LAUNDRY TREATING APPLIANCE WITH CONTROLLED OSCILLATING MOVEMENT
Disclosed is a laundry treating appliance having a drum and a torsionally flexible drive mechanism. The drum simultaneously rotates in a first rotational direction and oscillates about an axis of rotation.
A laundry treating appliance is a common household device for treating laundry in accordance with a preprogrammed treating cycle of operation. A subset of laundry treating appliances use a generally horizontally rotating drum to define a chamber in which the laundry is received for treatment according to the cycle of operation. The drum may be rotated at a predetermined speed in a predetermined direction as required by the cycle. Some laundry treating appliances may reverse and/or oscillate the direction of rotation in accordance with the preprogrammed cycle. The rotation of the drum may be used to impart mechanical action to the laundry, which may be attributable to the lifting and falling of the laundry as the drum is rotated and/or the relative sliding of individual laundry items.
The mechanical action associated with the horizontally rotating drum is relative low compared to other types of laundry appliances. Given that thermal action, chemical action, and mechanical action are the three primary sources of cleaning action for the laundry, a laundry treating appliance with a relatively low mechanical action will need to have greater thermal action and/or chemical action to obtain the same degree of cleaning.
BRIEF DESCRIPTION OF THE INVENTIONIn one aspect, the invention is a laundry treating appliance and a method of operating the laundry treating appliance, the appliance having a drum rotatable about an axis of rotation; an electric motor having a rotor; a torsionally flexible drive mechanism coupling the rotor with the drum such that rotation of the motor effects a rotation of the drum; and a controller operably coupled with the motor and configured to supply a control signal to the motor to effect a rotation of the drum comprising a simultaneous general rotation in a first rotational direction and a oscillation about an axis of rotation.
In the drawings:
Referring now to the figures,
For illustrative purposes, the different embodiments will be described with respect to a washing machine with the fabric being a laundry load, with it being understood that the invention may be used with other types of laundry treating appliances for treating fabric. The laundry treating appliance 1 may have a stationary tub 2, a drum 4 rotatable about an in at least one of rotational directions about an axis of rotation, an oscillation mechanism 6 rotationally oscillating the drum 4 about the axis of rotation and a motor 8 operably coupled with the drum 4 to rotate the drum 4 at various speeds in either a first rotational direction and a second rotational direction, opposite the first rotational direction. The oscillating mechanism 6 may be couple with the motor 8 and/or may couple the motor 8 with the drum 4. Shown configuration of the laundry treating appliance 1 oscillates the drum 4 about the axis of rotation while the drum 4 is being rotated at the predetermined operating speed.
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.
In the laundry treating appliance 1, the laundry is cleaned by three main sources of energy: chemical, thermal, and mechanical. Mechanical energy can further be divided into two components: clothes-to-clothes friction and the falling action associated with the tumbling of clothes due to the rotation of the drum 4. Depending on the various characteristics of the treating appliance 1, such as the size of the drum 4, the size of the laundry load, and the control signal, the rotation of the drum 4 may result in various types of laundry load movement inside the drum 4. For example, the laundry load may undergo at least one of tumbling, rolling (also called balling), sliding, satellizing (also called plastering), and combinations thereof. During tumbling, the fabric items in the drum 4 rotate with the drum 4 from a lowest location of the drum 4 towards a highest location of the drum 4, but fall back to the lowest location before reaching the highest location. The terms tumbling, rolling, sliding and satellizing are terms of art that may be used to describe the motion of some or all of the fabric items forming the laundry load. However, not all of the fabric items forming the laundry load need exhibit the motion for the laundry load to be described accordingly.
Referring now to
Referring now to
An automatic motor 18 may be coupled to the drum 14 via a drive shaft 32 to rotate the drum 14 at various speeds in either rotational direction. The motor 18 may be a direct drive motor, for example, a brushless permanent magnet (BPM) motor, an induction motor, a permanent split capacitor (PSC) motor, etc. Alternately, the motor 18 may be indirectly coupled with the drive shaft 32 via for example a belt, as is known in the art.
The washing machine 10 may further include a liquid supply and recirculation system. Liquid, such as wash aid, which is typically water, alone or in a mixture with other wash aids, may be supplied to the washing machine 10 from a water supply 40 in the case of water, such as a household water supply. A supply conduit 42 may fluidly couple the water supply 40 to a detergent dispenser 44. An inlet valve 46 may control flow of the liquid from the water supply 40 and through the supply conduit 42 to the detergent dispenser 44. A liquid conduit 48 may fluidly couple the detergent dispenser 44 with the tub 12. The liquid conduit 48 may couple with the tub 12 at any suitable location on the tub 12 and is shown as being coupled to a front wall of the tub 12 in
The liquid supply and recirculation system may further include one or more devices for heating the liquid; exemplary devices include sump heaters and steam generators. Additionally, the liquid supply and recirculation system may differ from the configuration shown in
A steam generator 45 may be provided to supply steam to the treating chamber 26, either directly into the drum 14 or indirectly through the tub 12 as illustrated. The valve 46 may also be used to control the supply of water to the steam generator 45. The steam generator 45 is illustrated as a flow through steam generator, but may be other types, including a tank type steam generator. Alternatively, the heating element 61 may be used to generate steam in place of or in addition to the steam generator 45. The steam generator 45 is controlled by the controller 22 and may be used to heat to the laundry as part of a cycle of operation, much in the same manner as heating element 61. The steam generator 45 may also be used to introduce steam to treat the laundry as compared to merely heating the laundry.
In case of a dryer, an air flow system (not shown) is used, having a blower to first draw air across a heating element and into the drum, through a lint filter, and finally out through an exhaust conduit that is connected to an exhaust vent system leading out of the house.
Turning now to
As illustrated in
The controller 22 may be operably coupled with the motor 18 and the oscillating mechanism 16 and configured to supply a control signal to both the motor 18 and the oscillating mechanism 16 to effect the rotation of the drum 14. Alternatively, a separate controller (not shown) may be used to control an operation of the oscillating mechanism 16.
The controller 22 also may be a combination of a machine controller and motor controller within one physical location or a practical implementation may require their physical separation. The type and configuration of the controller 22 are not germane to the invention. Any suitable control system capable of outputting control signals to the motor 18 and to the oscillating mechanism 16 may be used. The controller 22 may be configured to supply a control signal to effect the rotation of the drum 14 about the axis of rotation O. The oscillation may be obtained by rotating the drum 14 in such a manner to induce oscillations in the drive shaft 32, with the oscillation generating the forces described by force vectors below.
The control signal from the controller 22 may be a composite signal of first and second superimposed signals, where the first signal effects the general rotation of the drum in the first rotational direction A and the second signal effects the oscillation of the drum about the axis of rotation O. The first signal may be selected to effect a predetermined operating speed of the drum 14 in accordance with a particular phase of the cycle of operation. The predetermined operating speed of the drum 14 may be, for example, a constant speed, an accelerating/decelerating speed, a tumbling speed, etc., or a combination of thereof. The second signal may be a sinusoidal wave form, a step wave form to cycle the motor 14 between ON and OFF states, a step wave form to cycle the motor 14 between a full motor torque and less than the full motor torque states, a signal accelerating and decelerating the motor 14, or other high frequency signals effecting the drum 14 to oscillate.
The drum 14 and the laundry load in the drum collectively define a system mass having a resonance frequency and the oscillation mechanism 16 may rotationally oscillate the mass at a rate sufficiently close to the resonance frequency to initiate the excitation of a resonance response of the system mass. In a case of the drum oscillation at the resonance frequency, a smaller amount of force is required to reach greater amplitude of the drum oscillation and a motor force feels only losses of that resonant system. The resonance of the system may occur at a natural frequency that is higher than the predetermined operating speed of the drum 14.
Similarly, the resonance may be excited by the controller 22 superimposing a force in the resonant frequency to the normal running forces of the motor 18. Using the resonance frequency will decrease an otherwise large force needed to rotate the drum 14. It will be understood, that it is within the scope of the present invention to use other types of oscillation mechanism 16 to enable slight interruptions/oscillations in the continuous rotation of the drum 14 about the axis of rotation O.
For example, the oscillation mechanism 16 may be embodied as a torsion spring system, defining a resonant system between the mass of the drum 14 and the mass of the rotor 34. When the oscillation mechanism 16 is embodied as a torsion spring system, the resonance frequency f0 of the system may be based on the stiffness K of the drive shaft 70 and the inertia of the drum JD and rotor JR according to equation (1) below.
For example, for an exemplary washing machine where JD=1.26 kg*m2, JR=0.138 kg*m2 and K of the drive shift is 529.8 N*m/rad, the resonance frequency of the system may be determined using equation (1) as 10.4 Hz. The determined resonance frequency can be used to apply a composite control signal in which a second signal, such as described above with respect to
The previously described washing machine 10 provides the structure necessary for the implementation of a method of applying mechanical energy to the load of laundry in the laundry treating appliance 10 with the controller 22 configured to supply the motor 18 with a composite control signal to control the applied torque. The controller 22 may supply the motor 18 with a composite signal including a first torque signal to rotate the drum 14 at a predetermined operating speed and a second torque signal to apply an oscillating rotational force. An exemplary method 100 will now be described as illustrated by
As discussed above, the drum 14 and rotor 34 may be considered as defining a resonant system in which the resonance frequency f0 of the system may be determined based on equation (1). The controller 22 may use the determined resonance frequency to determine a frequency at which to apply the second signal in the form of a dynamic torque to the drum 14. For example, the controller 22 may use the resonance frequency to determine a frequency at which to apply a sinusoidal torque signal. The mass of the rotor 34 may be predetermined and stored in a memory accessible by the controller 22 and used to determine the inertia JR of the rotor 34. The inertia of the drum 14 may be determined at any point during a cycle of operation after the laundry has been placed in the drum 14 using any known method, non-limiting examples of which include determining the time it takes to accelerate between two pre-determined speeds under a constant applied torque, determining the time to decelerate from a first speed to a second speed and measuring the torque required to rotate a load at a predetermined constant speed.
The amplitude of the dynamic torque signal may be selected by the controller 22 to provide a predetermined maximum tangential acceleration at to effect the sliding movement of the laundry within the drum 14. The laundry may be excited to slide within the drum 14 if the force to move the laundry relative to the drum Fat is greater than the frictional force between the laundry and the drum friction. Fat is equal to the tangential acceleration at times the mass of the laundry and Ffriction is equal to the fabric friction constant μ times the acceleration a and mass of the laundry, the acceleration being equal to the maximum vertical acceleration due to gravity and the centrifugal acceleration. The fabric friction constant μ may be determined experimentally or empirically for different types of fabric such as cotton, silk and denim, for example, and stored within a memory accessible by the controller 22. The type of fabric comprising the load may be determined manually, such as by user input through a user interface, or automatically by the washing machine 10 according to any known method, such as based on the absorbency of the load, for example.
The amplitude of the applied sinusoidal torque signal 110 may be determined as described above based on the mass and type of fabric of the laundry. The frequency of the sinusoidal torque signal 110 may be selected based on the stiffness K of the drive shaft 70 and the inertia of the drum JD and rotor JR as discussed above with reference to equation (1) to generate resonance between the rotor 34 and the drum 14. Generating resonance between the rotor 34 and the drum 14 may result in less force being required to achieve a predetermined amplitude of drum oscillation.
As illustrated in
The dynamic torque signal may be applied one or more times at any suitable time during the course of a cycle of operation to provide sliding movement of the laundry load relative to the drum 14 to improve the mechanical cleaning action during a course of operation. The method 100 may also be used to apply the dynamic torque signal as a step wave form, similar to that described with respect to
While the method 100 is described as generating a dynamic torque signal 110 at the resonance frequency of the system based on equation (1), it is also within the scope of the invention for the dynamic torque signal to be generated at a frequency based on a harmonic of the drum rotation frequency. For example, if the drum 14 is rotating at 40 rpm or 0.667 Hz, the frequency for generating a dynamic torque signal may be the 14th harmonic or approximately 10 Hz. Alternatively, an independent frequency may be superimposed on the torque signal.
It is also within the scope of the invention for the controller 22 to monitor the amplitude of the rotor oscillations and adjust the frequency of the applied dynamic torque signal to achieve a desired amplitude. The amplitude of the rotor oscillations may be determined based on the back EMF from the motor or the current fluctuation. The controller 22 may also use the determined amplitude to determine when resonance starts or when the amplitude is at a maximum. This information may then be used by the controller 22 to set one or more operating parameters, such as how long to apply the dynamic torque signal or when to apply a treatment chemistry, for example.
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.
Claims
1-16. (canceled)
17. A method of applying mechanical energy to a load of laundry in a treating chamber of a laundry treating appliance having a rotatable drum defining the treating chamber and rotatable about an axis of rotation, a motor configured to rotate the drum, and a controller configured to supply the motor with a control signal to control the rotational speed of the drum, the method comprising:
- rotating the drum in a first rotational direction at a predetermined operating speed; and
- oscillating the drum about an axis of rotation to effect a sliding of the laundry relative to the drum while the drum is rotated in the first rotational direction at the predetermined operating speed.
18. The method of claim 17 wherein the predetermined operating speed is a constant speed.
19. The method of claim 17 wherein the predetermined operating speed is a tumbling speed.
20. The method of claim 19 wherein the oscillating the drum comprises oscillating the drum at a frequency greater than the tumbling speed.
21. The method of claim 17 wherein the supplying the motor with a control signal comprises supplying superimposed first and second control signals, with the first control signal effecting the rotation of the drum at the predetermined operating speed and the second control signal effecting the oscillating of the drum.
22. The method of claim 21 wherein the second control signal is selected to oscillate the drum at a frequency causing excitation of a torsional resonance of a drive shaft coupling the motor and the drum.
23. The method of claim 22 wherein the torsional resonance is determined based on the collective rotational inertia of the drum and the load of laundry in the treating chamber.
24. The method of claim 21 wherein the second control signal comprises a sinusoidal wave form.
25. The method of claim 21 wherein the second signal comprises a step wave form to cycle the motor between ON and OFF states.
26. The method of claim 21 wherein the second signal accelerates and decelerates the motor.
27. The method of claim 17 wherein the oscillating the drum about an axis of rotation occurs at a frequency causing excitation of a resonance of a drive shaft coupling the motor and the drum.
28. The method of claim 17 wherein the oscillation about the axis of rotation comprises rotation between the first and a second rotational direction, opposite the first rotational direction.
Type: Application
Filed: Aug 19, 2013
Publication Date: Dec 12, 2013
Applicant: Whilrlpool Corporation (Benton Harbor, MI)
Inventor: DIETMAR E. LILIE (JOINVILLE)
Application Number: 13/969,918
International Classification: D06F 37/20 (20060101);