e.g., primary cleaning fluid, detergent, or combinations thereof) may be injected into the surface 24 and then removed, with the dissolved grime and debris, by the suction nozzle. The flow of the cleaning fluid may be stopped by releasing the trigger. This process may be repeated as necessary. To extract even more cleaning fluid, grime and debris from the treated surface 24, an operator may again move the delivery wand 36 over the surface 24, but without depressing the trigger on the spray jet.

Novel cleaning systems 10 in accordance with the contemplated breadth and scope of the present invention may include one or more delivery wands 36 of various types. In one presently preferred embodiment, the delivery wands 36, and the conduits 21 delivering cleaning fluids thereto, may be arranged in such a manner so as to maintain temperature and pressure of the cleaning fluids. For example, the conduits 21 leading to one or more delivery wands 36 may be insulated, configured to recirculate, or both.

In certain embodiments, a collector 14a in accordance with the present invention may include a pump 54, a filter 56, a separator 58, and various conduits 60. A pump 54 may have or use any suitable configuration or principle of operation. For example, but not by way of limitation, suitable pumps 54 may include positive displacement blowers, a multi-stage centrifugal pumps, regenerative blowers, and the like. In general, the greater the vacuum produced by the pump 54, the greater the ability of the collector 14a to remove additional waste, including cleaning fluids, from the treated surface 24. Greater removal capabilities, in turn, improve the cleanliness of the surface 24 and reduce the drying time. Selected pumps 54, in accordance with one presently preferred embodiment of the present invention, may pull a vacuum of 25.4 cm Hg or greater.

In one presently preferred operation of the present invention, a collector 14a may collect a mixture of liquid and gas. The liquid may include the cleaning fluid, foam or suds, as well as the entrapped grime and debris. The gas may include air drawn into the delivery wand 36 from an ambient reservoir 62. A separator 58 may separate the liquid from the gas. The liquid may then be properly discarded and the gas may continue on its path to the pump 54.

A separator 58 may have or use any suitable configuration or principle of operation. In some embodiments, a separator 58 may use the acceleration of gravity to separate the heavier liquid from the lighter gas. In other embodiments, a separator 58 may use centrifugal force to effect the separation. If desired, a separator 58 system may be sized and shaped to apply a centrifugal acceleration greater than gravitational acceleration. Such design may facilitate a compact device producing a rapid separation.

For example, in certain embodiments, one or more delivery wands 36 may connect to an inlet conduit 60a extending from an inlet aperture 64 of the separator 58. In one presently preferred embodiment of the present invention, the separator 58 may have a generally cylindrical shape. The inlet aperture 64 may introduce flow into the separator 58 in a substantially tangential direction 66 with respect to the cylindrical shape. An outlet conduit 60b may extend from an outlet aperture 68 of the separator 58 to the pump 54. The outlet aperture 68 may be centrally located. With such an arrangement, the heavy liquid may be forced to a wall 70 of the separator 58, where it may fall down 72, collect, and drain out a drain aperture 74. In contrast, the gas may be forced to the center of the separator 58, where it may be evacuated out the outlet aperture 68 by the pump 54.

The pump 54 designed to pull high vacuums may have close tolerances. To increase the life of such pumps 54, these tolerances must be protected from the debris and moisture picked up during the cleaning operation. In certain embodiments, one or more filters 56 may be positioned between a separator 58 and a pump 54 to protect the pump 54 from trash, waste, grim, grease oil, sand, moisture, and the like. For example, a filter 56 may be positioned along an outlet conduit 60b to remove debris from the flow before it reaches the pump 54.

In selected embodiments as shown more specifically in FIGS. 5 and 6, a separator 58 may include, or be coupled with, a volume 76 where, during operation, liquid may collect. For example, a separator 58 may have an internal volume 76 sized to contain a selected quantity of liquid. Alternatively, an external volume 76 (e.g., external tank) may be coupled to the separator 58 to contain the liquid. When this volume 76 is filled, it may be emptied, thereby permitting the collector 14a to continue its normal operation.

In one presently preferred embodiment of the present invention, various steps of procedures may be followed to empty a volume 76, as illustrated in FIG. 6. These procedures may depend upon the characteristics of the collector 14a. For example, in embodiments like that shown in FIG. 5, the first step may be to detect 78 that the volume is full. The collector 14a may then be deactivated 80. Once the collector 80 has ceased operation, a drain valve 82 regulating the flow between the volume 76 and a drain 84 may be opened 86 and remain so until the volume 76 has completely drained 88. The drain valve 82 may then be closed 90 and the collector 14a activated 92.

Referring now to FIGS. 9 and 10, in selected embodiments, a collector 14b may provide continuous operation. To provide such functionality, a collector 14b may include a first tank 94a and a second tank 94b (i.e., external volumes 76a, 76b), both connected to the drain aperture 74 of the separator 58. By alternating between the first and second tanks 94a, 94b, continuous operation of the collector 14b may be achieved.

In certain embodiments, various valves may be used to alternately fill and drain the first and second tanks 94a, 94b. For example, a first separator valve 96a may regulate flow into the first tank 94 while a first drain valve 82a regulates flow out of the first tank 94a. Similarly, a second separator valve 96b may regulate flow into the second tank 94b while a second drain valve 82b regulates flow out of the second tank 94b. If desired or necessary, balancing conduits 98 with first and second balance valves 100a, 100b may connect the first and second tanks 94a, 94b, respectively, to the outlet conduit 60b.

Operation of a collector 14b providing continuous operation may begin with the activation 102 of the cleaning system 10. In one presently preferred embodiment of the present invention, steps may be taken to close 104 the first drain valve 82a, close 106 the second drain valve 82b, open 108 the first separator valve 96a, and close 110 the second separator valve 96b. In such a configuration, the first tank 94a may receive liquid from the separator 58 while the second tank 94b does not. However, the second tank 94b may be ready to take over when needed. The operation of the collector 14b may then be monitored 112 to determine when a change in the tanks 94a, 94b is needed.

When a full tank 94a, 94b is detected 114, the corresponding balance valve 100a, 100b may be closed 116. That is, if a full first tank 94a is detected 114, then the first balance valve 100a may be closed 116. Alternatively, if a full second tank 94b is detected 114, then the second balance valve 100b may be closed 116. Next, the non-corresponding separator valve 96b, 96a may be opened 118 and the corresponding separator valve 96a, 96b closed 120. Accordingly, liquid from the separator 58 may stop entering the full tank 94a, 94b and begin entering the other tank 94b, 94a.

At this stage, the full tank 94a, 94b is closed off from the rest of the collector 14b. Accordingly, the corresponding drain valve 82a, 82b may be opened 122, and remain so until the full tank 94a, 94b has drained 124. Various methods may be used to determine when the tank 94a, 94b has completely drained 124. In selected embodiments, the time required for a complete drain may be determined. Accordingly, by opening 122 the corresponding drain valve 82a, 82b and waiting the required time (plus, perhaps, a safety factor), it may reasonably be assured that the tank 94a, 94b has completely drained 124. Alternatively, one or more sensors 52 (e.g., float sensors) may be used to determine the fluid level within the tank 94a, 94b.

Once the tank 94a, 94b has drained 124, the corresponding drain valve 82a, 82b may be closed 126 and the corresponding balance valve 100a, 100b opened 128. The pump 54 may then pump down 130 the now empty tank 94a, 94b until its internal pressure matches that of the separator 58, thus ensuring a smooth transition of the tank 94a, 94b back into operation. In selected embodiments, the size (e.g., inner diameter) of the balance conduits 98 may be selected to limit how fast the empty tank 94a, 94b may be pumped down 130. In general, the smaller the conduit 98, the longer the tank pump down 130 process.

Again, the operation of the collector 14b may be monitored 112 to determine when a change in the tanks 94a, 94b is needed. When that need arises, the empty tank 94a, 94b may be returned to duty while the other 94b, 94a is taken off-line and emptied. This process may continue until the collector 14b is no longer needed. At that point, the system 10 may be deactivated 132.

As discussed hereinabove, a collector 14b, in accordance with one presently preferred embodiment of the present invention may include one or more filters 56. In selected embodiments, a collector 14b may have two filters 56a. If desired, the filters 56a, 56b may be identical. Alternatively, each filter 56a, 56b may perform a different function. For example, in one embodiment, a first filter 56a may provide an easily cleaned, reusable pre-filter, which protects the second filter 56. Additionally, the first filter 56a may act as a demister, pulling additional moisture from the flow. The second filter 56b may then be a less expensive filter than would otherwise be suitable in a collector 14b with just one filter 56. Such a design may increase the ruggedness of the cleaning system 10 and decrease maintenance frequency and cost.

Referring now to FIGS. 11 and 12, in selected previously preferred embodiments, a collector 14c may provide continuous operation in a more compact design. For example, certain collectors 14c providing continuous operation in accordance with the present invention may include one tank 94 connected to a separator 58. To provide such functionality, a separator 58 may include a volume 76 of selected size therewithin. Accordingly, liquid may be collected within this volume 76 while the connected, external tank 94 is being empty. By alternating between the volume 76 located within the separator 58 and the external tank 94, continuous operation of the collector 14c may be achieved.

In one presently preferred embodiment of the present invention, operation of such a collector 14c may begin with the activation 112 of the cleaning system 10. Steps may be taken to close 104 the drain valve 82, open 108 the separator valve 96, and close 116 the balance valve 100. So configured, all liquid extracted from the flow will pass out of the separator 58 and into the tank 94. The operation of the collector 14c may then be monitored 112 to determine when a change in the tank 94 is full.

When a full tank 94 is detected 114, the separator valve 96 may be closed 120. Accordingly, liquid may stop entering the full tank 94 and begin to collected within the drain conduit 60c and the volume 76 within the separator 58. At this stage, the full tank 94 is closed off from the rest of the collector 14c. Accordingly, the drain valve 82 may be opened 122, and remain so until the tank 94 has drained 124. The drain valve 82 may then be closed 126 and the balance valve 100 opened 128. The pump 54 may pump down 130 the now empty tank 94 until its internal pressure matches that of the separator 58.

Finally, the separator valve 96 may again be opened 108. As a result, any liquids that have collected within the drain conduit 60c and the volume 76 of the separator 58 may pass into the tank 94. In that the time required to empty the tank 94 may be relatively short, the amount of liquid collected within the separator 58 may be limited. However, the volume 76 within the separator 58 may be sized to match any anticipated liquid collection rate.

Once in normal operation, the collector 14c may again be monitored 112 to determine when the tank 94 full. When that occurs, the tank 94 may again be taken off-line and emptied. This process may continue until the collector 14c is no longer needed. At that point, the cleaning system 10 may be deactivated 132.

Referring now to FIG. 13, in selected presently preferred embodiments, a selected component of a cleaning system 10, in accordance with the present invention may be applied to a skid 134 or other portable or modular device. This may significantly reduce the size or footprint of the system 10 as well as reduce the time required for installation, relocation, and the like.

In certain embodiments, various components may be incorporated into the skid 134. For example, railings 136 on the skid 134 may be used to secure various components. Additionally, in selected embodiments, the base 138 of the skid 134 may be formed as one or more closed containers. These closed containers may then function as tanks 94, as discussed hereinabove. The bottom of the base 138 may be slopped as necessary to facilitate draining 124.

Referring to FIG. 14, in selected presently preferred embodiments, a controller 16a in accordance with the present invention may include a computer 140. The computer 140 may include a processor 142 coupled to a memory device 144. In some presently preferred embodiments, the computer may constitute a PLC. The computer 140 may receive information from a sensor suite 146. Various logic contained within the computer 140 may direct it how to respond to this information. Responses may manifest themselves in commands issued to an actuator suite 148. Accordingly, through the sensor suite 146, the computer learns what is transpiring with the cleaning system 10 and through the actuator suite 148, various operations, corrections, adjustments, warnings, and the like may be implemented.

Referring now to FIGS. 15 and 16, in certain embodiments, a sensor suite 146 may include any combination of fluid level sensors 52a, valve position sensors 52b, pressure sensors 52c, temperature sensors 52d, flow sensors 52e, filter sensors 52f, concentration sensors 52g, current sensors 52h, RPM sensors 52i, as well as any other sensors 52j that may collect desired or necessary information. These sensors 52 may collect information from the cleanser 12, the collector 14, or even the controller 16, itself. For example, the sensors 52 may alert the computer 140 when a tank 94 is full, a pump 32, 46, 54 is working too hard, a detergent reservoir 34 is low, a valve 26, 40, 82, 96, 100 is not functioning properly, a pressure is too high, a temperature is too low, and the like.

In a monitoring mode 112, a computer 140 may search information received from the sensor suite 142 in an effort to identify any error conditions. When an error is detected 150, the computer 140 may determine 152 whether the error is critical. If the error is not critical, the computer 140 may simply inform 154 the operator of the condition. This communication may be made through the use of any appropriate display message, light, sound, combination thereof, or the like. If the error is critical, the computer 140 may inform 154 the operator and take 156 appropriate measures. For example, if a senor 52f senses an excessively dirty filter 56, the computer 140 may send a command to deactivate the collector 14. Such precautionary action is intended to prevent valuable equipment (e.g., the pump 54) from being damaged or harmed.

Referring to FIG. 17, in selected presently preferred embodiments of the present invention, an actuator suite 148 may provide the mechanisms through which commands issued by a computer are implemented. In certain embodiments, an actuator suite 148 may include any combination of valve actuators 158a, and pump actuators 158b, power actuators 158c, as well as any other actuators 158d that may be desired or necessary. Actuators 158, in accordance with one presently preferred embodiment of the present invention, may have or use any suitable configuration or principle of operation. For example, valve actuators 158a may be solenoids, while pump actuators 158b may be electrically operated switches.

Consistent with the foregoing, the present invention provides an integrated cleaning system comprising a cleanser, a collector, and a controller. The cleanser may condition and distribute cleaning fluids such as detergents and heated water for dissolving, trapping in solution, or otherwise lifting grime (e.g. ,dirt, debris, oil, etc.) from the surface being cleaned. A cleanser may apply heated water to the surface being cleaned at a temperature of between about 48° C. and about 121° C. The collector may extract (e.g., vacuum) the soiled cleaning fluids from the treated surface. A collector may include one or more filters positioned to protect the close tolerances of a high vacuum, positive displacement pump. The controller may selectively monitor and control the operation of the cleanser and collector.

Unlike the prior art, the present invention provides an integrated, compact cleaning system that supports continuous operation, enables water to be applied at near optimal temperatures, produces sufficient vacuum to remove more grime and reduce drying time, and eliminates or greatly reduces the need for chemicals.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

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.