Laundry treating appliances, such as clothes dryers may have several components that draw a high level of power from the power source to the appliance. These components may include the electric heating element and the airflow system of the clothes dryer. Sometimes, the power supply to homes and laundromats may be wired incorrectly so that the electrical power delivered to the clothes dryer may not be what is expected. Additionally, it may not be known if the home or the laundromat has 2-phase or 3-phase power available. If the power source type is not known or if the home or laundromat is wired incorrectly, the components of the clothes dryer may not perform as expected. A lower than expected power delivery to the electric heating element may result in the generation of less than optimal heat by the electric heating element, potentially leading to longer than expecting drying times.
The invention relates to a method of determining a voltage across an electric heating element in a clothes dryer supplied by AC mains (L1, L2, and N). L1 to N voltage and L2 to N voltage applied to the electric heating element are determined sequentially. A zero-crossing timing signal from the zero crossings of the L1 to N signal with the same frequency as the AC line frequency is generated and received by a controller. A peak time corresponds to a peak in the amplitude of the L2 signal applied to the electric heating element is determined and a time differential between the peak time and a zero-crossing from the zero-crossing signal is determined. A phase relationship between L1 and L2 is determined by matching the time differential to at least one time window indicative of an anticipated phase relationship and L1 to L2 voltage is determined based on the L1 to N voltage, L2 to N voltage, and the phase relationship.
In the drawings:
The present invention relates generally to determining the phase compensated L1 to L2 line voltage across an electrical heating element in a clothes dryer. More specifically, the L1 to L2 phase compensated line voltage is determined without any adding any additional hardware to a clothes dryer and without the ability to measure both the L1 to N line voltage and the L2 to N line voltage at the same time.
The power input via L1, L2 and N may be 2-phase power from local power utility companies and distributed throughout the house using standard household electrical wiring. The clothes dryer may be plugged into a wall socket (not shown) delivering sinusoidal alternating current (AC) with L1, L2 and N connections. The L1 and L2 lines may both be 120 V with frequency of 60 Hz, and a phase offset from each other by 180 degrees (π radians) for an L1 to L2 root mean square (RMS) voltage of 240 V. This may be the predominant power source in North America and parts of South America. Alternatively, the L1 and L2 lines may be 230 V sinusoidal with frequency of 50 Hz, and a phase offset from each other by 180° degrees (π radians) for an L1 to L2 RMS voltage of 460 V. This may be the predominant power source in Europe, most of Asia, Australia, Africa, and parts of South America. As a further alternative, the clothes dryer may receive three-phase power including L1, L2, L3, and N lines, where each phase is offset from the other by 120° (2π/3 radians).
Longer drying cycle times resulting from low power availability to the clothes dryer can result in customer dissatisfaction. For example, the consumer may have some expectations of drying times for a particular load based on sales information, advertisements, clothes dryer specifications, or sales demonstrations. If the clothes dryer consistently underperforms compared to the consumer's expectations, it may lead to customer frustration, potential return of the product, or poor consumer reviews. Additionally, the controller of the clothes dryer may predict an end of cycle time based on an assumption that the dryer is receiving the power that is expected form the power supply and the L1 and L2 power connections. If the clothes dryer is receiving less than the expected power from the L1 and L2 power connections, then the controller may consistently under predict the end of cycle times, again with the potential of customer frustration. As a result, it may be beneficial for the clothes dryer to determine the actual L1 to L2 phase and L1 to L2 phase compensated voltage. Such L1 to L2 voltage may be reported to the consumer or service personal by the clothes dryer to indicate if there is a potential issue with power supply to the clothes dryer. L1 to L2 voltage information would indicate if slow dry times are due to problems with the clothes dryer or with the supply of power to the clothes dryer. It may also be beneficial to use L1 to L2 voltage information to make more accurate predictions of drying times and time to the end of cycle. A method of determining the L1 to L2 phase compensated voltage without the addition of any hardware to the clothes dryer is disclosed.
An air inlet temperature sensor 44 may be located in fluid communication with the air flow system to detect the air inlet temperature. The air inlet temperature sensor 44 may be located at the air inlet 42 or anywhere else in the inlet conduit 38. An air outlet temperature sensor 48 may also be in fluid communication with the air flow system to detect the air outlet temperature. The air outlet temperature sensor 48 may be located at the air outlet 46 or anywhere else in the outlet conduit 62. The inlet temperature sensor 42 and the outlet temperature sensor 48 may be thermistors or any other known temperature sensing device. A moisture sensor 70 for detecting the presence of moisture in the laundry may be located within the drying chamber 34.
A controller 80 may be communicatively coupled to the various electronic components of the clothes dryer 10 including the electric heating element 40, the inlet temperature sensor 44, the outlet temperature sensor 48, the humidity sensor 70, the motor 54, and the blower 60 via electrical communication lines 90. The controller 80 may be a control board with a microprocessor, microcontroller, field programmable gate array (FPGA), application specific integrated circuit (ASIC), or any other known circuit for control of electronic components.
The clothes dryer 10 also includes power inputs including L1 line power (L1), L2 line power (L2), and neutral line (N). The power delivered through a combination of L1, L2, and N power all of the electrical components of the clothes dryer 10 and the delivery of the power to each component of the clothes dryer 10, such as the electric heating element 40 and the blower 60 is controlled by the controller 80.
From the electrical wiring diagram, it is seen that L1 voltage and L2 voltage can not be determined simultaneously with the voltage detection circuitry 150 at the heater relay return node 140. The circuit is configured so as to prevent an overload situation, which may arise when the motor 54 is stated at the same time as the heater. The power required to start the motor 54 is substantially higher than that required to run the motor after start. As a result, the voltages of L1 and L2 have to be sensed in sequence as each voltage is applied to the voltage detection circuitry 150. For example, during the start-up of the dryer cycle of operation, an opportunity may exist to measure the L2 and then the L1 voltage at the heater relay return node 140 as the L2 voltage and then the L1 voltage are sequentially present at the heater while the motor 54 is starting up, thus preventing excessive power draw by the clothes dryer 10. In addition, timing information for at least one of L1 and L2 must be available simultaneously with the peak timing information of the other of L1 and L2 to determine the phase difference between L1 and L2. A method to determine L1 and L2 in sequence and then to determine L1 and L2 timing information simultaneously thus extracting L1 to L2 phase information and L1 to L2 voltage using the controller 80 is disclosed herein.
Upon start-up of operation of the clothes dryer 10, it is important to note that due to the potential of excessive power draw, when the motor 54 is starting, the electric heating element 40 may not be simultaneously energized. Therefore, upon start-up, the motor start winding 130 and the motor main winding 134 may be energized by the controller 80 and during this time the electric heating element 40 may not be energized. As a result, the heater switch 124 of the centrifugal switch 120 is open when the motor start winding 130 and motor run winding 132 is energized. When the motor 54 achieves a critical speed the motor start winding 130 is de-energized by appropriately actuating the motor winding switch 122 so that the motor main winding 134 continues and at the same time the heater switch 124 closes. At this point, L2 is electrically connected to heater relay return node 140 as illustrated in the simplified electrical representation of
Although the L1 to N voltage and the L2 to N voltage is determined, the phase relationship between L1 and L2 is not known. To determine the phase relationship, the L1 connection to the L1 input node 106 of the controller 80 applied to the zero-cross circuit 104 generates a periodic L1 zero-crossing timing signal as depicted in the graph of
In this example, the three time windows are referenced to the falling edge of the L1 trigger signal t1 of
where Phase_Window is the phase relationship corresponding to the particular time window, and
f is the frequency of the power line.
Using the equation above, the 120° (2π/3 radians), 180° (π radians), and 240° (4π/3 radians) phase windows may be centered at 1.39, 4.17, and 6.94 ms, respectively, from the falling edge of the L1 trigger signal for a 60 Hz power source. In other words, t6-t1 may be 1.39 ms, t8-t1 may be 4.17 ms, and t10-t1 may be 6.94 ms. For a 50 Hz power source the three time windows may be centered at 1.67 ms, 5 ms, and 8.33 ms, for the 120° (2π/3 radians), 180° (π radians), and 240° (π radians) time windows, respectively. Since the controller can determine the frequency (50 or 60 Hz) at the zero-cross circuit 104, the center points of each of the windows may either be fixed assuming the incoming signal frequency or determined based on the measured frequency at the zero-cross circuit 104.
The width of the time windows may be predetermined to be a fixed temporal width based on the anticipated conditions or determined based on the frequency of the incoming line voltage. For example, the predetermined temporal width may be 2.78 ms, such that the 120° (2π/3 radians) time window extends from 0 to 2.78 ms, and the 180° (π radians) window extends from 2.78 ms to 5.56 ms, and the 240° (4π/3 radians) window extends from 5.56 ms to 8.34 ms after the falling edge of the L1 trigger signal at t1, for a 60 Hz power source. In such a case, the time windows are temporally abutting each other. Alternatively, there may be some temporal spacing between the three time windows. If a determination of the L2 peak is not made after the first falling edge of the L1 trigger at t1, then a determination may be made after the second falling edge of the L2 trigger at t3, with time windows (not shown) centered at t12, t13, and t14, corresponding to the 120° (2π/3 radians), 180° (π radians), and 240° (4π/3 radians) time windows, respectively. Repeated readings over multiple line voltage periods may be used to gain confidence in the determined phase relationship.
When the peak in the L2 voltage is being detected by the voltage detection circuit 150 at the heater relay return node 140, the heater relay 152 may be open. By doing so, the L1 signal may not interfere with the voltage detection circuit 150, while the L2 voltage is detected. The voltage detection circuit 150 may include an analog-to-digital converter (ADC) that provides time series voltage levels of L2 to N to the controller 80. The controller 80 in turn may take the time series voltage levels of L2 to N and do a point-to-point difference of the data and look for a near-zero difference in the time series of voltage levels to identify the L2 peak voltage and corresponding peak time. Alternatively, the controller 80 may perform a point-to-point difference of the time series of voltage levels and identify the peak value and the peak time by identifying when the point-to-point difference transitions from a positive number to a negative number. As an alternative, analog peak detection circuitry may be used to provide the controller 80 with the peak voltage timing.
Once the phase between L1 to L2 is known the peak voltage can also be determined. If the phase relationship between L1 and L2 is 180° (π radians), then the L1 to L2 voltage may be:
L1 to L2=(L1 to N)+(L2 to N)
If the (L1 to N) and (L2 to N) voltages were each determined to be 120 V, then the RMS voltage for an L1 to L2 phase relationship of 180° (π radians) may be 240 V. On the other hand, if the phase relationship between L1 and L2 is either 120° (2π/3 radians) or 240° (4π/3 radians), then the L1 to L2 voltage may be:
L1 to L2=0.866*((L1 to N)+(L2 to N))
If the (L1 to N) and (L2 to N) voltages were determined to be 120 V, then the RMS voltage for an L1 to L2 phase relationship of 120° (2π/3 radians) or 240° (4π/3 radians) may be 208 V.
Alternatively, the L1 to L2 information may be used by the controller 80 to alter the control of the clothes dryer, predict cycle drying times, or predict time to end of drying cycle. For example, if it is known that the electric heating element 40 is receiving less than the expected level of power, then the controller 80 may compensate for this by energizing the electric heating element 40 for longer periods of time compared to what it would do otherwise.
The sequence of steps depicted is for illustrative purposes only, and is not meant to limit the method 199 in any way as it is understood that the steps may proceed in a different logical or sequential order and different, additional, overlapping, or intervening steps may be included without detracting from the invention.
There are many uses for identifying L1 to L2 voltage. Among these are to identify reasons for the clothes dryer not performing to expectations, identify if the house or laundromat is wired incorrectly, provide better control of the components of the dryer including the heater and the airflow system, and predict more accurate total cycle times and time remaining to the end of cycle. If the power supply to the clothes dryer is wired incorrectly, or if less than expected power is delivered to the clothes dryer, dryer cycle times may be longer than if the power supply was wired correctly and the power levels were to specification. This may have an impact on consumer satisfaction of the clothes dryer, if the consumer believes that the clothes dryer is not performing to specification. It can also have an impact on revenue at a laundromat, where throughput of customers may be improved if a dryer cycle times can be reduced.
The method disclosed herein has the advantage of identifying a phase compensated L1 to L2 voltage, with only a single voltage detection circuit. This is performed by first determining the L2 to N voltage at a voltage detection node. Next L1 to N is determined at the same voltage detection node. After, detecting both L1 to N and L2 to N voltage, the phase between L1 and L2 is still required to know the L1 to L2 voltage. The phase may be determined by generating a zero-crossing trigger signal corresponding to L1 at one node of the controller and then monitoring the peak voltage of L2 relative to a point on the zero-crossing trigger signal from the voltage detection node. By determining the time of the peak of the L2 signal relative to a zero-crossing event of the zero-crossing timing signal, and determining if that timing signal falls within one of three time windows corresponding to the same zero-crossing event, the phase between L1 and L2 can be ascertained. This method may not require any additional hardware beyond hardware that is typically found on clothes dryers and therefore may be a low cost method of providing L1 to L2 voltage information.
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.
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