Washer Extractor Inner Door Sensing to Prevent Cylinder Jamming

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Solution Overview

Problem

Commercial washing machines in industrial settings face issues with door jamming due to open inner doors during the wash cycle, leading to machine downtime and potential damage, and existing door locking mechanisms are not robust enough to withstand harsh environments and operator overrides.

Innovation Solution

A door sensing system using laser time-of-flight sensors and robust stainless steel targets is implemented to reliably determine if inner doors are closed before initiating a wash cycle, providing a secure and durable solution that can be retrofitted onto existing machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If an optical sensor is used to detect door closing status, then the system can detect whether the lock has rotated to the locked position, but the system becomes easy to override by operators and susceptible to failure in harsh environments

Engineering Contradiction:

Improvedoor closing detection accuracyVSAvoidsystem robustness

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces the optical sensor system with a mechanical sensing system that uses physical contact and mechanical linkages to detect door closing status. This mechanical approach is inherently more resistant to environmental factors like water, steam, and corrosive chemicals while being much harder for operators to override accidentally or intentionally.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a mechanical intermediary system consisting of linkages, levers, and physical contacts that translate door position into sensor activation. This intermediary mechanical system acts as a buffer between the door and the detection mechanism, providing reliable detection while protecting against direct environmental exposure and operator interference.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a door locking mechanism with optical sensor is used, then door position can be detected, but the system is vulnerable to operator overrides and environmental damage

Engineering Contradiction:

Improvedoor position monitoringVSAvoidenvironmental harshness impact

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent employs protective enclosures and sealed mechanical components that shield the sensing mechanism from water, steam, and corrosive chemicals. The mechanical linkages are designed with protective housings that maintain operational reliability in harsh commercial laundry environments while allowing the door position monitoring function to operate effectively.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses simple, robust mechanical components that are inexpensive to replace if damaged. The mechanical sensing elements are designed to be durable but can be easily swapped out, providing a cost-effective solution that maintains operational continuity in harsh environments where component wear is expected.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If the washing cylinder rotates at high speed, then washing efficiency is improved, but laundry can escape if inner doors are left open causing jams and machine damage

Engineering Contradiction:

Improvewashing efficiencyVSAvoidlaundry escape and machine jamming

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent implements a preliminary door closing verification system that checks whether all inner doors are properly closed before the washing cycle begins. The mechanical sensing system detects door position in advance, preventing the wash cycle from starting if doors are open, thereby eliminating the risk of laundry escape and machine damage while allowing high-speed operation when doors are properly secured.

Inventive Principle:

Principle #10Preliminary action

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 system ensures that all inner doors are closed before starting a wash cycle, preventing jams and machine damage, while being resistant to environmental harshness and operator overrides, thus reducing operational costs and extending machine lifespan.

Implementation Method 1

A door sensing system using laser time-of-flight sensors and robust stainless steel targets is implemented to reliably determine if inner doors are closed

Methodology Applied

Scientific EffectLaser time-of-flight: Time of Flight

Data Source

PatentUS10934656B2Washer extractor machine with improved door closing sensing system

Publication Date: 2021.03.02 ELLIS CORP

AI summary

A washer extractor machine is provided. The washer extractor machine includes a casing defining an interior chamber that is accessed through a first opening in the casing that has an associated outer door. A cylinder body is supported for rotation in the interior chamber of the casing. The cylinder body has a hollow interior that is accessed through a second opening in the cylinder body. An inner door is supported on the cylinder body for movement relative to the second opening between open and closed positions. A door closing sensing system includes a sensor element and a target element supported on the inner door. The sensor element and the target element being arranged relative to one another such that the target is in alignment with the line-of-sight of the sensor element when the inner door is in the closed position.