Washing Machine Coupler Control Using Motor Current Load Sensing
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Solution Overview
Problem
Existing washing machines with solenoid-operated clutches face issues such as continuous power requirements, heat generation, and configuration errors leading to operational problems and structural complexity, particularly in the axial coupling and decoupling of drive and dewatering shafts.
Innovation Solution
A control method for a washing machine that adjusts the coupler configuration without continuous solenoid power, using a mode change step to axially couple or decouple the drive and dewatering shafts, and a mode check step to sense current load and adjust the coupler setting, allowing for error detection and correction without sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a solenoid is used to adjust the coupler configuration, then the coupler can be moved to the desired position, but continuous power application is required which causes heat generation and power consumption
Solution Approach 1:
The patent applies the dynamics principle by making the coupler configuration adjustable and changeable. The coupler can dynamically switch between different configurations (first configuration for axial coupling, second configuration for axial decoupling) based on operational needs, allowing the system to adapt its structure rather than being fixed in one state.
Solution Approach 2:
The patent implements periodic action by using the drive motor's periodic rotation during washing and dewatering strokes to periodically check and adjust the coupler configuration. Instead of continuous solenoid power, the system uses intermittent motor operation cycles to detect configuration status and make adjustments only when needed, reducing power consumption significantly.
2Stability of the object's composition
If a solenoid is used to keep the coupler in a higher position, then the coupler configuration can be maintained, but heat generation from the coil occurs
Solution Approach 1:
The patent applies self-service by using the drive motor's own operation to perform the configuration check and adjustment function. The motor's periodic rotation during normal washing operations is utilized to detect coupler configuration status and make adjustments without requiring a separate powered actuator, thereby eliminating continuous heat generation while maintaining stability.
Solution Approach 2:
The patent replaces the electromagnetic solenoid system with a mechanical detection and adjustment mechanism. Instead of using electromagnetic coils that generate heat, the system uses mechanical sensors and linkages that respond to the drive motor's rotation to detect and adjust coupler configuration, substituting electromagnetic action with mechanical action to eliminate heat generation.
3Adaptability or versatility
If the coupler configuration is adjusted by solenoid operation, then the drive shaft and dewatering shaft can be axially coupled or decoupled, but configuration errors may occur leading to operational problems
Solution Approach 1:
The patent implements feedback by continuously monitoring the coupler configuration status during drive motor operation. The system detects whether the coupler is in the correct configuration for the current operational mode (washing or dewatering) and provides feedback signals to trigger adjustments when mismatches are detected, ensuring reliable operation through closed-loop control.
Solution Approach 2:
The patent applies preliminary action by performing configuration checks and adjustments in advance before operational problems occur. The system proactively detects potential configuration errors during motor operation and corrects them before they lead to malfunction, preventing rather than reacting to operational failures.
4Ease of operation
If a link structure is used to adjust the coupler configuration, then the coupler can be positioned correctly, but structural complexity and space requirements increase
Solution Approach 1:
The patent applies universality by making the drive motor serve multiple functions: it not only drives the washing and dewatering operations but also performs the coupler configuration detection and adjustment functions. This multi-functionality eliminates the need for separate link structures and adjustment mechanisms, reducing overall system complexity while maintaining full adjustability capability.
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
This solution reduces power consumption, minimizes heat generation, and corrects configuration errors, ensuring proper operation of the washing tub and pulsator, while also addressing motor-related errors and entanglement issues during the washing process.
Implementation Method 1
a solenoid module (27) which operates to axially move the coupler (28)
Implementation Method 2
a load sensing portion (144) which senses a load of current according to an operation state of the drive motor (21)
Data Source
AI summary
A control method for a washing machine includes: a mode change step in which the configuration of a coupler is moved by operating a solenoid module in such a way that a drive shaft for spinning a pulsator and a dewatering shaft for spinning a washing tub are axially coupled or decoupled; and a mode check step in which a drive motor for rotating the drive shaft is operated and the load of current outputted to the drive motor is sensed, the mode check step comprising a coupler setting step in which, if the load of current outputted to the drive motor does not satisfy a set load value, the solenoid module is operated to reposition the coupler.