Washing Drum Spin-Up Control for Dynamic Load Balancing
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Solution Overview
Problem
Conventional horizontal axis washing machines face challenges in balancing loads during spin cycles, leading to noise and vibrations due to unbalanced loads, which existing suspension systems fail to completely mitigate, and require additional counterbalancing methods that are costly and inefficient.
Innovation Solution
A system comprising a perforated rotatable drum with imbalance sensing means and a digital processor that monitors and adjusts the drum's speed to distribute the load evenly, using water in balancing chambers to counteract imbalances dynamically, allowing the drum to reach full spin speed while minimizing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional suspension assemblies are used to isolate vibration, then noise and vibrations are reduced, but the suspension assemblies deteriorate with age and never isolate vibration completely
Solution Approach 1:
The patent removes the traditional suspension assembly entirely from the washing machine design. Instead of using springs and dampers to isolate vibration, the invention uses an active balancing system with counterweights that eliminate the need for suspension components, thereby solving the reliability issue of deteriorating suspension assemblies while maintaining vibration isolation through active control
Solution Approach 2:
The patent replaces the passive mechanical suspension system with an active electronic control system. The imbalance sensing means detects vibration and the digital processor controls balancing mechanisms to counteract imbalance forces, substituting the mechanical suspension approach with an electromechanical control approach that eliminates the need for deteriorating suspension components
2Object-affected harmful factors
If traditional suspension assemblies are used to counteract imbalance forces, then vibration is reduced, but considerable extra costs result
Solution Approach 1:
The patent eliminates the need for expensive suspension assemblies by using an active balancing control system. The imbalance sensing means and digital processor control counterweights to balance the drum dynamically, removing the need for costly passive suspension components and reducing overall manufacturing costs
Solution Approach 2:
The system uses the washing machine's own drum and counterweight mechanisms to balance itself dynamically. The imbalance sensing means detects imbalance and the digital processor automatically adjusts counterweights to compensate, allowing the system to self-regulate without requiring additional expensive suspension components
3Productivity
If high spin speed is used to extract water, then drying time is reduced, but noise and vibrations increase due to unbalanced load
Solution Approach 1:
The patent implements preliminary balancing actions before high-speed spinning begins. The imbalance sensing means detects load distribution and the digital processor adjusts counterweights to balance the drum at lower speeds, preparing the system for high-speed operation without excessive vibration or noise
Solution Approach 2:
The patent uses dynamic balancing throughout the spin cycle. The imbalance sensing means continuously monitors drum balance and the digital processor dynamically adjusts counterweight positions to maintain balance as the drum speed changes and water is extracted, enabling high spin speeds without generating excessive noise or vibration
4Object-affected harmful factors
If active balancing system is used to compensate for imbalance, then vibration is reduced, but water additions to balance chambers are not reversible leading to accumulation
Solution Approach 1:
The patent uses a dynamic control system where the digital processor continuously monitors imbalance and reversibly adjusts counterweights in real-time. Unlike fixed water additions to balance chambers, this system can add and remove counterbalancing mass dynamically, preventing accumulation and allowing continuous adaptation to changing load conditions throughout the spin cycle
Solution Approach 2:
The patent implements a feedback control loop where the imbalance sensing means continuously detects drum balance status and feeds this information to the digital processor. The processor then adjusts counterweights accordingly, creating a closed-loop system that automatically corrects imbalance without manual intervention or irreversible adjustments
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 effectively reduces vibrations and noise by dynamically balancing the load during spin cycles, eliminating the need for traditional suspension systems and maintaining efficient operation even with varying imbalances, thus enhancing the washing machine's performance and reducing maintenance costs.
Implementation Method 1
imbalance sensing means for detecting any static dynamic imbalance in the rotation of said drum
Implementation Method 2
in a spin-up phase, energise said driving means so as to evenly distribute the load within said drum
Data Source
AI summary
A laundry appliance having a perforated rotatable drum for spin dehydrating a wet textile load, an electric motor for providing an accelerating force which in use causes the drum to rotate, load sensors for detecting any static dynamic imbalance in the rotation of the drum, and a controller which receives inputs from the load sensors and is programmed to, in a spin-up phase, energize said electric motor so as to evenly distribute the load within the drum and thereby minimize any static or dynamic imbalance when the drum rotates.