Patent Grant
8578532
A laundry treating appliance is a common household device for treating articles in accordance with a treating cycle, and includes clothes washing machines and clothes dryers. A clothes washing machine cleans loads of articles, such as clothing and other fabric items, in accordance with a preprogrammed wash cycle.
For automatic washers, there are three primary sources of cleaning action: mechanical action, chemical action, and thermal action. All other things being equal, any change in one or more of these actions requires a corresponding offsetting change in the other actions to obtain the same degree of cleaning effectiveness.
Automatic washing machines can generally be categorized as horizontal axis machines or vertical axis machines. Horizontal axis machines are sometimes referred to as “front loaders” and comprise a perforated drum located within an imperforate tub, with the drum rotating about a generally horizontal axis, although the axis can be canted relative to the horizontal.
Vertical axis and horizontal axis machines differ in the manner in which they impart mechanical energy to the laundry. Vertical axis machines tend to use an impeller or agitator that directly impacts the laundry to impart mechanical energy. Horizontal axis machines impart mechanical energy primarily by the tumbling of the articles in the drum as the drum rotates.
The different manners for imparting mechanical energy results in different operational consequences. One consequence is that horizontal axis machines impart much less mechanical energy to the laundry than vertical axis machines. Another of which is that it is practical to determine the amount of mechanical energy imparted in a vertical axis machine and impractical to determine in a horizontal axis machine. The direct contact of the impeller/agitator to the laundry to impart the mechanical energy in a vertical axis machine as compared to the tumbling of the laundry in a horizontal axis machines provides for direct sensing through the forces of the impeller/agitator as a means for determining the imparted mechanical action forces, which is not possible with the horizontal axis machines.
The invention relates to a laundry treating appliance and a method of operating a laundry treating appliance based on the mechanical energy due to the falling action of the laundry.
In the drawings:
Referring now to the figures,
Washing machines are typically categorized as either a vertical axis washing machine or a horizontal axis washing machine. As used herein, the “vertical axis” washing machine refers to a washing machine having a rotatable drum that rotates about a generally vertical axis relative to a surface that supports the washing machine. In some vertical axis washing machines, the drum rotates about a vertical axis generally perpendicular to a surface that supports the washing machine. However, the rotational axis need not be perfectly vertical or perpendicular to the surface. The drum can rotate about an axis inclined relative to the vertical axis. As used herein, the “horizontal axis” washing machine refers to a washing machine having a rotatable drum that rotates about a generally horizontal axis relative to a surface that supports the washing machine. In some horizontal axis washing machines, the drum rotates about a horizontal axis generally parallel to a surface that supports the washing machine. However, the rotational axis need not be perfectly horizontal or parallel to the surface. The drum can rotate about an axis inclined relative to the horizontal axis, with fifteen degrees of inclination being one example of inclination.
Vertical axis and horizontal axis machines can be differentiated by the manner in which they impart mechanical energy to the load. In vertical axis machines, an article moving element moves within the drum to impart mechanical energy directly to the load or indirectly through wash liquid in the drum. In horizontal axis machines, mechanical energy is typically imparted to the load by tumbling the load resulting from rotating the drum. The tumbling involves repeated lifting and dropping of the articles in the load. The illustrated washing machine 10 of
The drum 18 may be coupled with a motor 26 having a stator 27 and a rotor 28 through a drive shaft 30 for selective rotation of the treating chamber 22 during a cycle of operation. The motor 26 may rotate the drum 18 at various speeds in either rotational direction. Both the tub 14 and the drum 18 may be selectively closed by a door 32. A bellows 34 couples an open face of the tub 14 with the cabinet 12, and the door 32 seals against the bellows 34 when the door 32 closes the tub 14.
A controller 70 may be coupled with various working components of the washing machine 10 to control the operation of the washing machine 10. The controller 70 can be operably coupled to a control panel 36 with a user interface provided on the exterior of the cabinet 12 that may include one or more knobs, switches, displays, and the like for communicating with the user, such as to receive input and provide output.
While the illustrated washing machine 10 includes both the tub 14 and the drum 18, with the drum 18 defining the laundry treatment chamber 22, it is within the scope of the invention for the laundry treating appliance to include only one receptacle, with the receptacle defining the laundry treatment chamber for receiving the load to be treated.
The washing machine 10 of
The liquid supply and recirculation system may further include one or more devices for heating the liquid such as a steam generator 62 and/or a sump heater 64. The steam generator 62 may be provided to supply steam to the treating chamber 22, either directly into the drum 18 or indirectly through the tub 14 as illustrated. The valve 46 may also be used to control the supply of water to the steam generator 62. The steam generator 62 is illustrated as a flow through steam generator, but may be other types, including a tank type steam generator. Alternatively, the heating element 64 may be used to generate steam in place of or in addition to the steam generator 62. The steam generator 62 may be controlled by the controller 70 and may be used to heat to the load as part of a treating cycle, much in the same manner as heating element 64. The steam generator 62 may also be used to introduce steam to treat the load as compared to merely heating the load.
Additionally, the liquid supply and recirculation system may differ from the configuration shown in
Referring now to
Many known types of controllers may be used for the controller 70. The specific type of controller is not germane to the invention. It is contemplated that the controller is a microprocessor-based controller that implements control software and sends/receives one or more electrical signals to/from each of the various working components to effect the control software. As an example, proportional control (P), proportional integral control (PI), and proportional derivative control (PD), or a combination thereof, a proportional integral derivative control (PID control), may be used to control the various components.
The washing machine 10 may perform one or more manual or automatic treating cycles, and a common treating cycle includes a wash phase, a rinse phase, and a spin extraction phase. Other phases for treating cycles include, but are not limited to, intermediate extraction phases, such as between the wash and rinse phases, and a pre-wash phase preceding the wash phase, and some treating cycles include only a select one or more of these exemplary phases. In a horizontal axis washing machine, the drum may be rotated during any one of these phases to effect tumbling of the articles making up the load. In particular tumbling may be combined with a wash phase to create a tumble wash phase. Regardless of the phases employed in the treating cycle, the methods described below may relate to determining an optimized rotational speed.
Before specific embodiments of the methods are presented, a description of theory behind the methods may be constructive. In a washing machine, the articles making up the load are cleaned by three main sources of energy: chemical, thermal, and mechanical. Referring to
The tumbling motion of the articles 82 is irregular. For example, some articles 82 may fall during one rotation of the drum 18 and not the next due to tangling or twisting of the articles 82. Each lifting/falling action changes the load on the motor 26 (
One challenge in using the motor torque signature to identify falling action is that a load imbalance will also create a variation in the motor torque signature. Thus, it is necessary to distinguish motor torque variations caused by falling action, and those attributable to load imbalance. Distinguishing between load imbalance and falling action becomes more difficult for larger loads, since there may be little or no falling action because the drum 18 is more packed.
It has been found that a more sinusoidal motor torque signature indicates a load imbalance, rather than falling action, which is non-sinusoidal.
One way to distinguish between sinusoidal and non-sinusoidal waveforms is by determining the crest factor of the waveform. The crest factor, or peak-to-average ratio (PAR), is a measurement of a waveform, calculated from the peak amplitude of the waveform divided by the RMS (time-averaged) value of the waveform, and can be expressed by the following equation:
The crest factor is minimum for a sinusoidal wavefrom, and increases as a waveform becomes more non-sinusoidal; thus, a larger crest factor indicates that there is falling action of the articles and the relative magnitude of the crest factor is indicative of the relative amount of falling action.
The method of the invention can use the crest factor of the motor torque signature to distinguish between load imbalance and falling action. If the crest factor indicates that there is falling action, then the motor torque signature can be used to determine the degree of mechanical falling action being transferred to the articles in the drum. This can be estimated or inferred from the area underneath the motor torque signature waveform. The area can be viewed as a measurement system for the mechanical energy due to falling action imparted to the articles.
This measurement system can be used to control the rotational speed of the drum to control the amount of mechanical energy imparted by falling action to the laundry. For example, if it is desired to maximize the amount of mechanical energy, the rotational speed can be varied, e.g. increased or decreased, until the crest factor has been maximized. When the crest factor is maximized, the mechanical energy due to falling action being imparted to the articles is also maximized. Maximizing the mechanical energy may be useful to shorten the cycle time or when the laundry is of a more robust material. However, the amount of mechanical energy may be controlled to ensure lesser amounts of mechanical energy are imparted to the laundry, such as when the laundry is of a more delicate fabric.
This measurement system can also be used to determine when to terminate the treating cycle. For example, the mechanical energy due to falling action can be measured over time and, when the accumulated mechanical energy (area under the motor torque signature waveform) due to falling action has reached a predetermined value, a phase of the treating cycle or the entire treating cycle can be terminated. The predetermined value may be the minimum amount of mechanical energy due to falling action that sufficiently cleans the articles. Thus, this method optimizes the treating cycle to achieve a good cleaning performance while minimizing wear on the articles. Each treating cycle or each treating cycle phase may be provided with a predetermined mechanical energy that, when satisfied, may be used alone or in combination with other parameters to terminate the treating cycle or treating cycle phase.
The method 90 may begin with at 92 with rotating the drum 18. Rotating of the drum 18 may occur subsequent to or simultaneously with wetting of the load by the liquid supply and recirculation system (
At 94, a determination of a cumulative value indicative of cumulative mechanical energy due to falling action may occur subsequent to or simultaneously with the rotating of the drum 18 by the motor 26 at 92. The cumulative value can be determined by determining a crest factor of a motor torque waveform for the motor 26 rotating the drum 18. As discussed above, this helps distinguish between falling action and a load imbalance. If the crest factor indicates that there is falling action of the articles, then the area beneath the motor torque waveform for the motor 26 can be used to determine the degree of mechanical falling action being transferred to the articles in the drum. This area or the degree of mechanical falling action determined from the area can be accumulated or summed over time to determine the cumulative value. The determination of the cumulative value can be carried out by the controller 70.
At 96, the cumulative value determined at 94 is compared with a predetermined threshold value. The threshold value is a reference value to compare with the cumulative value to determine whether to terminate at least a portion of the treating cycle. The threshold value may be a desired value of mechanical energy to impart to the laundry during the treating cycle.
The threshold value may be a function of at least one a laundry type and a load size, either of which can be a quantitative or qualitative value. One example of quantitative laundry type is the article's material, such as cotton, silk, or polyester. Examples of qualitative laundry type are delicates, permanent press, or heavy duty. Examples of quantitative load sizes are the mass, volume, or surface area of the load, or the number of articles making up the load. Examples of qualitative load sizes are extra-small, small, medium, large, or extra-large.
The threshold value may be predetermined, or may be determined for each load or treating cycle. For the later case, the threshold value may be automatically determined for the load, or may be manually set by the user. For the former case, the controller 70 may be loaded with one or more predetermined threshold values during manufacture.
The comparison may be carried out by the controller 70 and may be based on a predetermined relationship between the cumulative value and the threshold value. Based on the comparison, the method 90 may return to 94 to determine the cumulative value again, or may terminate at least a portion of the treating cycle. One example of a predetermined relationship is illustrated at 98 and 100. If it is determined that the cumulative value is below the threshold value, as shown at 98, the method 90 returns to 94. If it is determined that the cumulative value is at or above the threshold value, as shown at 100, the method 90 continues to 102, and at least a portion of the treating cycle is terminated.
Termination of at least a portion of the treating cycle may entail terminating a treating phase of the treating cycle, such as a tumble wash phase, or may entail terminating the treating cycle entirely. Termination of at least a portion of the treating cycle may alternately entail setting the duration of a treating phase or the treating cycle.
While not illustrated as part of the method 90, the cumulative value determined at 94 may be used to determine an operating rotational speed of the drum 18. If the cumulative value is determined from the crest factor, the rotational speed can be varied until the crest factor has been maximized, at which speed substantially maximum mechanical energy is imparted to articles in the load. The crest factor can also be determined for rotational speeds other than the maximum mechanical energy. It is contemplated to select a rotation speed less than, such as a percentage of, the rotational speed associated with the maximum crest factor. It is also contemplated to create a crest factor versus rotational speed profile for a given laundry load and to select the most advantageous rotational speed for a given load based on the profile.
It should be noted that while this description is written in absolute terms, such as determining the maximum crest factor, in practice, it is likely and often unnecessary to determine the absolute value of any parameter or value described. For example, it is contemplated that digital sampling techniques will be used, which may well miss the absolute maximum crest factor. However, the maximum crest factor as determined under such techniques will be close enough for a practical application of the invention.
The method 110 may begin at 112 by setting a rate of mechanical energy due to be transmitted to the load by falling action. The rate may be set by the user through the one or more user inputs using the user interface 36, such as by the selection of a treating cycle. From the user input, the rate may be automatically determined by the controller 70. The controller 70 may store different rates associated with particular treating cycles or a particular combination of user inputs, or may have a scheme for calculating the rate from the user input. The rate may be a function of at least one a laundry type and a load size, either of which can be a quantitative or qualitative value as described above. For example, if the user selects a ‘delicate’ treating cycle, the rate may be lower than if the user selected a ‘heavy duty’ treating cycle, since ‘delicate’ article are more subject to wear than ‘heavy duty’ articles.
The rate can be one that substantially maximizes the mechanical energy transmitted to the articles, such as through falling action of the articles as the drum 18 is rotated. By maximizing mechanical energy, the duration of the treating cycle or a portion of the treating cycle may be reduced since articles may be cleaned in less time.
At 114, a rotational speed S for the drum 18 is determined based on the rate set at 112. The rotational speed S may be a speed suitable to induce tumbling of the load wherein the load is subject to falling action. The rotational speed S can be determined by determining a crest factor of a motor torque waveform for the motor 26 rotating the drum 18. By increasing or decreasing the rotational speed of the drum 18 until the crest factor is maximized, the mechanical energy due to falling action being imparted to the articles is also maximized. Thus, the rotational speed when the crest factor is maximized can be considered a maximum mechanical energy rotational speed.
At 116, the drum 18 is rotated at the rotational speed S determined at 114. Rotation of the drum 18 may occur subsequent to or simultaneously with wetting of the load by the liquid supply and recirculation system (not shown). Rotation of the drum 18 may occur subsequent to or simultaneously with a particular treating phase of a treating cycle, such as a tumble wash phase.
In the washing machine 10 of
The method 120 may begin with at 122 with initiating rotation of the drum 18. The initial rotational speed may be one suitable to induce tumbling of the load. An exemplary initial speed is 25 RPM. Rotating of the drum 18 may occur subsequent to or simultaneously with the wetting of the load by the liquid supply and recirculation system (not shown). In the washing machine 10 of
According to one embodiment, the motor 26 rotates the drum 18 at the initial speed at a steady state for at least a portion of 122. For example, the drum 18 may rotate according to a constant speed setpoint, wherein the motor 26 is controlled to rotate the drum 18 according to a constant speed while the actual speed of the drum 18 fluctuates about the constant speed setpoint due to the rotation of the load in the drum 18 and imbalance in the load.
At 124, the current crest factor is determined from the waveform of the motor torque signature for the motor 26 operating to rotate the drum 18 at the initial speed.
At 126, the current crest factor is compared to a past crest factor. The past crest factor is the crest factor determined prior to the current crest factor, or is the previous current crest factor determined in the previous cycle though the method 120. In the first cycle through the method 120, the past crest factor is equal to zero.
If it is determined that the current crest factor is not greater than the past crest factor, the method 120 moves on to 128, in which the rotational speed of the drum 18 is decreased. The method 120 then returns to 124.
If it is determined that the current crest factor is greater than the past crest factor, the method moves on to 130 to determine if the rotational speed has been optimized. The rotational speed is considered to be optimized when the crest factor is maximized because this means that the mechanical energy due to falling action being imparted to the articles is also maximized. If it is determined that the rotational speed has not been optimized, the method 120 moves on to 132, and the rotational speed is increased.
If there is no past crest factor, i.e. past crest factor=0, as the case would be the first time the current crest factor is determined at 124, the method 120 will cycle through 130 and 132 to return to 124.
At 128 or 132, the rotational speed may be changed (i.e. increased or decreased) in predetermined increments. A preset scheme for increasing/decreasing the rotational speed may be programmed into the controller 70. For example, the rotational speed may be changed in smaller increments each time the method 120 cycles through 128 or 132.
The maximum crest factor can be determined by cycling through the method 120 until the a maximum crest factor is reached, or by cycling through the method 120 a preset number of times, i.e. a present number of drum rotational speed changes, that is estimated to reach the maximum crest factor within a certain degree of accuracy, for example ±5%. The estimation of the number of times the method must be cycled through to reach the maximum crest factor within a certain degree of accuracy may be predetermined based on empirical testing.
The rotational speed associated with the maximum crest factor may be used to control the rotational speed of the drum as desired, which may be considered the “optimum” for that particular treating cycle or treating cycle phase. In most cases, the actual rotational speed will be set to the rotational speed corresponding to the maximum crest factor to obtain the most mechanical energy imparted to the system because, all things being considered, horizontal axis machines input relatively small amounts of mechanical energy, even at their maximum. If the rotational speed has been optimized, the method 120 may end, or the method may return to 124. If the later is the case, at least 128 and 130 may be periodically run during the treating cycle to make sure rotational speed remains optimized.
One or more of the methods 90, 110, 120 discloses herein may be performed for or during a single treating cycle. For example, methods 90 and 120 could be combined such that the crest factor determination could be used to both determine when to terminate a portion of the treating cycle, as outlined in method 90, and to optimize rotational speed of the drum, as outlined in method 120. These two methods 90, 120 may easily work in together since one way of determining the cumulative value indicative of cumulative mechanism energy due to falling action, as required at 94 of method 90, is by determining crest factor, as done at 124 of method 120.
The embodiments of the method function to determine an optimum rotational speed that maximizes the mechanical agitation of the load. This can provide better article care and reduce wear on the articles since the exposure of the load to movement, heat, and treating chemistry is limited to the amount of time needed for optimum cleaning. Furthermore, the washing machine 10 may be more energy efficient since rotational speed is optimized.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3923889 | Schmeidl et al. | Dec 1975 | A |
| 4489455 | Spendel | Dec 1984 | A |
| 5166592 | Bashark | Nov 1992 | A |
| 6581230 | Weinmann | Jun 2003 | B2 |
| 6671915 | Bringewatt et al. | Jan 2004 | B2 |
| 20020029428 | Weinmann | Mar 2002 | A1 |
| 20040200008 | Weinmann | Oct 2004 | A1 |
| 20080115295 | Vadakkeveedu et al. | May 2008 | A1 |
| 20080157781 | Mason et al. | Jul 2008 | A1 |
| Number | Date | Country |
|---|---|---|
| 3436786 | Apr 1986 | DE |
| 19619603 | Nov 1997 | DE |
| 19849403 | May 2000 | DE |
| 10217009 | Oct 2003 | DE |
| 10316879 | Dec 2004 | DE |
| 102007057331 | Jun 2009 | DE |
| Entry |
|---|
| German Search Report for DE102010016454, Feb. 6, 2012. |
| Number | Date | Country | |
|---|---|---|---|
| 20110016738 A1 | Jan 2011 | US |
