Method for detecting and correcting out of balance conditions in a washing machine appliance
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Solution Overview
Problem
Existing washing machine technologies fail to accurately monitor and correct out-of-balance conditions during the wash cycle, leading to noise, vibrations, and premature component failure, as they typically detect imbalances only during high-speed spin cycles when damage has already occurred.
Innovation Solution
A camera assembly within the washing machine uses machine learning image recognition to determine the cloth coverage ratio of the load and adjusts operating parameters, such as basket speed, to prevent out-of-balance scenarios by redistributing clothes before high-speed spin, thereby reducing vibrations and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load balance monitoring is performed during high-speed spin cycle, then out-of-balance conditions can be detected, but noise, vibrations, and component wear have already occurred
Solution Approach 1:
The system performs load balance monitoring during the wash cycle at low speeds before the spin cycle begins. The camera captures images of the wash basket contents during washing, allowing the processor to analyze load distribution and predict potential out-of-balance conditions before high-speed rotation occurs, thereby preventing noise and vibrations
2Reliability
If camera assembly is added to monitor load balance, then early detection is enabled, but device complexity increases
Solution Approach 1:
The camera assembly serves multiple functions: it monitors load balance distribution, tracks wash basket rotation, and captures images for analysis by the processor. This multi-functional approach enables reliable load balance monitoring without adding separate dedicated components for each function, thereby limiting the increase in device complexity
3Reliability
If basket speed is adjusted to redistribute clothes, then out-of-balance conditions are prevented, but wash cycle time increases
Solution Approach 1:
The system adjusts basket speed periodically during the wash cycle based on camera analysis of load distribution. Rather than continuous adjustment, the processor analyzes images at intervals and makes speed modifications only when out-of-balance conditions are detected, thereby maintaining load balance stability while minimizing additional cycle time
Data Source
AI summary
A method of operating a washing appliance includes obtaining images of a wash chamber using a camera assembly operating at a frame rate equivalent to the basket speed. The one or more images are analyzed, e.g., using a machine learning image recognition process, to determine a cloth coverage ratio of the load of clothes in the wash basket. The cloth coverage ratio is compared to a predetermined coverage threshold for reducing out of balance conditions. Specifically, if the cloth coverage area is greater than the threshold, the wash basket may be ramped up to a hold or plaster speed. By contrast, if the cloth coverage area is less than the threshold, the basket speed may be maintained or lowered to permit the clothes to redistribute before ramping to the hold or plaster speed.