Patent Grant
10801154
The present subject matter relates generally to washing machine appliances, such as vertical axis washing machine appliances, and methods for controlling a spin cycle thereof.
Washing machine appliances generally include a cabinet that receives a tub for containing wash and rinse water. A wash basket is rotatably mounted within the tub. A drive assembly is coupled to the wash basket and configured to rotate the wash basket within the tub in order to cleanse articles within the wash basket. Upon completion of a wash cycle, a pump assembly can be used to rinse and drain soiled water to a draining system. Some washing machine appliances may also rotate the wash basket at a relatively high speed for a spin cycle to further drain or shed water from articles within the wash basket.
Washing machine appliances include vertical axis washing machine appliances and horizontal axis washing machine appliances, where “vertical axis” and “horizontal axis” refer to the axis of rotation of the wash basket within the tub. Vertical axis washing machine appliances typically have the tub suspended in the cabinet with suspension devices. The suspension devices generally allow the tub to move relative to the cabinet during operation of the washing machine appliance.
In conventional washing machine appliances, a spin cycle is often performed for a predetermined amount of time. The predetermined amount of time may be set, for instance, by a user or by selecting a specified load size or article type. However, such appliances and methods often fail to account for the variations in unique loads or collections of articles within a wash basket. For instance, it may be difficult to know in advance how an actual load (e.g., individual load) of articles provided by a user will be affected during a given washing operation. The provided articles may be a unique mixture of fabrics of varying volumes and mass. Moreover, it may be difficult for a user to guess what setting is appropriate for an individual load. Thus, a predetermined amount of time for a spin cycle may be inappropriate for certain loads.
Undesirable operation may result from an inappropriate spin cycle. For instance, if the spin cycle is too brief, the articles within wash basket will remain excessively wet (e.g., such that water continues to drip from the articles when removed from the washing machine appliance). If the spin cycle is too long, excessive energy may be expended by the washing machine appliance. In addition, undesired noise may be generated, especially if a pump assembly runs dry (i.e., continues to pump without any water or liquid to flow therethrough).
Accordingly, improved methods and assemblies for controlling basket spin (e.g., spin cycles) of a washing machine appliance are desired. In particular, it would be advantageous to provide methods and assemblies to monitor and influence basket spin based on one or more detected characteristics of an individual load.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one exemplary aspect of the present disclosure, a method of operating a washing machine appliance is provided. The method may include flowing a volume of liquid into a tub, and activating a drain pump to motivate at least a portion of the volume of liquid from the tub. The method may also include spinning a basket at a precursor rotation velocity while the drain pump is active, measuring movement of the tub during spinning the basket at the precursor rotation velocity, and determining the measured movement exceeds a movement threshold. The method may still further include spinning the basket at a successor rotation velocity in response to determining the measured movement exceeds the movement threshold, the successor rotation velocity being greater than the precursor rotation velocity.
In another exemplary aspect of the present disclosure, a washing machine appliance is provided. The washing machine appliance may include a tub, a basket, a nozzle, a measurement device mounted to the tub, a motor, a drain pump, and a controller. The basket may be rotatably mounted within the tub. The nozzle may be in fluid communication with the tub to selectively flow liquid thereto. The motor may be in mechanical communication with the basket to selectively rotate the basket within the tub. The drain pump may be in fluid communication with the tub to selectively motivate wash fluid therefrom. The controller may be operative communication with the measurement device, the motor, and the drain pump. The controller may be configured to initiate a washing operation. The washing operation may include flowing a volume of liquid into the tub, activating the drain pump to motivate at least a portion of the volume of liquid from the tub, spinning the basket at a precursor rotation velocity while the drain pump is active, measuring movement of the tub during spinning the basket at the precursor rotation velocity, determining the measured movement exceeds a movement threshold, and spinning the basket at a successor rotation velocity in response to determining the measured movement exceeds the movement threshold, the successor rotation velocity being greater than the precursor rotation velocity.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
It is noted that, for the purposes of the present disclosure, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”).
Turning now to the figures,
As shown, washing machine appliance 50 includes a cabinet 52 and a cover 54. In some embodiments, a backsplash 56 extends from cover 54, and a control panel 58, including a plurality of input selectors 60, is coupled to backsplash 56. Control panel 58 and input selectors 60 collectively form a user interface input for operator selection of machine cycles and features, and in certain embodiments, a display 61 indicates selected features, a countdown timer, and other items of interest to machine users. A lid 62 is mounted to cover 54 and is rotatable about a hinge (not shown) between an open position (not shown) may access to a wash tub 64 located within cabinet 52, and a closed position (shown in
As illustrated in
Generally, tub 64 includes a bottom wall 66 and a sidewall 68. Moreover, a basket 70 is rotatably mounted within tub 64. In some embodiments, a drain pump or pump assembly 72 is located beneath tub 64 and basket 70 for gravity assisted flow when draining tub 64. As would be understood, pump assembly 72 includes a pump 74 and a motor 76. In some embodiments, pump assembly 72, including motor 76, is mounted or attached to tub 64. For instance, pump assembly 72 may be fixed to tub 64 at bottom wall 66. A pump inlet hose or channel may extend from a tub outlet defined in tub bottom wall 66 to a pump inlet. A pump outlet hose 86 may extend from a pump outlet 88 to an appliance fluid outlet 90 and, ultimately, to a building plumbing system discharge line (not shown) in fluid communication with outlet 90.
Generally, wash basket 70 is movably disposed and rotatably mounted in tub 64 in a spaced apart relationship from tub side wall 68 and tub bottom 66. Basket 70 includes a plurality of perforations therein to facilitate fluid communication between an interior of basket 70 and tub 64.
In some embodiments, a hot liquid valve 102 and a cold liquid valve 104 deliver liquid, such as water, to basket 70 and tub 64 through a respective hot liquid hose 106 and cold liquid hose 108. Liquid valves 102, 104 and liquid hoses 106, 108 together form a liquid supply connection for washing machine appliance 50 and, when connected to a building plumbing system (not shown), provide a fresh water supply for use in washing machine appliance 50. Liquid valves 102, 104 and liquid hoses 106, 108 are connected to a basket inlet tube 110, and liquid is dispersed from inlet tube 110 through a nozzle assembly 112 having a number of openings therein to direct washing liquid into basket 70 at a given trajectory and velocity. A dispenser (not shown), may also be provided to produce a liquid or wash solution by mixing fresh water with a known detergent or other additive for cleansing of articles in basket 70.
In some embodiments, an agitation element 116, such as a vane agitator, impeller, auger, or oscillatory basket mechanism (or some combination thereof) is disposed in basket 70 to impart an oscillatory motion to articles and liquid in basket 70. In various exemplary embodiments, agitation element 116 may be a single action element (oscillatory only), double action (oscillatory movement at one end, single direction rotation at the other end) or triple action (oscillatory movement plus single direction rotation at one end, single direction rotation at the other end). As illustrated, agitation element 116 is oriented to rotate about a vertical axis 118.
Basket 70 and agitation element 116 are driven by a motor 120 through a transmission and clutch system 122. The motor 120 drives shaft 126 to rotate basket 70 within tub 64. Clutch system 122 facilitates driving engagement of basket 70 and agitation element 116 for rotatable movement within tub 64, and clutch system 122 facilitates relative rotation of basket 70 and agitation element 116 for selected portions of wash cycles. Motor 120 and transmission and clutch system 122 collectively are referred herein as a motor assembly 148.
Referring now to
Operation of washing machine appliance 50 is controlled by a controller 150 that is operatively coupled (e.g., electrically coupled or connected) to a user interface (e.g., user interface 58) located on washing machine backsplash 56 (
Controller 150 may include a memory (e.g., non-transitory storage media) and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with a washing operation or cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory (e.g., as software). The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 150 may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry, such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Control panel 58 and other components of washing machine appliance 50, such as motor assembly 148 and measurement devices 130 (discussed herein), may be in operative communication with controller 150 via one or more signal lines, shared communication busses, or wireless networks to provide signals to or receive signals from the controller 150. Optionally, a measurement device 130 may be included with controller 150. Moreover, measurement devices 130 may include a microprocessor that performs the calculations specific to the measurement of motion with the calculation results being used by controller 150.
In an illustrative embodiment, laundry items or articles are loaded into basket 70, and a washing operation is initiated through operator manipulation of control input selectors 60 (shown in
Referring now to
A measurement device 130 in accordance with the present disclosure may include an accelerometer which measures translational motion, such as acceleration along one or more directions. Additionally or alternatively, a measurement device 130 may include a gyroscope, which measures rotational motion, such as rotational velocity about an axis. A measurement device 130 in accordance with the present disclosure is mounted to the tub 64 (e.g., bottom wall 66 or a sidewall 68 thereof) to sense movement of the tub 64 relative to the cabinet 52 by measuring uniform periodic motion, non-uniform periodic motion, or excursions of the tub 64 during appliance 50 operation. Advantageously, measurement device 130 may be positioned or mounted along a common plane (e.g., defined by bottom wall 66) with pump assembly 72. During use, movement may be detected or measured as discrete identifiable components (e.g., in a predetermined plane or direction).
Optionally, a measurement device 130 may be or include an accelerometer, which measures translational motion (e.g., as an acceleration component), such as acceleration along one or more predetermined directions. Additionally or alternatively, a measurement device 130 may be or include a gyroscope, which measures rotational motion (e.g., as a rotation component), such as rotational velocity about a predetermined axis. Additionally or alternatively, a measurement device 130 may be or include an optical sensor, an inductive sensor, a Hall Effect sensor, a potentiometer, a load cell, a strain gauge, or any other suitable device capable of measuring, either directly or indirectly, translational or rotational movement of tub 64.
A measurement device 130 in accordance with the present disclosure can be mounted to the tub 64 (i.e. bottom wall 66 or a sidewall 68 thereof), the basket 70, or the cabinet 52, as required to sense movement of the tub 64 relative to the cabinet 52. In particular exemplary embodiments, such as when accelerometers or gyroscopes are utilized, the accelerometers or gyroscopes may be mounted to the tub 64.
In exemplary embodiments, a measurement device 130 may include at least one gyroscope or at least one accelerometer. The measurement device 130, for example, may be a printed circuit board which includes the gyroscope and accelerometer thereon. The measurement device 130 may be mounted to the tub 64 (e.g., via a suitable mechanical fastener, adhesive, etc.) and may be oriented such that the various sub-components (e.g., the gyroscope and accelerometer) are oriented to measure movement along or about particular directions as discussed herein. In certain embodiments, at least one measurement device 130 is mounted to bottom wall 66 or otherwise positioned in a plane parallel to the pump assembly 72.
Notably, the gyroscope and accelerometer in exemplary embodiments are advantageously mounted to the tub 64 at a single location (e.g., the location of the printed circuit board or other component of the measurement device 130 on which the gyroscope and accelerometer are grouped). Such positioning at a single location advantageously reduces the costs and complexity (e.g., due to additional wiring, etc.) of detecting or measuring movements to the tub 64 caused by the pump assembly 72, while still providing relatively accurate movement detection as discussed herein. Alternatively, however, the gyroscope and accelerometer need not be mounted at a single location. For example, a gyroscope located at one location on tub 64 can measure the rotation of an accelerometer located at a different location on tub 64, because rotation about a given axis is the same everywhere on a solid object such as tub 64.
As illustrated in
Turning to
As generally illustrated in
Turning to
Referring now to
As would be understood, although
Turning specifically to
At 320, the method 300 includes activating the drain pump or pump assembly to motivate at least a portion of the volume of liquid from the tub. As described above, the pump or impeller may be rotated by the motor to draw water or wash fluid from the tub. In some such embodiments, 320 follows 310 or another cycle, such as a wash cycle, rinse cycle, etc. Before 320, articles within the tub may be agitated prior to halting all movement (e.g., of the wash basket or agitator) within the cabinet and calibrating the measurement device.
At 330, the method 300 includes spinning the wash basket at a precursor rotation velocity (e.g., while the drain pump is active). In certain embodiments, 330 begins after activating drain pump (e.g., subsequent to the start of 320). In additional or alternative embodiments, spinning at 330 begins prior to the start of 320, but continues subsequent to the start of 320 (e.g., while the drain pump is active). During at least a portion of 330, the drain pump may continue to operate such that an impeller of the pump is rotated to motivate water from the tub. Generally, the precursor rotation velocity is a predetermined velocity [e.g., defined in rotations per minute (RPM)] for rotating the wash basket about rotation axis. Moreover, the precursor rotation velocity may be a sub-shedding velocity (e.g., above 5 RPM). In other words, the precursor rotation velocity may be a velocity at which articles within the wash basket would not be fully plastered to the sidewalls of the wash basket. In certain embodiments, precursor rotation velocity is less than 1000 RPM.
In optional embodiments, multiple precursor rotation velocities are provided. In some such embodiments, 330 includes spinning the wash basket at progressively higher precursor rotation velocities. As an example, three or more progressively higher precursor rotation velocities may be provided (e.g., 140 RPM, 450 RPM, 800 RPM). In some such embodiments, the wash basket spins at 140 RPM for a set period. The wash basket may then spin at 450 RPM for another set period. Subsequent to spinning at 450 RPM (and thereby subsequent to spinning at 140 RPM), the wash basket may spin at 800 RPM for yet another set period. Optionally, each of the set periods may include a predetermined span of time (e.g., in seconds). Additionally or alternatively, each of the set periods may be equal to each other.
At 340, the method 300 includes measuring movement of the tub. In particular, 340 is performed while the wash basket spins at the precursor rotation velocity or velocities (e.g., during at least a portion of 330 or 320). As described above, measured movement may have one or more components (e.g., rotation component or acceleration component) detected at a suitable measurement device, such as an optical sensor, an inductive sensor, a Hall Effect sensor, a potentiometer, a load cell, a strain gauge, a gyroscope, or an accelerometer. In turn, 340 includes receiving a measurement signal corresponding to movement of the tub as the wash basket spins at one or more of the precursor velocities. Optionally, a delay period (e.g., a predetermined span of time between 1 second and 10 seconds, such as 3 seconds) may be provided between the point at which a specific precursor velocity is reached and the point at which a measurement signal is received or transmitted from the measurement device. Thus, movement of the tub may not be measured until after the specific precursor velocity is reached and a delay period expires.
In certain embodiments, measured movement includes a tub acceleration component. The tub acceleration component may be measured during 330 based on an acceleration signal received from the accelerometer mounted to the tub with the measurement device. Additionally or alternatively, the accelerometer may be mounted on a common plane with the drain pump (e.g., a plane defined by the X-axis and Y-axis, as described above). For instance, both the accelerometer and drain pump may be mounted to the bottom wall of the tub.
In additional or alternative embodiments, measured movement includes a tub rotation component. The tub rotation component may be measured during 330 based on a rotation signal received from the gyroscope mounted to the tub with the measurement device. Additionally or alternatively, the gyroscope may be mounted on a common plane with the drain pump (e.g., a plane defined by the X-axis and Y-axis, as described above). For instance, both the gyroscope and drain pump may be mounted to the bottom wall of the tub.
At 350, the method 300 includes determining the measured movement at 340 exceeds a movement threshold. The determination of 350 may be made during an evaluation of the measured movement performed during at least a portion of 330. In other words, the determination of 350 may be made while the wash basket continues to spin or rotate at one or more of the precursor velocities.
In embodiments wherein measuring movement includes a tub acceleration component, the movement threshold may be or include a predetermined acceleration value. The determination at 350 may include comparing the tub acceleration component to the predetermined acceleration value. For instance, 350 may require that the tub acceleration component exceed the predetermined acceleration value.
In embodiments wherein measuring movement includes a rotation component, the movement threshold may be or include a predetermined rotation value. The determination at 350 may include comparing the rotation component to the predetermined rotation value. For instance, 350 may require that the rotation component exceed the predetermined rotation value.
At 360, the method 300 includes spinning the basket at a successor rotation velocity. In some embodiments, 360 is initiated in response to 350 (i.e., in response to determining the measured movement exceeds the movement threshold). Generally, the successor rotation velocity is greater or higher than the precursor rotation velocity (e.g., each of the precursor rotation velocities). For instance, the successor rotation velocity may be a velocity at which articles within the wash basket would be fully plastered to the sidewalls of the wash basket. In certain embodiments, the successor rotation velocity is equal to or greater than 1000 RPM.
In some embodiments, method 300 may include repeatedly evaluating measured movement. For instance, measurements of movement made by the tub while the wash basket spins at the precursor velocity or velocities may be compared to the movement threshold repeatedly, such as in a closed loop (e.g., before 350). In some embodiments, the measured movement at 340 is not the first measured movement but a second (or later) measured movement. The method 300 may thus include determining that a measured movement (e.g., first or earlier measured movement) does not exceed the movement threshold prior to 350. In response, the precursor rotation velocity may be maintained. Movement may be subsequently measured (e.g., as a second or later measured movement) and again compared to the movement threshold. Moreover, the steps may be repeated, for instance, until 350 is met with a washing operation is otherwise halted.
Turning specifically to
At 420, the method 400 includes agitating articles within the tub (e.g., disposed within the wash basket) for a set period of time. Agitating may be performed by agitation element as discussed above. During such agitation (which is a sub-phase of the agitation phase of the wash cycle), the volume of liquid flowed into the tub in step 410 remains in the tub (e.g., no drainage of liquid may occur between steps 410 and 420). Optionally, the period of time for 420 is a defined period of time programmed into the controller, and may be dependent upon the size of the load of articles and other variables that may, for example, be input by a user interacting with control panel and input selectors thereof.
At 430, the method 400 includes halting movement within the cabinet of the washing machine appliance. In other words, the tub, wash basket, and agitator are prevented from moving. Thus, at 430 the agitation at 420 is stopped. However, the volume of liquid within the tub may remain. In certain embodiments, the measurement device mounted to the bottom of the tub is calibrated while the wash basket is halted. As would be understood, a zero rate or zero G-level bias at the measurement device may be offset.
At 440, the method 400 includes activating the drain pump or pump assembly to motivate at least a portion of the volume of liquid from the tub. As described above, the pump (e.g., impeller thereof) may be rotated by the motor to draw water or wash fluid from the tub.
At 450, the method 400 includes spinning the wash basket at a precursor rotation velocity (e.g., while the drain pump is active). In certain embodiments, 450 begins after activating drain pump (e.g., subsequent to the start of 440). In additional or alternative embodiments, spinning at 330 begins prior to the start of 320, but continues subsequent to the start of 320 (e.g., while the drain pump is active). The drain pump may continue to operate such that an impeller of the pump is rotated to motivate water from the tub. Generally, the precursor rotation velocity is a predetermined velocity [e.g., defined in rotations per minute (RPM)] for rotating the wash basket about rotation axis. Moreover, the precursor rotation velocity may be a sub-shedding velocity (e.g., above 5 RPM). In other words, the precursor rotation velocity may be a velocity at which articles within the wash basket would not be fully plastered to the sidewalls of the wash basket. In certain embodiments, precursor rotation velocity is less than 1000 RPM.
In optional embodiments, multiple precursor rotation velocities are provided. In some such embodiments, 450 includes spinning the wash basket at progressively higher precursor rotation velocities. As an example, three or more progressively higher precursor rotation velocities may be provided (e.g., 140 RPM, 450 RPM, 800 RPM). In some such embodiments, the wash basket spins at 140 RPM for a set period. The wash basket may then spin at 450 RPM for another set period. Subsequent to spinning at 450 RPM (and thereby subsequent to spinning at 140 RPM), the wash basket may spin at 800 RPM for yet another set period. Optionally, each of the set periods may include a predetermined span of time (e.g., in seconds). Additionally or alternatively, each of the set periods may be equal to each other.
At 460, the method 400 includes measuring movement of the tub. In particular, 460 is performed while the wash basket spins at the precursor rotation velocity or velocities (e.g., during at least a portion of 450 or 440). As described above, the measured movement may have one or more components (e.g., rotation component or acceleration component) detected at a suitable measurement device, such as an optical sensor, an inductive sensor, a Hall Effect sensor, a potentiometer, a load cell, a strain gauge, a gyroscope, or an accelerometer. In turn, 460 includes receiving a measurement signal corresponding to movement of the tub as the wash basket spins at one or more of the precursor velocities. Optionally, a delay period (e.g., a predetermined span of time between 1 second and 10 seconds, such as 3 seconds) may be provided between the point at which a specific precursor velocity is reached and the point at which a measurement signal is received or transmitted from the measurement device. Thus, movement of the tub may not be measured until after the specific precursor velocity is reached and a delay period expires.
In certain embodiments, measured movement includes a tub acceleration component. The tub acceleration component may be measured during 450 based on an acceleration signal received from the accelerometer mounted to the tub with the measurement device. Additionally or alternatively, the accelerometer may be mounted on a common plane with the drain pump (e.g., a plane defined by the X-axis and Y-axis, as described above). For instance, both the accelerometer and drain pump may be mounted to the bottom wall of the tub.
In additional or alternative embodiments, measured movement includes a tub rotation component. The tub rotation component may be measured during 450 based on a rotation signal received from the gyroscope mounted to the tub with the measurement device. Additionally or alternatively, the gyroscope may be mounted on a common plane with the drain pump (e.g., a plane defined by the X-axis and Y-axis, as described above). For instance, both the first and drain pump may be mounted to the bottom wall of the tub.
At 470, the method 400 includes evaluating measured movement. In particular, the measured movement (e.g., the tub acceleration component or the rotation component) is compared to movement threshold. Evaluation of 470 may be performed as the wash basket continues to spin at precursor rotation velocity. If measured movement does not exceed the movement threshold, movement may be measured again (i.e., the method 400 may return to 460). The precursor rotational velocity may be maintained. Optionally, 460 may be repeated (e.g., and a closed loop) such that subsequent movement measurements continue to be made as long as movement does not exceed movement threshold. If measured movement does exceed movement threshold, the method 400 may continue to 480.
At 480, the method 400 includes spinning the basket at a successor rotation velocity in response to the measured movement mixing the movement threshold at 470. Generally, the successor rotation velocity is greater or higher than the precursor rotation velocity (e.g., each of the precursor rotation velocities). For instance, the successor rotation velocity may be a velocity at which articles within the wash basket would be fully plastered to the sidewalls of the wash basket. In certain embodiments, the successor rotation velocity is equal to or greater than 1000 RPM.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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