Overflow protection for a washing machine

• US 6,125,870 A
• Filed: 06/04/1996
• Issued: 10/03/2000
• Est. Priority Date: 06/04/1996
• Status: Expired due to Fees

• Current Assignee: Nidec Motor Corporation (Nidec Corporation)
• Original Assignee: Emerson Electric Company
• Inventors: Furmanek, Ralph D.
• Primary Examiner(s): Walton, George L.
• Application Number:
  US08/659,016
• Time in Patent Office: 1,582 Days
• Field of Search: 137/386, 137/387, 137/392, 137/624.11, 137/624.13, 137/624.14, 137/624.15, 137/624.18, 137/624.192, 137/624.2, 68/12.02, 68/12.05, 68/12.19, 68/12.21, 68/207, 68/208, 307/141, 307/118, 361/178
• US Class Current: 137/2
• CPC Class Codes: D06F 2105/58 Indications or alarms to the control system or to the user
• CPC Class Codes: D06F 33/47 Responding to irregular working conditions, e.g. malfunctioning of pumps safety arrangements D06F37/42
• CPC Class Codes: D06F 39/081 Safety arrangements for preventing water damage
• CPC Class Codes: Y10T 137/0324 With control of flow by a condition or characteristic of a fluid
• CPC Class Codes: Y10T 137/729 Washing machine cycle control
• CPC Class Codes: Y10T 137/7306 Electrical characteristic sensing
• CPC Class Codes: Y10T 137/86389 Programmer or timer
• CPC Class Codes: Y10T 137/86405 Repeating cycle

Abstract

Improved overflow protection for washing machines and other applications in which a liquid from a controllable valve fills a tub is achieved by a circuit in which a single pulse train generated cooperatively by a pressure sensor and a controller is monitored by a lockout timer. If an interruption in the train of pulses occurs that is longer than a predetermined time-out period indicating a failure of either the pressure sensor or the controller that would otherwise prevent the valve from shutting off the flow of liquid into the tub, the lockout timer will cause the valve to turn off. The controller is also able to override the lockout timer and cause a relay to shut off power to the controllable valve to force it off if the pressure sensor detects a continued rise in liquid level after the controller has signalled the controllable valve to shut off.

Claims

1. An improvement for an overflow protector of a control circuit of a liquid supply portion of a fillable tub that interrupts a supply of liquid to the tub in response to a sensed failure of the control circuit, regardless of a liquid level of the fillable tub, the improvement comprising:

an electrically controlled liquid valve;

a liquid level sensing circuit;

a controller operatively coupled to the liquid level sensing circuit and the electrically controlled liquid valve, the controller emitting a regularly varying control signal that is operatively received by the liquid level sensing circuit;

the liquid level sensing circuit emitting a regularly varying sensor signal indicative of a level of liquid in the tub in response to the regularly varying control signal; and

a lockout circuit operatively coupled to the liquid level sensing circuit and the electrically controlled liquid valve, the lockout circuit interrupting power to the liquid valve in response to an interruption in the regularly varying sensor signal, the presence of the regularly varying sensor signal being indicative of the proper operation of both the liquid level sensing circuit and the controller.

2. The improvement of claim 1, further comprising:

a gating circuit operatively coupled to the liquid level sensing circuit and the controller, the gating circuit for modulating power supplied to the liquid level sensing circuit in response to the regularly varying control signal.

3. The improvement of claim 2, wherein:

the regularly varying sensor signal is a pulsed sensor signal and the lockout circuit has a time-out period and is responsive to interruptions in the pulsed sensor signal longer than the time-out period for interrupting power to the liquid valve.

4. The improvement of claim 1, wherein:

the regularly varying sensor signal is an analog signal.

5. The improvement of claim 4, further comprising:

a means coupled to the liquid level sensing circuit for introducing an amplitude offset into the regularly varying sensor signal.

6. The improvement of claim 1, wherein:

the liquid level sensing circuit comprises a pressure sensor.

7. The improvement of claim 1, wherein:

the electrically controlled liquid valve includes an electromechanical relay and the lockout circuit interrupts power to the electrically controlled liquid valve by controlling the electromechanical relay.

8. The improvement of claim 1, wherein:

the control circuit is part of a washing machine.

9. An improvement for an overflow protector of a control circuit of a liquid supply portion of a fillable tub that interrupts a supply of liquid to the tub in response to a sensed failure of the control circuit, regardless of a liquid level of the fillable tub, the improvement comprising:

an electrically controlled liquid valve;

a liquid level sensing circuit;

a controller operatively coupled to the liquid level sensing circuit and the electrically controlled liquid valve, the liquid level sensing circuit emitting a regularly varying sensor signal indicative of a level of liquid in the tub, the regularly varying sensor signal being operatively received by the controller;

the controller emitting a regularly varying control signal in response to receiving the regularly varying sensor signal; and

a lockout circuit operatively coupled to the controller and the electrically controlled liquid valve, the lockout circuit interrupting power to the electrically controlled liquid valve in response to an interruption in the regularly varying control signal, the presence of the regularly varying control signal being indicative of the proper operation of both the liquid level sensing circuit and the controller.

10. The improvement of claim 9, wherein:

power supplied to the liquid level sensing circuit is modulated such that the regularly varying sensor signal is a pulsed sensor signal, the regularly varying control signal emitted by the controller also being a pulsed control signal in response to the pulsed sensor signal.

11. The improvement of claim 10, wherein:

the lockout circuit has a time-out period and Is responsive to interruptions in the pulsed control signal longer than the time-out period for interrupting power to the electrically controlled liquid valve.

12. The improvement of claim 9, wherein:

the regularly varying sensor signal is an analog signal.

13. The improvement of claim 12, further comprising:

a means coupled to the liquid level sensing circuit for introducing an amplitude offset into the regularly varying sensor signal.

14. The improvement of claim 9, wherein:

the liquid level sensing circuit comprises a pressure sensor.

15. The improvement of claim 9, wherein:

the electrically controlled liquid valve includes an electromechanical relay and the lockout circuit interrupts power to the electrically controlled liquid valve by controlling the electromechanical relay.

16. The improvement of claim 9, wherein:

the control circuit is part of a washing machine.

17. A method for preventing liquid overflow in a fillable tub in response to a sensed failure of a control circuit of a liquid supply portion of the fillable tub, regardless of a liquid level of the fillable tub, the method comprising:

providing the control circuit with a controller, a liquid level sensing circuit for sensing a level of liquid in the tub, and at least one electrically controlled liquid valve for controlling a supply of liquid to the tub;

generating a regularly varying control signal at an output of the controller;

generating a regularly varying sensor signal at an output of the liquid level sensing circuit in response to the regularly varying control signal, the regularly varying sensor signal being indicative of a level of liquid in the tub; and

interrupting power to the at least one electrically controlled liquid valve in response to a variation of the regularly varying sensor signal indicative of a failure of at least one of the controller and the sensor.

18. The method of claim 17, wherein:

the step of generating the regularly varying control signal comprises using a gating circuit to modulate power supplied to the liquid level sensing circuit in response to the regularly varying control signal.

19. The method of claim 18, wherein:

the step of generating the regularly varying sensor signal includes modulating power supplied to the liquid level sensing circuit such that the regularly varying sensor signal is a pulsed signal and the step of interrupting power to the at least one electrically controlled liquid valve comprises using a lockout circuit having a time-out period, the lockout circuit being responsive to interruptions in the pulsed sensor signal longer than the time-out period for interrupting power to the at least one electrically controlled liquid valve.

20. The method of claim 17, wherein:

the step of generating a regularly varying sensor signal produces an analog regularly varying sensor signal.

21. The method of claim 20, further comprising:

introducing an analog offset into the regularly varying sensor signal.

22. The method of claim 17, wherein:

the step of generating a regularly varying sensor signal comprises using a pressure sensor that measures head pressure of the liquid in the fillable tub.

23. The method of claim 17, wherein:

the step of interrupting power to the at least one electrically controlled liquid valve comprises interrupting power to the at least one electrically controlled liquid valve by controlling an electromechanical relay operatively coupled with the at least one electrically controlled liquid valve.

24. The method of claim 17, wherein:

the method is used by a control circuit that is part of a washing machine.

25. A method for preventing liquid overflow in a fillable tub in response to a sensed failure of a control circuit of a liquid supply portion of the fillable tub, regardless of a liquid level of the fillable tub, the method comprising:

providing the control circuit with a controller, a liquid level sensing circuit for sensing a level of liquid in the tub, and at least one electrically controlled liquid valve for controlling a supply of liquid to the tub;

generating a regularly varying sensor signal at an output of the liquid level sensing circuit, the regularly varying sensor signal being indicative of a level of liquid in the tub;

generating a regularly varying control signal at an output of the controller in response to the regularly varying sensor signal; and

interrupting power to the at least one electrically controlled liquid valve in response to a variation of the regularly varying control signal indicative of a failure of at least one of the controller and the sensor.

26. The method of claim 25, wherein:

the step of generating the regularly varying sensor signal includes modulating power supplied to the liquid level sensing circuit such that the regularly varying sensor signal generated is a pulsed signal and the step of generating the regularly varying control signal comprises generating a pulsed signal in response thereto.

27. The method of claim 26, wherein:

the step of interrupting power to the at least one electrically controlled liquid valve comprises using a lockout circuit having a time-out period, the lockout circuit being responsive to interruptions in the pulsed control signal longer than the time-out period for interrupting power to the at least one electrically controlled liquid valve.

28. The method of claim 25, wherein:

the step of generating a regularly varying sensor signal produces an analog regularly varying sensor signal.

29. The method of claim 28, further comprising:

introducing an analog offset into the regularly varying sensor signal.

30. The method of claim 28, wherein:

the step of generating a regularly varying sensor signal comprises using a pressure sensor that measures head pressure of the liquid in the fillable tub.

31. The method of claim 26, wherein:

the step of interrupting power to at least one electrically controlled liquid valve comprises interrupting power to the liquid valve by controlling an electromechanical relay.

32. The method of claim 25, wherein:

the method is used by a control circuit that is part of a washing machine.