Laundry Dryer Load-Based Cycle Control for Sensor Failure Resilience
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Solution Overview
Problem
Laundry treatment appliances face issues with moisture sensors providing inaccurate moisture readings, leading to inconsistent drying cycle completion times due to varying laundry loads, which can result in over-drying or under-drying.
Innovation Solution
A laundry treatment appliance with a sensor to detect load size and operational parameters after a washing cycle, determining a maximum drying cycle length, and adjusting the drying cycle accordingly to compensate for sensor failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If moisture sensors are used to detect drying completion, then drying cycle automation is improved, but measurement precision deteriorates due to false readings
Solution Approach 1:
The controller acts as an intermediary between the moisture sensor and the drying cycle control. It receives sensor signals, validates them against expected patterns, and determines drying completion based on multiple factors including sensor readings, load size, and operational parameters. This intermediary layer filters out false readings while maintaining automated control.
Solution Approach 2:
The system implements feedback by continuously monitoring moisture sensor readings throughout the drying cycle and comparing them against expected moisture reduction patterns. The controller adjusts the drying cycle based on this feedback, validating sensor signals against operational parameters to distinguish true drying progress from sensor errors.
2Device complexity
If fixed maximum drying time is used, then device complexity is reduced, but adaptability deteriorates for different laundry loads
Solution Approach 1:
The system performs preliminary action by detecting the load size at the completion of the washing cycle and using this information to determine an appropriate maximum drying cycle time before the drying cycle begins. This preliminary load assessment allows the system to adapt the drying cycle to different laundry loads without requiring complex real-time adjustments during drying.
Solution Approach 2:
The maximum drying cycle time is made dynamic rather than fixed. The controller adjusts the maximum drying time based on the detected load size and operational parameters from the washing cycle. This dynamic adjustment allows the system to adapt to different laundry loads while maintaining relatively simple control logic.
3Device complexity
If sensor failure is not detected, then device complexity is reduced, but reliability deteriorates due to incorrect drying completion determination
Solution Approach 1:
The controller implements feedback monitoring of sensor signals to detect failures. It validates sensor readings against expected patterns and operational parameters, identifying when the sensor is providing false or inconsistent readings. This feedback mechanism detects sensor failures without requiring complex additional monitoring hardware.
Solution Approach 2:
The system performs self-diagnosis by monitoring its own sensor signals for consistency and validity. The controller identifies sensor failures through the pattern of sensor readings and operational context, allowing the system to detect and respond to sensor problems without external monitoring systems.
Data Source
AI summary
A laundry treatment appliance includes a tub; a laundry basket rotatably mounted within the tub; a sensor positioned within the laundry basket; and a controller operably coupled to the sensor and configured to perform an operation. The operation includes detecting a load size of the laundry load at a completion of a recently performed washing cycle; obtaining a plurality of operational parameters from the recently performed washing cycle; determining a maximum drying cycle length of time for the laundry load based on the detected load size and the plurality of operational parameters; detecting a failure of the sensor; and directing a drying cycle according to the maximum drying cycle length of time in response to detecting the failure of the sensor.