The invention relates to a balancing system for a washer or dryer appliance to compensate for the unbalance created by a not uniform distribution of the laundry in the drum.
In general a washing machine includes a drum to be loaded with clothes and a motor to rotate the drum and perform a series of phases in a washing cycle such as washing, rinsing and spinning phases.
When the laundry is not uniformly distributed in the drum and a certain mass is concentrated in a part of the drum, during the rotation of the drum in the spinning phase, vibrations and noise occur due to eccentric rotation of the drum. If such eccentric rotation becomes severe, some parts of the washing machine, such as the drum, the bearings supporting the drum, or the tub may be damaged.
Normally to prevent the above listed damages an unbalance measurement check is implemented, that before spinning measures the unbalance level. In case of excessive unbalance the appliance control tries to better redistribute the laundry in the drum and, if after several attempts, the unbalance level is still to high, it performs the spinning at reduced rpm.
The unbalance has several negative effects on the customer satisfaction because of the generated noise and vibrations, the longer washing/drying cycle duration due to the re-balancing attempts and the poor drying performance when, in case of excessive unbalance level the spinning rpm speed is reduced. Moreover the generated mechanical vibrations cause a significant stress to the mechanical structure reducing the appliance reliability that is partially compensated in the washer design by the use of bigger, more robust and expensive parts. Therefore in the washing machine design it is beneficial the use of a balancer, which offsets unbalanced load generated from inside of the drum, to stabilize the drum rotation.
The known balancer systems make use of a balancer ring with a hollow space where are positioned some masses, typically spherical shaped that are free to move in the balancer ring. Often the balancer ring is filled with a fluid to limit the speed of the movement of the balancing masses. Even if this known balancer systems help to reduce the unbalance level they suffer of several drawbacks:
In order to improve the balancing process active balancers are revealed. In particular WO2020/253988 reveals a balancer ring with balancing units receiving wireless power from a transmission coil provided at the tub. The transmitter coil is wound centered with respect the drum axis while the receiver coils in the balancing unit have their winding axis parallel to the radial direction defined by the drum axis.
The orthogonal configuration between the transmitter coil winding axis and the receiver coil winding axes ensures a constant power transfer to the balancing units when they rotate with the drum facing the transmitter coil winding.
In addition WO2020/253988 reveals a detection coil positioned on the transmitter coil winding that allows, during the drum rotation, the detection of the balancing units passage at its position. The appliance controller, to balance the drum load, exploits the action of gravitational and inertial forces acting on the balancing units. It enables their movement with a proper timing, based on their positions and the unbalance amplitude and position.
Previous art disclosures use electromagnetic actuators having moving parts that can brake a balancing unit wheel or can act interacting directly with the housing walls.
The actuators based on moving parts are more complicated to build, are expensive to integrate into the complete system and have a response time that depends on the moving part mass.
A first invention objective is to provide an active balancing system that uses an improved actuator solution without moving parts that is cheaper, has faster reaction time, a high reliability while ensuring a low friction force for the balancing unit. It permits a large rpm range where the balancing unit can be moved under the action of the gravitational and inertial that includes the wash unit resonance frequency.
It allows the possibility to cross the resonance frequency with a balanced drum and to perform balancing adjustment above the resonance frequency compensating the laundry unbalance changes due to the water extraction when the drum spinning speed is increased.
To solve the problem the invention disclose an electromagnet in the balancing unit that interacts with a ferromagnetic race of the housing channel.
A simple application of an electromagnet in the balancing unit due to its sliding friction coefficient would give a limited the rpm range where it is possible to move it.
According to the invention there is a wheel that transfers to the outer race the largest part of the acceleration force acting on the balancing unit; while the electromagnet transfers the remaining much smaller part of the acceleration force. It is obtained by having the balancing unit centre of gravity on one side very close the wheel shaft while on the opposite side, at the end, there is the electromagnet.
The small force transferred by the electromagnet surface is enough to ensure it a mechanical contact with the ferromagnetic outer race of the housing.
This configuration ensures a low friction between the balancing unit and the housing as the large part of the force is transferred through the wheel, which has a low rolling friction coefficient. The smaller remaining part of the force is transferred through the electromagnet surface which has a higher sliding friction coefficient, but its contribution is limited by the low percentage of the transferred force.
Being the housing outer race made of ferromagnetic material the controllable magnetic force acting between the electromagnet surface and the housing outer race generates an additional friction force that acts on the balancing unit.
This frictional force is proportional to the magnetic force multiplied by the electromagnet surface sliding friction coefficient with the housing outer race. In this way it is possible to change the balance unit friction permitting or blocking its movement in the housing.
In a first embodiment the electromagnet has a coil that wound around ferromagnetic material and the current flowing in the coil generates the magnetic field. In this embodiment when both balancing units must stay in braked condition a multiplexing of two the two balancing unit resonance frequencies is used to supply a controlled average current to both balancing units electromagnets.
In a second embodiment a magnet generates the magnetic field in the electromagnet and in this case a coil generates an opposite magnetic field that can cancel the resulting magnetic field. It simplifies the wireless powering transfer to the balancing units. In this case both balancing units are normally braked by the magnetic material and only the one that must be moved needs to be powered by transferring power at its resonating frequency.
Other advantages and features of a balancing system for a laundry treating appliance, according to the present invention will be clear from the following detailed description, provided only as a non limitative example, in which:
In the figures same parts are indicated with the same reference number.
In
At the external perimeter of the drum 50 is fixed, centred with respect its axis 51, a housing ring shaped 500 facing a transmitter coil 620.
The balancing unit body 410 dimensions radial and axial are smaller that the housing channel dimensions so that it can move in the housing channel. On Its side opposite to the driving wheel 431 there is a parking actuator 201 that interacting with an opening 352 on the inner race 341, keeps the balancing unit blocked at its parking position when the drum is rotating at low rpm.
At one of the balancing unit 410 body ends there is an electromagnet 200 facing the outer race 331. The electromagnet 200 sectional view is shown in detail in
The electromagnet 200 mechanical design and its position fixation on the balancing unit 410 body ensure a continuous contact between the surfaces of the electromagnet 200 core extensions 240 and the inner race 331.
When the electromagnet winding is powered both its ferromagnetic core 240 and the inner race 331 contacted surface are magnetized. It generates an attraction force between the two surfaces that increases the friction force between the balancing unit 400 and the outer race 331.
By changing the current flowing in the electromagnet winding 250 it is possible to brake in a controlled way the balancing unit movement.
When the parking actuator winding 251 is powered or when the drum 50 rotates at higher rpm, respectively the generated magnetic force and/or the centrifugal force retracts the pin 241 from the opening 352, enabling the balancing unit 400 movement in the housing 500 channel.
The balancing unit 400 has its masses distributed so that the position of its centre of gravity is between the driving wheel 431 axis 432 and the electromagnet 200, but much closer to the driving wheel axis 432.
In this way the radial force acting on the balancing unit 400 is transferred to the outer race 331 mostly through the driving wheel 431, while the remaining force fraction is transferred by the electromagnet 200 contacting surface 240. The resulting friction coefficient between the balancing unit 400 and the outer race 331 can be calculated as the sum of the wheel 431 rolling friction and the electromagnet sliding friction.
Because the largest part of the centrifugal force is transferred through the wheel 431, it can be configured to minimise its rolling friction coefficient keeping the balancing unit friction at high drum speed as low as possible.
For example the driving wheel 431 could be made of hardened steel and the outer race 331 could be formed by a steel sheet providing a possible coefficient of rolling friction c=0, 1 mm. While the electromagnet sliding friction Ks, assuming steel material for its core 240, could have a range of values Ks=0, 2-0, 5.
Moreover the position the balancing unit 400 could be designed to have its resulting centre of gravity at a position that ensures that the centrifugal force transferred by the electromagnet 200 to the outer race 331 is much smaller, for example 1/20 smaller, than the force transferred by the driving wheel 431.
The resulting balancing unit friction coefficient could be, calculated the weighting the force sharing Fc=0, 95*Kr+0, 05 Ks given by the contributions of the wheel 431 rolling friction Kr and the maximum actuator static friction Ks.
On the basis of the above assumptions, if the driving wheel 431 has 10 mm radius, we could have Kr=0, 1 mm/10 mm=0, 01 and the resulting balancing unit friction coefficient would be Kc=0, 95*0, 01+0,05*0,5=0, 0095+0, 025=0, 0345.
The friction force F acting between the balancing unit 400 and outer race 331 could be F=Kc*Fc+Ks*Fm, where Fc is the radial force acting on the balancing unit and Fm is the magnetic force acting between the outer race 331 and the electromagnet 200 when its coil 250 is powered.
At low rpm in order to block the balancing unit movement the the magnetic force must be grater than the gravitational force. It means that enough current must be supplied to the electromagnet 200 to ensure that the balancing stays attached to the outer race 331 and it does not slide on its surface. Assuming a worst case Ks=0, 2 it would require 0,2 *Fm>M*g where M is the balancing unit mass and g is the gravity acceleration constant, i.e. Fm>5*m*g, a magnetic force 5 times higher than the gravitational force. In this condition the balancing unit is blocked at its position.
During the drum 50 rotation period by stopping, with a proper timing, the supplied current to the electromagnet 200, the gravitational force can move the balancing unit in the desired direction.
The balancing unit 400 is equipped inside the body 410 with receiver coils 630. The balancing unit receiver coils 630 are wound around a cylindrical ferrite core extending in radial direction, perpendicular to the drum axis 51.
A front view of the transmitter coil 620 is shown in
The position configuration between the transmitter coil 620 and the balancing unit receiver coils 630 ensures a constant magnetic coupling when the drum 50 is rotating or the balancing units 400 move in the housing 500 facing the transmitter coil 620 winding. The constant magnetic coupling ensures a continuous wireless electric power transfer from the transmitter coil 620 fixed on the tub 30 to the balancing units 400 in the housing 500.
On the transmitter coil winding 620, as shown in
As shown in the block diagram of
The local controller 710 can also change the transmitter coil 620 resonance frequency by selecting compensating capacitors 723 with switches 721.
In the balancing unit 400, as shown in the block diagram of
The balancing units have receiver coils resonating at different frequencies. The local controller 710 by changing the generator 725 operating frequency can select the balancing unit resonance frequency to power its electromagnet 200 and the parking actuator 201.
The local controller 710 can set the power transferred to the two balancing units by multiplexing the duration times tm1 and tm2 when the generator 725 output frequency operates at the two balancing units resonance frequencies. The multiplexing time frequency 1/tm is much lower than the average resonance frequencies F1 and F2 of the balancing units receiver coils, 1/tm<<(F1+F2)/2. For example F1=200 KHz, F2=220 KHz and 1/tm=1 KHz. In each tm time slot the appliance controller can set within the time range tm>t>0 the times tm1 and tm2 lengths when the generator 725 is active for the selected frequencies F1 and F2.
The resonant current induced in the receiver coils 630 by the electromagnetic coupling with the transmitter coil 620 generates a voltage at the detection coils 621622 series output when the balancing unit 400 is in their proximity. It allows the detection of the balancing units passage.
The appliance manager (not shown) through the local controller 710 can change the balancing units 400 positions based on unbalance sensors (not shown) information to effectively balance the drum 50.
The appliance manager can leverage the action of the gravitational and inertial forces acting on the balancing units to change their positions. It can enable the selected balancing unit movement with a proper timing by stopping the power transferred to its electromagnet 400 that normally brakes it.
At low drum rpm, for example in washing, the balancing units parking actuators 201 movable parts have their extension pin 241 in the inner race openings 352.
The appliance manager (not shown) to perform the spinning cycle first increases the drum speed until the laundry is satellized, said s1 this drum rpm speed. The parking actuators 201 springs 221 are configured to ensure that at this speed s1 their force is higher than the centrifugal force acting on the movable ferromagnetic part 231.
The two balancing units 400 and 400 are kept opposite each other in the parking actuators defined positions as shown in
In
The balancing process changing the balancing units positions is performed keeping the drum 50 first rotation speed s1 constant.
The first time diagram 810 shows the detection pulses 812 and 813 associated to the balancing units passage at the detection coils 620621 position. The appliance manager receives a reference periodical pulse 811 generated each drum turn rotation time period 814 when a reference point on the drum is aligned with a reference position on the tub.
The appliance manager based on this timing information can calculate the balancing units positions with respect to the drum reference position and knows the unbalance position from his interna sensing function.
The appliance manager knowing the relative positions of the balancing units with respect to the unbalance 80 can calculate the new balancing units positions that can balance the drum 50.
At the satellization speed s1 the gravitational force acts to move the balancing units each drum rotation turn back and forward with respect the drum rotation direction.
The appliance manager by enabling the balancing unit movements, with the proper timing within the drum turn, can change in steps their positions leveraging the action of the gravitational force.
The time diagrams 820 and 830 respectively shown the average power levels 821 and 831 transferred to the two balancing units 400.
By transferring power to the two balancing units 400 the parking actuators 201 extension pins 241 are retracted from the inner race openings 352. At the same time the attraction forces Fm between the electromagnets 200 and the outer race 331 keep the balancing units blocked at their positions. The attraction force depends on the average power supplied to the electromagnets coils 250 that can be regulated by changing within the multiplexing period tm, the time duration tm1 and tm2 when the generator 725 output frequency is respectively F1 and F2.
The appliance manager reduces the average transferred power 831 to the selected balancing unit to be moved. The parking actuator 201 is configured so that, once its ferromagnetic part 231 has moved retracting its pin 241, a certain hysteresis behaviour and the reduced power are enough to keep the pin 241 in the retracted condition.
The power reduction pulse 832 starts at the time 833 until the time 834, the time interval where the enabled balancing unit moves under the action of the gravitational force in the desired direction. To reduce the average power to the moved balancing unit, which has in this case the receiver coils resonant frequency F2, the time slot 844 duration associated to the frequency F2 is reduced. While the average power transferred to the balancing unit with resonance frequency F1 is kept constant not having changed its time slot duration.
The time diagram 840 shows in a zoomed time scale, in detail, the transition at the instant of the start of the average power reduction 833. After the pulse reduction start 833 the F2 time slot duration 841 is reduced. The appliance manager after the pulse power reduction 832, in the next drum turn, can evaluate the new balancing unit position using the pulse 812 detecting its passage at the detection coils 620621 positions. Repeating iteratively the described positioning steps, the appliance manager, as shown in
A big advantage of using an electromagnet as brake is the possibility the adjust the resulting balancing unit movement changing the average power transferred that changes the braking force effect of the electromagnet current.
In a second embodiment the electromagnet 200 could have a permanent magnet (not shown) that magnetise its core 240. The electromagnet with permanent magnet has also a coil 250 wound around the core 240. The coil 20 magnetic field, when powered, generates an opposite magnetic canceling the permanent magnet field. In this embodiment when both electromagnets coils are not powered the magnetic force can keep the balancing units blocked at their positions.
It means that in washing the balancing units cannot move; if at the end of each spinning cycle the appliance manager position them opposite each other, the parking actuator (201) function is not needed. To move one balancing unit the appliance manager in this embodiment needs to power its electromagnet by transferring power at its receiver coils resonance frequency.
In both embodiments the appliance manager by changing the generator 725 time slot 841 duration for the selected resonance frequency can change the balancing unit braking force, result of the average power transfer change. It permits a fine tuning of the balancing unit movement step, where, while keeping the drum rotation speed constant, the movement in the half drum rotation period can be adjusted by the braking force reduction amplitude and duration.
Number | Date | Country | Kind |
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102021000024053 | Sep 2021 | IT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2022/075986 | 9/19/2022 | WO |