Drum Balancer Module Control for Washing Machine Vibration
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Solution Overview
Problem
Washing machines experience vibration and noise due to unbalanced laundry distribution during spin-drying cycles, which can damage components and are not effectively addressed by existing balancer technologies.
Innovation Solution
A washing machine with advanced balancer systems that include position identification units, sensors, and balancing modules, which detect unbalance through phase differences and move to compensate for the imbalance by generating drive forces to stabilize the drum rotation, using Hall sensors, infrared sensors, or optical fiber sensors for position detection and ZigBee communication for control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If balancers are used to compensate for unbalanced load, then drum rotation stability is improved, but vibration and noise are not sufficiently reduced
Solution Approach 1:
The balancer is divided into multiple independent balancing modules (first balancing module, second balancing module, etc.), each capable of moving independently to different positions. This segmentation allows more precise compensation for unbalanced loads by distributing the balancing mass across multiple discrete units, thereby reducing both vibration and noise more effectively than a single continuous balancer.
Solution Approach 2:
The balancing modules are designed to be movable rather than fixed, allowing them to dynamically adjust their positions based on the detected unbalanced load distribution. The modules can move along the circumferential direction to different angular positions around the drum, enabling real-time adaptation to changing load conditions during the spin-drying cycle, thus achieving superior vibration and noise reduction.
2Measurement precision
If position sensors and identification units are added to detect unbalance, then balancing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical vibration sensing systems with non-contact position sensors (such as Hall sensors, infrared sensors, or optical fiber sensors) that detect the position of magnetic bodies or light-emitting units on the drum and balancing modules. This substitution uses electromagnetic or optical fields instead of mechanical contact, achieving high-precision unbalance detection while reducing mechanical complexity and wear.
Solution Approach 2:
The position sensors serve multiple functions: they detect the position of the drum (first position identification unit), detect the positions of individual balancing modules (second position identification units), and provide data for both control and monitoring systems. This multi-functionality reduces the need for separate sensors for each detection task, thereby managing system complexity while maintaining high measurement precision.
3Object-affected harmful factors
If balancing modules move to compensate for unbalance, then vibration reduction is improved, but energy consumption increases
Solution Approach 1:
The balancing modules operate using periodic action by moving to compensating positions only when unbalance is detected during the spin-drying cycle, rather than continuously adjusting. The controller monitors the drum rotation and triggers balancing module movement only when vibration exceeds threshold levels, allowing the system to consume energy selectively rather than continuously, thus reducing overall energy consumption while maintaining effective vibration reduction.
Solution Approach 2:
The balancing modules function as movable counterweights that are positioned to generate centrifugal forces opposing the unbalanced load. By strategically placing these counterweights at specific angular positions around the drum, the system achieves vibration compensation through force balance rather than continuous mechanical adjustment, reducing the energy required for balancing operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces vibration and noise during spin-drying cycles, enhances drum stability, and allows for increased drum RPM, thereby improving washing machine performance and reducing the need for additional vibration suppression units, such as dampers, leading to cost savings.
Implementation Method 1
Each of the position sensors may include one of a Hall sensor, an infrared sensor and an optical fiber sensor
Implementation Method 2
Each of the position sensors may include one of a Hall sensor, an infrared sensor and an optical fiber sensor
Implementation Method 3
Each of the position sensors may include one of a Hall sensor, an infrared sensor and an optical fiber sensor
Implementation Method 4
The controller may detect the intensity of the unbalance through signals sensed by the vibration sensors
Data Source
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AI summary
A washing machine (1) which improves performance of balancers, and a control method thereof. The washing machine (1) includes a drum (30) accommodating laundry and rotated by rotary force transmitted from a drive source (40,42), balancer housings (112) mounted on the drum, each of the balancer housings including a disc-shaped channel (111) formed therein, balancing modules (113) movably disposed in the channels of the balancer housings, vibration sensors (21) to sense unbalance applied to the drum during rotation of the drum, position sensors (22,23) to sense the positions of the balancing modules (113), and a controller (80) controlling movement of the balancing modules to positions to compensate for the unbalance sensed by the vibration sensors.