Washing Machine Load Balancing Using Motor Parameter Estimation
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Solution Overview
Problem
Washing machines lack efficient methods to detect and adjust for unbalanced loads during operation, leading to increased energy consumption and potential damage, without relying on costly sensors.
Innovation Solution
A method using parameter estimation algorithms to monitor torque, acceleration, and speed of the drum to determine the angular position of an unbalanced load, allowing for real-time adjustments to redistribute the load and optimize cycle efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are used to detect unbalanced loads, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system uses the motor's own operational parameters (torque, acceleration, speed, angular position) to detect unbalanced loads. The parameter estimator algorithm processes these self-generated signals to identify load imbalances, eliminating the need for external sensors. This self-service approach resolves the contradiction by achieving accurate detection without adding complex sensing hardware.
Solution Approach 2:
The patent replaces mechanical/sensor-based detection systems with a computational approach using parameter estimation algorithms. Instead of using physical sensors to measure load distribution, the system substitutes a mathematical model that infers unbalance conditions from motor operational data, thereby reducing device complexity while maintaining measurement capability.
2Device complexity
If unbalanced loads are not adjusted, then device complexity is reduced, but energy consumption increases and reliability decreases
Solution Approach 1:
The system implements feedback control by continuously monitoring motor parameters and using the parameter estimator to detect unbalanced loads. When unbalance is detected, the system adjusts the wash cycle (modifying drum rotation patterns) to redistribute the load. This feedback mechanism resolves the contradiction by enabling energy-efficient operation through intelligent cycle adjustment rather than complex mechanical load redistribution devices.
Solution Approach 2:
The patent applies dynamic adjustments to the wash cycle based on real-time load conditions. The controller modifies drum rotation speeds and patterns dynamically to optimize load distribution and energy efficiency. This dynamic approach replaces static mechanical adjustment mechanisms, reducing device complexity while improving energy consumption and reliability.
3Productivity
If drum rotation is continuously monitored at high speed, then productivity is improved, but use of energy increases
Solution Approach 1:
The system uses periodic monitoring of motor parameters during the wash cycle to detect unbalanced loads. Rather than continuous high-speed monitoring, the parameter estimator analyzes motor data at strategic intervals to identify load imbalances and trigger cycle adjustments. This periodic approach maintains productivity by detecting issues efficiently while reducing energy consumption compared to continuous monitoring.
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 approach enables cost-effective load balancing and cycle optimization, reducing energy consumption and extending the lifespan of washing machine components by minimizing physical stresses on the system.
Implementation Method 1
rotating the drum above a satellization speed for the laundry load
Implementation Method 2
decelerating rotation of the drum below the satellization speed
Data Source
AI summary
A method of adjusting an unbalance load in a laundry treating appliance includes rotating the drum above a satellization speed for the laundry load, determining, during the rotation, a torque of the motor, an acceleration of the drum, a speed of the drum, and/or an angular position of the drum, estimating with a parameter estimator, during the rotation, an angular position of the unbalance load relative to the drum, based on the torque, acceleration, speed, and/or angular position of the drum, determining values of the angular position of the unbalance load relative to the drum and the angular position of the drum, adding the values of the angular position of the unbalance load relative to the drum and the angular position of the drum to establish a reference value, and comparing the reference value to a threshold.