Control system and process for automatically controlling agitator motion patterns in a washing machine

• US 6,415,469 B1
• Filed: 05/31/2000
• Issued: 07/09/2002
• Est. Priority Date: 12/30/1999
• Status: Expired due to Term

• Current Assignee: Mabe Mã©Xico, S. De R.L. De C.V. (Controladora MABE SA de CV), MABE
• Original Assignee: Mabe Mã©Xico, S. De R.L. De C.V. (Controladora MABE SA de CV)
• Inventors: Flores Islas, Erick, Reyes Turrubiarte, Pedro Roberto, Gonzalez Garcia Ancira, Juan Carlos, Diaz Fernandez, Alfredo
• Primary Examiner(s): COE, PHILIP R
• Application Number:
  US09/583,858
• Time in Patent Office: 769 Days
• Field of Search: 815/8, 815/9, 68/120.1, 68/120.2
• US Class Current: 8/158
• CPC Class Codes: D06F 13/02 wherein the agitator has an oscillatory rotary motion only
• CPC Class Codes: D06F 2103/18 Washing liquid level
• CPC Class Codes: D06F 2103/24 Spin speed; Drum movements
• CPC Class Codes: D06F 2103/46 of the motor driving the drum
• CPC Class Codes: D06F 2105/48 Drum speed
• CPC Class Codes: D06F 2105/50 Starting machine operation, e.g. delayed start or re-start after power cut
• CPC Class Codes: D06F 2105/58 Indications or alarms to the control system or to the user

Abstract

A process and system for controlling respective agitator motion patterns in a washing machine having a motor drive coupled to energize a motor that drives the agitator is provided. The process allows for selecting a desired agitator motion pattern based on one or more pattern selection signals. The process further allows measuring one or more parameters indicative of the actual agitator motion pattern. A comparing step allows for comparing the actual agitator motion pattern against the desired agitator motion pattern, and an adjusting step allows for adjusting one or more control signals supplied to the motor drive for correcting deviations between the actual agitator motion pattern and the desired motion pattern.

Claims

1. A process for controlling respective agitator motion patterns in a washing machine having a motor drive coupled to energize a motor that drives the agitator, the process comprising:

selecting a desired agitator motion pattern based on one or more pattern selection signals;

measuring one or more parameters indicative of the actual agitator motion pattern;

comparing the actual agitator motion pattern against the desired agitator motion pattern; and

adjusting one or more control signals supplied to the motor drive for correcting deviations between the actual agitator motion pattern and the desired motion pattern.

2. The process of claim 1 wherein the selected agitator motion pattern comprises controlling angular travel of the agitator during each stroke of the agitator.

3. The process of claim 2 wherein the adjusting step comprises a step of setting initial values of respective variables that determine a respective agitator motion pattern.

4. The process of claim 3 further comprising a step of accumulating pulses indicative of agitator RPM and/or agitator travel upon start of each respective agitator stroke.

5. The process of claim 4 wherein the respective variables comprise a variable (X) having a respective value indicative of target pulses during a motor-on state, a variable (Y) having a respective value indicative of target pulses during a complete stroke, a variable (V_f) having a respective value indicative of a target final velocity of the agitator and a variable (D) indicative of a delay value.

6. The process of claim 5 further comprising a step of maintaining the motor-on state until the accumulated pulses reach the value of the X variable.

7. The process of claim 6 further comprising a step of maintaining a respective motor-off state until the agitator reaches the target final velocity, V_f.

8. The process of claim 7 further comprising a step of waiting in a dormant state for a period of time equal to the value of the delay D upon the agitator reaching the target final velocity, V_f.

9. The process of claim 8 further comprising a step of comparing pulses actually accumulated during the complete agitator stroke against the value of the Y variable.

10. The process of claim 9 further comprising a step of incrementing the value of the X variable depending on whether the value of the pulses actually accumulated during the complete agitator stroke is below the value of the Y variable.

11. The process of claim 10 further comprising a step of decrementing the value of the delay variable D by a predetermined amount.

12. The process of claim 11 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

13. The process of claim 9 further comprising a step of decrementing the value of the X variable depending on whether the value of the accumulated pulses is equal or above the value of the Y variable.

14. The process of claim 13 further comprising a step of computing number of strokes per unit of time by computing the inverse of elapsed time from start to finish of a respective stroke.

15. The process of claim 14 further comprising a step of comparing the computed value of number of strokes per unit of time against a target value of strokes per unit of time.

16. The process of claim 15 further comprising a step of incrementing the delay variable D by a predetermined amount when the computed value of strokes per unit of time exceeds the target value of strokes per minute.

17. The process of claim 16 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

18. The process of claim 15 further comprising a step of decrementing the delay variable D by a predetermined amount when the computed value of strokes per unit of time is below or at the target value of strokes per unit of time.

19. The process of claim 18 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

20. The process of claim 1 wherein the selected agitator motion pattern comprises controlling the number of strokes of the agitator per unit of time.

21. The process of claim 20 wherein the adjusting step comprises a step of setting initial values of respective variables that determine a respective agitator motion pattern.

22. The process of claim 21 further comprising a step of accumulating pulses indicative of agitator RPM upon start of each respective agitator stroke.

23. The process of claim 22 wherein the respective variables comprise a variable (X) having a respective value indicative of target pulses during a motor-on state, a variable (Y) having a respective value indicative of target pulses during a complete stroke, a variable (V_f) having a respective value indicative of a target final velocity of the agitator, and a variable (D) indicative of a delay value.

24. The process of claim 23 further comprising a step of maintaining the motor-on state until the accumulated pulses reach the value of the X variable.

25. The process of claim 24 further comprising a step of maintaining a respective motor-off state until the agitator reaches the target final velocity (V_f).

26. The process of claim 25 further comprising a step of waiting in a dormant state for a period of time equal to the value of the delay.

27. The process of claim 26 further comprising a step of computing number of strokes per unit of time by computing the inverse of elapsed time from start to finish of a respective stroke.

28. The process of claim 27 further comprising a step of comparing the computed value of number of strokes per unit of time against a target value of strokes per unit of time.

29. The process of claim 28 further comprising a step of decrementing the X variable if the computed value of number of strokes per unit of time is equal or less than the target value of strokes per unit of time.

30. The process of claim 29 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and,D for each respective successive reciprocating strokes of the agitator at least until completion of an agitation time cycle of the washing machine.

31. The process of claim 28 further comprising a step of comparing pulses actually accumulated during the complete agitator stroke against the value of the Y variable.

32. The process of claim 31 further comprising a step of incrementing the X variable if the value of the accumulated pulses is less than the Y variable.

33. The process of claim 32 further comprising a step of decrementing the delay variable D by a predetermined amount.

34. The process of claim 33 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

35. The process of claim 31 further comprising a step of incrementing the delay variable D by a predetermined amount if the value of the accumulated pulses is more than or equal than the Y variable.

36. The process of claim 35 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating strokes of the agitator at least until completion of an agitation time cycle of the washing machine.

37. The process of claim 1 wherein the selected motion pattern comprises controlling angular travel of the agitator during each stroke and/or the number of strokes of the agitator per unit of time.

38. The process of claim 1 wherein the pattern selection signals are programmed based on the type of fabric to be washed.

39. The process of claim 1 wherein the step of measuring one or more parameters indicative of the actual agitator motion pattern comprises counting the number of pulses from a sensor coupled to supply a stream of pulses indicative of agitator RPM and/or agitator travel.

40. The process of claim 39 wherein the sensor comprises a Hall-effect sensor.

41. The process of claim 1 further comprising a sub-process for automatically controlling water-level in the washing machine prior to and/or during execution of a respective agitation cycle.

42. The process of claim 41 wherein the sub-process for controlling water level comprises:

selecting a target water agitator inertial response indicative of a desired water level;

measuring a parameter indicative of the actual water level based on an actual inertial response of the agitator;

comparing the actual agitator inertial response against the target agitator inertial response; and

selectively actuating one or more water valves for allowing passage of water so as to adjust the water level of the washing machine based on deviations between the actual agitator inertial response and the target agitator inertial response.

43. The process of claim 42 further comprising a step of generating a timer signal indicative of the inertial response of the agitator.

44. The process of claim 43 further comprising a step of setting initial values of respective variables for controlling the water level.

45. The process of claim 44 wherein the respective variables comprises a variable (T) having a respective value indicative of load tightness, a variable (L) having a respective value indicative of load looseness, a variable (V_f) having a respective value indicative of a target final velocity of the agitator, a target agitator stoppage time, and a variable (D) indicative of a delay value.

46. The process of claim 45 wherein the target agitator stoppage time is selected based on the type of fabric to be washed.

47. The process of claim 45 wherein the parameter indicative of water level based on the inertia response of the agitator comprises a respective actual agitator stoppage time upon the motor drive being deenergized up to the agitator reaching the target final velocity.

48. The process of claim 47 further comprising a step of actuating the one or more water valves to incrementally increase the actual water level towards a next available water level.

49. The process of claim 48 further comprising executing a predetermined number of agitator strokes to measure the respective actual stoppage time of each of the executed agitator strokes.

50. The process of claim 49 further comprising a step of comparing the respective actual stoppage time of each of the executed agitator strokes against the target stoppage time.

51. The process of claim 50 further comprising a step of incrementing the variable T if the actual stoppage time is more than the target stoppage time.

52. The process of claim 51 further comprising a step of incrementing the variable L if the stoppage time is less than the target stoppage time.

53. The process of claim 52 further comprising a step of comparing the value of the T variable against the value of the L variable.

54. The process of claim 53 further comprising a step of continuing the respective agitation cycle if the value of the L variable is larger than the value of the T variable.

55. The process of claim 54 further comprising a step of determining whether the actual water level is the highest water level allowed.

56. The process of claim 55 further comprising a step of incrementing the value of the delay variable D prior to returning to the agitation cycle.

57. The process of claim 48 further comprising a step of executing further iterations of the water valves actuating step and subsequent steps of the sub-process for controlling water level so as to reach the target water level.

58. A control system for controlling respective agitator motion patterns in

a washing machine having a motor drive coupled to energize a motor that drives the agitator, the system comprising:

a selecting module configured to select a desired agitator motion pattern based on one or more pattern selection signals;

a measuring module configured to measure one or more parameters indicative of the actual agitator motion pattern;

a comparing module configured to compare the actual agitator motion pattern against the desired agitator motion pattern; and

an adjusting module configured to adjust one or more control signals supplied to the motor drive for correcting deviations between the actual agitator motion pattern and the desired motion pattern.

59. The system of claim 58 wherein the selected agitator motion pattern comprises controlling angular travel of the agitator during each stroke of the agitator.

60. The system of claim 59 wherein the adjusting module includes an initialization submodule configured to set initial values of respective variables that determine a respective duty cycle of the one or more control signals applied to the motor drive.

61. The system of claim 60 further comprising an accumulator configured to accumulate pulses indicative of agitator RPM and/or agitator travel upon start of each respective agitator stroke.

62. The system of claim 61 wherein the respective variables comprise a variable (X) having a respective value indicative of target pulses during a motor-on state, a variable (Y) having a respective value indicative of target pulses during a complete stroke, a variable (V_f) having a respective value indicative of a target final velocity of the agitator and a variable (D) indicative of a delay value.

63. The system of claim 62 further comprising means for maintaining the motor-on state until the accumulated pulses reach the value of the X variable.

64. The system of claim 63 further comprising means for maintaining a respective motor-off state until starting another agitator stroke.

65. The system of claim 64 further comprising means for waiting in a dormant state for a period of time equal to the value of the delay D upon the agitator reaching the target final velocity, V_f.

66. The system of claim 65 further comprising means for comparing pulses actually accumulated during the complete agitator stroke against the value of the Y variable.

67. The system of claim 66 further comprising means for incrementing the value of the X variable depending on whether the value of the pulses actually accumulated during the complete agitator stroke is below the value of the Y variable.

68. The system of claim 67 further comprising means for decrementing the value of the delay variable D by a predetermined amount.

69. The system of claim 68 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

70. The system of claim 66 further comprising means for decrementing the value of the X variable depending on whether the value of the accumulated pulses is equal or above the value of the Y variable.

71. The system of claim 70 further means for computing number of strokes per unit of time by computing the inverse of elapsed time from start to finish of a respective stroke.

72. The system of claim 71 further comprising means for comparing the computed value of number of strokes per unit of time against a target value of strokes per unit of time.

73. The system of claim 72 further comprising means for incrementing the delay variable D by a predetermined amount when the computed value of strokes per unit of time exceeds the target value of strokes per minute.

74. The system of claim 73 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

75. The system of claim 72 further comprising means for decrementing the delay variable D by a predetermined amount when the computed value of strokes per unit of time is below or at the target value of strokes per unit of time.

76. The system of claim 75 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

77. The system of claim 58 wherein the selected agitator motion pattern comprises controlling the number of strokes of the agitator per unit of time.

78. The system of claim 77 wherein the adjusting module comprises an initializing submodule configured to set initial values of respective variables that determine a respective duty cycle of one or more of the control signals applied to the motor drive.

79. The system of claim 78 further comprising an accumulator configured to accumulate pulses indicative of agitator RPM and/or agitator travel upon start of each respective agitator stroke.

80. The system of claim 79 wherein the respective variables comprise a variable (X) having a respective value indicative of target pulses during a motor-on state, a variable (Y) having a respective value indicative of target pulses during a complete stroke, a variable (V_f) having a respective value indicative of a target final velocity of the agitator, and a variable (D) indicative of a delay value.

81. The system of claim 80 further comprising means for maintaining the motor-on state until the accumulated pulses reach the value of the X variable.

82. The system of claim 81 further comprising means for maintaining a respective motor-off state until starting another agitator stroke.

83. The system of claim 82 further comprising means for waiting in a dormant state for a period of time equal to the value of the delay upon the agitator reaching the target final velocity (V_f).

84. The system of claim 83 further comprising means for computing number of strokes per unit of time by computing the inverse of elapsed time from start to finish of a respective stroke.

85. The system of claim 84 further comprising means for comparing the computed value of number of strokes per unit of time against a target value of strokes per unit of time.

86. The system of claim 85 further comprising means for decrementing the X variable if the computed value of number of strokes per unit of time is equal or less than the target value of strokes per unit of time.

87. The system of claim 86 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating strokes of the agitator at least until completion of an agitation time cycle of the washing machine.

88. The system of claim 85 further comprising means for comparing pulses actually accumulated during the complete agitator stroke against the value of the Y variable.

89. The system of claim 88 further comprising means for incrementing the X variable if the value of the accumulated pulses is less than the Y variable.

90. The system of claim 89 further comprising means for decrementing the delay variable D by a predetermined amount.

91. The system of claim 90 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

92. The system of claim 88 further comprising means for incrementing the delay variable D by a predetermined amount if the value of the accumulated pulses is more than or equal than the Y variable.

93. The system of claim 92 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating strokes of the agitator at least until completion of an agitation time cycle of the washing machine.

94. The system of claim 58 wherein the selected motion pattern comprises controlling angular travel of the agitator during each stroke and/or the number of strokes of the agitator per unit of time.

95. The system of claim 58 wherein the pattern selection signals are programmed based on the type of fabric to be washed.

96. The system of claim 58 wherein the measuring module is further configured to count pulses from a sensor coupled to supply a stream of pulses indicative of agitator RPM and/or agitator travel.

97. The system of claim 96 wherein the sensor comprises a Hall-effect sensor.

98. A washing machine programmed for selectively controlling agitator motion patterns, the washing machine comprising:

a motor that drives the agitator;

a motor drive coupled to energize the motor; and

a controller coupled to supply one or more control signals to the motor drive, the controller in turn comprising;

a selecting module configured to select a desired agitator motion pattern based on one or more pattern selection signals;

a measuring module configured to measure one or more parameters indicative of the actual agitator motion pattern;

a comparing module configured to compare the actual agitator motion pattern against the desired agitator motion pattern; and

an adjusting module configured to adjust the one or more control signals supplied to the motor drive for correcting deviations between the actual agitator motion pattern and the desired motion pattern.

99. The washing machine of claim 98 wherein the selected agitator motion pattern comprises controlling angular travel of the agitator during each stroke of the agitator.

100. The washing machine of claim 99 wherein the adjusting module includes an initialization submodule configured to set initial values of respective variables that determine a respective duty cycle of the one or more control signals applied to the motor drive.

101. The washing machine of claim 100 further comprising an accumulator configured to accumulate pulses indicative of agitator RPM and/or agitator travel upon start of each respective agitator stroke.

102. The washing machine of claim 101 wherein the respective variables comprise a variable (X) having a respective value indicative of target pulses during a motor-on state, a variable (Y) having a respective value indicative of target pulses during a complete stroke, a variable (V_f) having a respective value indicative of a target final velocity of the agitator and a variable (D) indicative of a delay value.

103. The washing machine of claim 102 further comprising means for maintaining the motor-on state until the accumulated pulses reach the value of the X variable.

104. The washing machine of claim 103 further comprising means for maintaining a respective motor-off state until starting another agitator stroke.

105. The washing machine of claim 104 further comprising means for waiting in a dormant state for a period of time equal to the value of the delay D upon the agitator reaching the target final velocity, V_f.

106. The washing machine of claim 105 further comprising means for comparing pulses actually accumulated during the complete agitator stroke against the value of the Y variable.

107. The washing machine of claim 106 further comprising means for incrementing the value of the X variable depending on whether the value of the pulses actually accumulated during the complete agitator stroke is below the value of the Y variable.

108. The washing machine of claim 107 further comprising means for decrementing the value of the delay variable D by a predetermined amount.

109. The washing machine of claim 108 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

110. The washing machine of claim 106 further comprising means for decrementing the value of the X variable depending on whether the value of the accumulated pulses is equal or above the value of the Y variable.

111. The washing machine of claim 110 further means for computing number of strokes per unit of time by computing the inverse of elapsed time from start to finish of a respective stroke.

112. The washing machine of claim 111 further comprising means for comparing the computed value of number of strokes per unit of time against a target value of strokes per unit of time.

113. The washing machine of claim 112 further comprising means for incrementing the delay variable D by a predetermined amount when the computed value of strokes per unit of time exceeds the target value of strokes per minute.

114. The washing machine of claim 113 further comprising iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

115. The washing machine of claim 112 further comprising means for decrementing the delay variable D by a predetermined amount when the computed value of strokes per unit of time is below or at the target value of strokes per unit of time.

116. The washing machine of claim 115 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

117. The washing machine of claim 98 wherein the selected agitator motion pattern comprises controlling the number of strokes of the agitator per unit of time.

118. The washing machine of claim 117 wherein the adjusting module comprises an initializing submodule configured to set initial values of respective variables that determine a respective duty cycle of one or more of the control signals applied to the motor drive.

119. The washing machine of claim 118 further comprising an accumulator configured to accumulate pulses indicative of agitator RPM and/or agitator travel upon start of each respective agitator stroke.

120. The washing machine of claim 119 wherein the respective variables comprise a variable (X) having a respective value indicative of target pulses during a motor-on state, a variable (Y) having a respective value indicative of target pulses during a complete stroke, a variable (V_f) having a respective value indicative of a target final velocity of the agitator, and a variable (D) indicative of a delay value.

121. The washing machine of claim 120 further comprising means for maintaining the motor-on state until the accumulated pulses reach the value of the X variable.

122. The washing machine of claim 121 further comprising means for maintaining a respective motor-off state until the agitator reaches the target final velocity (V_f).

123. The washing machine of claim 122 further comprising means for waiting in a dormant state for a period of time equal to the value of the delay upon the agitator reaching the target final velocity (V_f).

124. The washing machine of claim 123 further comprising means for computing number of strokes per unit of time by computing the inverse of elapsed time from start to finish of a respective stroke.

125. The washing machine of claim 124 further comprising means for comparing the computed value of number of strokes per unit of time against a target value of strokes per unit of time.

126. The washing machine of claim 125 further comprising means for decrementing the X variable if the computed value of number of strokes per unit of time is equal or less than the target value of strokes per unit of time.

127. The washing machine of claim 126 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating strokes of the agitator at least until completion of an agitation time cycle of the washing machine.

128. The washing machine of claim 125 further comprising means for comparing pulses actually accumulated during the complete agitator stroke against the value of the Y variable.

129. The system of claim 128 further comprising means for incrementing the X variable if the value of the accumulated pulses is less than the Y variable.

130. The washing machine of claim 129 further comprising means for decrementing the delay variable D by a predetermined amount.

131. The washing machine of claim 130 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating stroke of the agitator at least until completion of an agitation time cycle of the washing machine.

132. The washing machine of claim 128 further comprising means for incrementing the delay variable D by a predetermined amount if the value of the accumulated pulses is more than or equal than the Y variable.

133. The washing machine of claim 132 further comprising means for iteratively executing the step for adjusting the one or more control signals supplied to the motor drive using the adjusted values of the respective variables X, Y, and D for each respective successive reciprocating strokes of the agitator at least until completion of an agitation time cycle of the washing machine.

134. The washing machine of claim 98 wherein the selected motion pattern comprises controlling angular travel of the agitator during each stroke and/or the number of strokes of the agitator per unit of time.

135. The washing machine of claim 98 wherein the pattern selection signals are programmed based on the type of fabric to be washed.

136. The washing machine of claim 98 wherein the measuring module is further configured to count pulses from a sensor coupled to supply a stream of pulses indicative of agitator RPM and/or agitator travel.

137. The washing machine of claim 136 wherein the sensor comprises a Hall-effect sensor.