Patent Grant
10184208
The invention relates to a laundry drying apparatus, in particular a dryer or a washing machine having drying function.
EP 2 516 719 B1 discloses a laundry dryer and a method for controlling a drying cycle in such a laundry dryer. The temperature of process air circulating within the dryer is controlled as a function of a parameter indicating the degree of humidity of the laundry placed in a drum of the dryer, wherein the process air temperature is reduced as laundry humidity decreases.
It is an object of the invention to provide an improved laundry drying apparatus and method.
A laundry drying apparatus is provided, in particular a dryer or a washing machine having drying function. The drying apparatus comprises a cabinet or housing, a control unit adapted to control a laundry drying cycle according to at least one drying program, a drum rotatably arranged within the cabinet for receiving laundry to be dried and a drying air channel adapted at least to guide drying air or process air into the drum. For example the drum may comprise a horizontal rotation axis (horizontal axis drum) or an inclined rotation axis (inclined axis drum), e.g. an axis inclination with respect to horizontal of 1 to 45°.
A heater unit is arranged at or in the drying air channel and is adapted to heat the drying air, wherein the heater unit comprises two or more heating levels. The control unit is adapted to control the heater unit to heat the drying air at a selected one of the two or more heating levels. For example the heating levels may include 0 (e.g. heater unit switched-off) and a first heating power level. Preferably three heating levels are provided: 0-level, first level and second level, wherein the first and second heating levels are preferably mutually different (i.e. not identical) and are not 0 (non-zero). The apparatus further comprises a temperature sensor unit which is adapted to detect the temperature of the drying air and to provide at least one temperature signal to the control unit. So it can be said that the control unit receives the at least one temperature signal from the temperature sensor unit to control the heater unit, wherein in turn for this control operation the control unit uses the selected or determined one of the two or more temperature threshold sets. Therein preferably the at least one temperature signal from the temperature sensor is compared to the temperature threshold values of the respectively or currently determined or selected temperature threshold set.
The control unit is adapted to select or determine and apply during the drying cycle one of two or more temperature threshold sets, wherein the two or more temperature threshold sets are used by the control unit for determining the heating level to be applied by the heater unit in dependency of the at least one temperature signal from the temperature sensor unit.
The control unit is adapted to select or determine one of the two or more temperature threshold sets in dependency of one or more operating parameters of the apparatus, wherein the temperature thresholds of the temperature threshold sets are mutually different or are not identical. The ‘condition’ that temperature thresholds of the temperature threshold sets are mutually different or are not identical includes the situation where in a first and second threshold set the upper (or lower) threshold value is the same but at least the lower (or upper) thresholds have different values. For example, in case each temperature threshold set comprises two thresholds, the threshold sets are not identical, wherein (i) one threshold of a first set may be the same as one threshold of a second set, or alternatively (i) both thresholds of the first and second set are different
During execution of the (selected) laundry drying cycle the control unit is adapted to select or determine one of the two or more temperature threshold sets in dependency of one or more of the following operation parameters:
The wording ‘in dependency of’ may include that if one or more or a combination of the above mentioned operation parameters reaches, exceeds or falls below a threshold for that/these or the combination of parameters. In general, the ‘or more parameters’ may mean a combination or any sub-combination of the listed parameters, e.g. combined in a mathematical formula having two or more or a plurality of variables (the operation parameters) or a look-up table using the two or more operation parameters.
Generally the control implemented by the control unit may be denoted as hysteresis-control(ler) using the selected or determined one of the temperature threshold sets.
Preferably the one or more operation parameters of the heater unit cited under b) include one or more of:
An abnormal situation or state of the heater unit may be detected if the heater unit is longer than a predetermined persistence time in the OFF state or in the ON state or at a fixed intermediate heating level without change.
Preferably, the electrical or mechanical parameter of the drum motor mentioned under c) is one or more of the motor current, the phase voltage, the consumed motor power, the phase of the voltage applied to the motor and the torque generated by the motor.
The heater unit may comprise at least three heating levels which comprise a non-heating (zero) level, a first heating level and a second heating level. The heating power at the first and second heating level is above 0 W, wherein the heating power of the second heating level is higher than the heating power of the first heating level. Alternatively or additionally the heater unit is an electrical resistivity heater unit which may comprise at least two resistivity heater elements. In this case a first heating level with a first heating power is provided by powering a first one of the resistivity heater elements and a second heating level with a second heating power is provided by powering a second one of the resistivity heater elements and/or the first and second resistivity heater elements. As an example for a multi-level heater unit, the heater unit may comprise two heater elements R1, R2 having different heating power, such that four heating levels may be achieved, namely 0 (zero=both heater elements switched-off), R1, R2, R1+R2.
In an embodiment when the heater unit has three or more heating levels (including zero), the switching ON or to a higher level includes switching to any one of the levels higher than the currently used level and/or the switching OFF or to a lower level includes switching to any of the levels lower than the currently used level. With exemplary levels R1<R2<R3
The laundry drying apparatus may be a condensate-type drying apparatus having a closed drying air loop comprising the drying air channel and the drum as a portion of the drying air loop, wherein a condensation unit is arranged in the drying air channel upstream the heater unit to dehumidify the process air before it is heated and supplied back to the laundry drum.
Preferably, the temperature sensor unit comprises at least one temperature sensor arranged to detect the drying air temperature at one or more of the following positions: downstream the heater unit and upstream the drum air inlet, downstream the drum air outlet, within a tub surrounding the drum and/or at the drum. For example a position at the drum is a surface forming a containment surface to the inner space of the drum. When for example the drying apparatus is a washer dryer which has a tub surrounding the drum, three temperature sensors may be provided a) at the drum inlet or upstream the drum, b) at the drum outlet or downstream the drum e.g. downstream the drum and upstream the condenser and c) in the tub, in particular in a space between the drum outer wall and the tub. For example the temperature sensor may be arranged at the fluid or washing liquid heater unit arranged in the tub (e.g. in the tub sump).
Apart from above preferred embodiments, the first temperature sensor may be positioned at any place along the drying air channel or drying air loop (e.g. inlet or outlet of the drum). A temperature sensor may even be positioned within or at a drum laundry receiving space. The drum air inlet may be provided at a drum mantle and/or at a drum rear wall. In particular, the drum rear wall may be integral part of drum, such that the rear wall rotates during drum rotation. Alternatively a stationary drum rear wall may be provided, such that the drum rear wall is fixed (or stationary during drum rotation). Preferably, the temperature sensor unit provides a combined temperature signal for judging the exceeding or falling below a temperature threshold. For example a combination of the drum inlet and outlet temperature, in particular the difference between inlet and outlet temperature.
Preferably, the control unit determining or selecting the one of the two or more temperature threshold sets in dependency of one or more operating parameters of the apparatus comprises that a storing element of the control unit stores at least two different predetermined temperature threshold sets and the control unit is adapted to select one of these predetermined temperature threshold sets in dependency of the one or more operating parameters. Alternatively the control unit determining or selecting the one of the two or more temperature threshold sets in dependency of one or more operating parameters of the apparatus comprises that a storing element of the control unit stores at least three different predetermined temperature thresholds and, in dependency of the one or more operating parameters, the control unit is adapted to select one of these predetermined temperature thresholds as the first lower temperature threshold and one as the second higher temperature threshold. According to a further alternative the control unit determining or selecting the one of the two or more temperature threshold sets in dependency of one or more operating parameters of the apparatus comprises that the control unit is adapted to determine one of the two or more temperature threshold sets by calculating at least one of the temperature thresholds for the next predetermined temperature threshold set to be applied on the basis of the one or more operating parameters.
Each one of the temperature threshold sets may comprise (i) a first higher temperature threshold used by the control unit for determining a drying air temperature state at which the heating power of the heater unit has to be set to a lower heating power, and (ii) a second lower temperature threshold used by the control unit for determining a drying air temperature state at which the heating power of the heater unit has to be set to a higher heating power. A temperature threshold set may comprise more than two thresholds, e.g. a third highest threshold at a high temperature at which a multi-level (three or more levels) heater unit is switched off or set to a very low heating power level; and additionally or alternatively a fourth lowest threshold at a lowest temperature at which the multi-level heater unit is set to the highest heating power.
According to a preferred embodiment, the control unit is adapted to select the one of the two or more temperature threshold sets independent of a detected laundry humidity or a current state of the laundry during execution of the laundry drying cycle.
In addition or alternatively the invention may provide the following apparatus and method:
Laundry drying apparatus, in particular dryer or washing machine having drying function, comprising:
a cabinet, a control unit adapted to control a laundry drying cycle according to at least one drying program, a drum rotatable arranged within the cabinet for receiving laundry to be dried, a drying air channel adapted at least to guide drying air into the drum, and a heater unit arranged at or in the drying air channel and being adapted to heat the drying air,
wherein the heater unit has two or more heating levels, and a temperature sensor unit adapted to detect the temperature of the drying air and to provide at least one temperature signal to the control unit,
wherein the control unit is adapted to control the heater unit to heat the drying air at a selected one of the two or more heating levels,
wherein during the drying cycle the control unit is adapted to control the heater unit using a selected one of two or more heater control subroutines and by applying at least one temperature threshold set for determining the heating level to be applied by the heater unit in dependency of the at least one temperature signal from the temperature sensor unit, and
wherein the control unit is adapted to select one of the two or more heater control subroutines in dependency of one or more of the following operation parameters:
a) the time or temporal progress of the laundry drying cycle,
b) one or more operation parameters of or for the heater unit,
c) an electrical or mechanical parameter of the drum motor,
d) a temporal gradient of the drying air temperature during execution of the laundry drying cycle,
e) an ambient temperature indicative for the temperature outside the apparatus cabinet or a temperature indicative of an apparatus component temperature.
f) a laundry parameter indicating the state or condition of the laundry received in the drum, and
g) a user selection of one of two or more different drying programs input by the user via an input unit of the apparatus.
In all of the above and below embodiments, preferably, during the drying cycle the control unit is adapted to control the heater unit using a selected one of two or more heater control subroutines by applying the selected or determined one of the temperature threshold sets, wherein the control unit is adapted to select one of the two or more heater control subroutines in dependency of one or more of the following operation parameters:
a) the time or temporal progress of the laundry drying cycle,
b) one or more operation parameters of or for the heater unit,
c) an electrical or mechanical parameter of the drum motor,
d) a temporal gradient of the drying air temperature during execution of the laundry drying cycle,
e) an ambient temperature indicative for the temperature outside the apparatus cabinet or a temperature indicative of an apparatus component temperature.
f) a laundry parameter indicating the state or condition of the laundry received in the drum, and
g) a user selection of one of two or more different drying programs input by the user via an input unit of the apparatus.
Generally, the selection of the heater control subroutine may be based on the same operation parameter(s) as the selection or determination of the temperature threshold(s) to be applied or may be based on totally different operation parameters or may be based on partially different operation parameters.
The operation parameter f) may be one or more of the following: the type of laundry, the starting humidity or targeted final humidity of the laundry, the humidity of the laundry, the laundry load, and the temperature of the laundry. Laundry load may refer to laundry volume and additionally or alternatively to laundry weight. The type, load, start or target humidity of the laundry may be determined based on a user selection or may be determined by the drying apparatus, i.e. by means of respective sensors of the apparatus.
Preferably, when a first heater control subroutine is executed by the control unit, the control unit is adapted to control the heater unit to change between a first and a second heating power level. When a second heater control subroutine is executed by the control unit, the control unit is adapted to control the heater unit to change between a first and a fourth or between a third and a fourth heating power level.
When the control unit changes the selected or determined temperature threshold set to be applied, it may concurrently change the heater control subroutine to be applied. Alternatively or additionally the control unit may change the selected or determined temperature threshold set independent or temporally independent of a change of the selected heater control subroutine. Preferably, the heater control subroutine is only changed if it was (previously) determined that another heater control subroutines has to be applied.
Preferably, the operation parameters a) to e) for selecting or determining the one of the two or more temperature threshold sets and/or the operation parameters a) to g) for selecting the one of the two or more heater control subroutines are in turn determined on the basis of one or more of the following parameters:
k) a drying program selector position;
l) a drying program options selected by a user;
m) the laundry type;
n) the laundry load;
o) the temperature of ambient where the drying apparatus is placed;
p) a temperature of the laundry drying apparatus;
q) the laundry weight;
r) the laundry humidity;
s) an electrical or mechanical parameter of a motor rotating the drum; and
t) an inertia of the drum.
With respect to parameter t), the drum inertia, it is estimated from an estimation unit, preferably provided by the control unit of the laundry drying apparatus, by monitoring the torque values provided by a motor control unit for controlling the drum and motor operation and speed. The estimation for drum inertia and the drum acceleration are based on the input values for the motor torque from the motor control unit. The moment of inertia Je determined as a function of the torque values itself. Estimating the drum inertia is explained in detail in EP 2 107 151 A1 to which reference is made. In particular paragraphs 0019 to 0024 therein are included in the present description by reference and with the requirement that what is disclosed in EP 2 107 151 A1 for a washing machine is fully applicable here for the laundry drying apparatus.
According to a preferred embodiment, subsequent to a first period of applying a first temperature threshold set and/or a first heater control subroutine or subsequent to a second period of applying a second temperature threshold set and/or a second heater control subroutine, for determining or selecting a second or third time the temperature threshold set to be used for heater unit control and/or for determining a second or third heater control subroutine, the respective operation parameters are determined on the basis of one or more of the following parameters:
Preferably, the control unit is adapted to select or determine—after having changed within the running drying cycle from applying a first set of temperature threshold set to a second temperature threshold set—a next temperature threshold set on one or more of the following operation parameters:
one or more of the operation parameters a) to e),
f) a laundry parameter indicating the state or condition of the laundry received in the drum, and
g) a user selection of one of two or more different drying programs input by the user via an input unit of the apparatus.
According to a method of controlling the temperature during a drying cycle in a laundry drying apparatus, in particular in an apparatus according to any of the above embodiments, the apparatus comprises: a cabinet, a drum rotatably arranged within the cabinet for receiving laundry to be dried, a heater unit for heating the drying air, wherein the heater unit has two or more heating levels for heating the drying air at a selected one of the two or more heating levels, and a temperature sensor unit for detecting the temperature of the drying air.
Specifically the method comprises the steps of: selecting or determining one of two or more temperature threshold sets, determining the heating level to be applied by the heater unit (6) in dependency of the at least one selected or determined temperature threshold set, and operating the heater unit at the determined heating level.
The temperature thresholds of the temperature threshold sets are mutually different or are not identical, and the one of the two or more temperature threshold sets is/are selected or determined in dependency of one or more of the following operating parameters of the apparatus:
As mentioned above, each one of the temperature threshold sets is used to control the heater power or temperature by comparing one or more or combined temperatures received from the temperature sensor unit to the at least two temperature thresholds given by each one of the temperature threshold sets.
Preferably the selecting or determining one of two or more temperature threshold sets is made permanently, repeatedly, periodically, in predefined intervals, and/or upon a change of one or more of the apparatus operation parameters (the ‘groups’ of parameters mentioned below). In an embodiment the conditions for changing the temperature threshold set changes at least upon at least one change of the threshold set. In an embodiment during the drying cycle the temperature threshold set is changed at least one, two or three times.
For the method and for the apparatus all embodiments and features are mutually applicable in any combination or sub-combination, i.e. any individual feature or combined features disclosed for the drying apparatus are also applicable for the method and vice versa.
Reference is made in detail to preferred embodiments of the invention, examples of which are illustrated in the accompanying figures, which show:
The following figures are not drawn to scale and are provided for illustrative purposes.
The condensate collector 30 is connected via a drain conduit 30, a drain pump 16 and a drawer pipe 38 to an extractable condensate drawer 40. I.e. the collected condensate can be pumped from the collector 30 to the drawer 40 which is arranged at an upper portion of the dryer 2 from where it can be comfortably withdrawn and emptied by a user. The dryer 2 comprises a control unit 4 for controlling and monitoring the overall operation of the dryer 2. As shown in
For example the heater unit 6 may be an electrical resistivity heater unit which comprises at least two resistivity heater elements. In this case a first heating level with a first heating power is provided by powering a first one of the resistivity heater elements and a second heating level with a second heating power is provided by powering a second one of the resistivity heater elements and/or the first and second resistivity heater elements. As an example for a multi-level heater unit 6, the heater unit 6 may comprise two heater elements R1, R2 having different heating power, such that four heating levels may be achieved, namely 0 (zero=all heater elements switched-off), R1, R2, R1+R2.
At least one temperature sensor 10a-c is provided to detect the temperature of the process air A. As shown in the example of
The heater unit 6 is driven through control unit 4 by detecting the process air temperature and activating the heater unit 6—or at least a heater element—when the detected process air temperature drops below a minimum temperature threshold (TMIN), and deactivating the heater unit 6—or at least a heater element—when the detected process air temperature gets higher than a maximum temperature threshold (TMAX). Thus, a so-called Hysteresis-control is applied.
Hysteresis values for controlling process air temperature may be changed during a drying cycle. Such change may involve changing just one of the two hysteresis values (TMIN/TMAX) or both values.
An operation parameter that determines a change of at least one of the process air temperature hysteresis thresholds so as to change the threshold set from a first set to a second set of thresholds, may be one or more of the following group I:
One or more of the operation parameters is detected during a drying operation. When the detected value of the operation parameter reaches a predetermined threshold, the process air temperature hysteresis threshold set is changed.
When process air temperature hysteresis threshold(s) are changed, a ‘heating power control logic’ for supplying heating power to the drying air may change at the same time or afterwards. Such change is operated to adapt the operation of the heater unit 6 to the new thresholds while avoiding too frequent activations of the heating device or a too slow ramp for reaching the new temperature thresholds.
In particular, a change in the ‘heating power control logic’ may be operated even before the process air temperature hysteresis threshold(s) change, i.e. independently from the change of the change of hysteresis threshold changes. This provides the advantage of adapting the energy consumption to a desired amount or regulating the drying cycle time.
The ‘heating power control logic’ controlling the heater unit 6 for supplying heating power to process air can be changed among a set of ‘heating power control logics’ based on one or more of the following group II:
‘Heating power control logic’ means the way of driving and regulating the heater unit 6 such that the heating power supplied to drying air by the heater unit 6 is comprised between a minimum and a maximum value (TMIN, TMAX). Such values can be selected between groups of values that the heater unit 6 can provide. For example the heater unit 6 as described above in form of an electric resistivity heater having two branches may be controlled using a first logic in which both branches are switched ON and OFF, or using a second logic in which a first branch is always ON and only the second branch is switched ON and OFF. The number of control logics available depends not only from the heating power amounts that the heater unit 6 can provide but also from the way in which such heating power amounts are supplied to drying air. The set, i.e. the number, of ‘heating power control logics’ selectable by a dryer control unit during a laundry drying cycle may be determined based on a parameter that may be selected among one or more of parameters indicated in Group III and IV below. For example, when a user selects a drying cycle, a specific group of heating power control logics may be assigned to that cycle by the control unit 4. The control unit 4 will change the heater unit 6 control from one control logic to another one based on comparison between the detected value of one or more operation parameters listed in Group II and specific thresholds assigned to the control unit 4. Assignment of such thresholds is described below.
It has to be noted that the change of at least one threshold of process air temperature hysteresis thresholds and the change of heating power control logic can be operated not only on the base of the same parameter or composition of parameters, but also based on different parameters or composition of parameters.
The threshold determined for the parameter, or group of parameters, causing a change of at least one of the process air temperature hysteresis thresholds may be the same, or not the same, as the threshold determined for the parameter, or group of parameters, causing a change of the ‘heating power control logic’. In this way, the change of at least one of the process air temperature hysteresis thresholds and the change of the ‘heating power control logic’ does not necessarily happen at the same time even in case they are modified based on the same parameter.
A first set of process air temperature hysteresis thresholds and/or ‘heating power control logics’ to be used in a first part of a drying cycle may be determined based on one or more of the parameters indicated in following group III:
A second or third set of process air temperature hysteresis thresholds and/or heating power control logics to be used in a second or third part of a drying cycle, subsequent to the first or second part of the same drying cycle, may be determined based on one or more of the following parameters indicated in following group IV:
The second process air temperature hysteresis thresholds set may be lower or higher than the first set.
For example, the third set may be lower than the first set but higher than the second set. In this way a too low threshold set change operated as first change may be compensated by means of a second change that will put the threshold set between the first set and the too low second set.
With the above described drying apparatus a drying cycle may be updated by means of a second threshold change, which determines whether the first change was appropriate or not in terms of activating/deactivating operations of the heater unit 6 (to reduce or minimize hardware stress), drying air temperature, drying speed/efficiency, energy consumption and overall drying time.
The following graphs relate to a laundry drying apparatus 2 as described above having a temperature sensor 10a for detecting drying air temperature at the drum inlet, and a heater unit in the form of an electrical resistivity heater 6 having at least two independently controllable heater elements or branches. The following
The graph shown in
As described above, the (selected) threshold set is changed during the drying cycle (periods I to III). As shown in
As shown in
When a maximum threshold value tOFF_ON_THR2 between switching the heater unit 6 OFF and ON is reached or exceeded, a third threshold set TMIN3/TMAX3 is selected for controlling the heater unit 6 during a third period III of the drying cycle. The minimum and maximum temperature values of the third threshold set are higher than the respective temperature values of the second threshold set.
This embodiment provides that the time or period between switching the heater unit 6 ON and OFF is maintained in a (time) frame which minimizes hardware stress and provides efficient heating.
In this embodiment, the detected operation parameter on which the selection of the threshold values depends is the temperature gradient ΔON_OFF. As shown in
When a maximum temperature gradient ΔON_OFF_THR2 is reached or exceeded, a third set of temperature thresholds TMIN3/TMAX3 is selected for controlling the operation of the heater unit 6. The minimum and maximum values of the third threshold set TMIN3/TMAX3 are lower than the respective values of the first threshold set TMIN1/TMAX1 and higher than the respective values of the second threshold set TMIN2/TMAX2.
In this embodiment, the detected operation parameter on which the selection of the threshold values depends is the power EOFF_ON. As shown in
When a maximum power EOFF_ON_THR2 is reached or exceeded, a third set of temperature thresholds TMIN3/TMAX3 is selected for controlling the operation of the heater unit 6. The minimum and maximum value of the third threshold set TMIN3/TMAX3 is lower than the respective value of the first threshold set TMIN1/TMAX1 and higher than the respective value of the second threshold set TMIN2/TMAX2.
This embodiment prevents that a first branch of the heater unit 6—which remains switched ON while the second branch is switched OFF—is overstressed. Thereby the service life of the heater unit 6 is increased. Additionally to changing the applied temperature threshold set, above described heating power control logic for the heater unit 6 may be changed in all above and below described embodiments to provide a more energy efficient operation of the heater unit 6.
In contrast to above embodiments of
| Number | Date | Country | Kind |
|---|---|---|---|
| 14178626 | Jul 2014 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2015/065432 | 7/7/2015 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2016/012228 | 1/28/2016 | WO | A |
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