EP4036300A1 - Method to estimate a load behavior in a laundry treatment machine - Google Patents

Method to estimate a load behavior in a laundry treatment machine Download PDF

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Publication number
EP4036300A1
EP4036300A1 EP22164092.3A EP22164092A EP4036300A1 EP 4036300 A1 EP4036300 A1 EP 4036300A1 EP 22164092 A EP22164092 A EP 22164092A EP 4036300 A1 EP4036300 A1 EP 4036300A1
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EP
European Patent Office
Prior art keywords
load
torque
observer
drive motor
angular speed
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Pending
Application number
EP22164092.3A
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German (de)
French (fr)
Inventor
Daniele Martinello
Viktor BOBEK
Pavol Petracek
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Haier Germany GmbH
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Haier Germany GmbH
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Priority to EP22164092.3A priority Critical patent/EP4036300A1/en
Publication of EP4036300A1 publication Critical patent/EP4036300A1/en
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    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F33/00Control of operations performed in washing machines or washer-dryers 
    • D06F33/50Control of washer-dryers characterised by the purpose or target of the control
    • D06F33/76Preventing or reducing imbalance or noise
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F34/00Details of control systems for washing machines, washer-dryers or laundry dryers
    • D06F34/14Arrangements for detecting or measuring specific parameters
    • D06F34/16Imbalance
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F58/00Domestic laundry dryers
    • D06F58/32Control of operations performed in domestic laundry dryers 
    • D06F58/34Control of operations performed in domestic laundry dryers  characterised by the purpose or target of the control
    • D06F58/52Preventing or reducing noise
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2103/00Parameters monitored or detected for the control of domestic laundry washing machines, washer-dryers or laundry dryers
    • D06F2103/24Spin speed; Drum movements
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2103/00Parameters monitored or detected for the control of domestic laundry washing machines, washer-dryers or laundry dryers
    • D06F2103/44Current or voltage
    • D06F2103/46Current or voltage of the motor driving the drum
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2105/00Systems or parameters controlled or affected by the control systems of washing machines, washer-dryers or laundry dryers
    • D06F2105/46Drum speed; Actuation of motors, e.g. starting or interrupting
    • D06F2105/48Drum speed
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2105/00Systems or parameters controlled or affected by the control systems of washing machines, washer-dryers or laundry dryers
    • D06F2105/52Changing sequence of operational steps; Carrying out additional operational steps; Modifying operational steps, e.g. by extending duration of steps
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06FLAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
    • D06F2105/00Systems or parameters controlled or affected by the control systems of washing machines, washer-dryers or laundry dryers
    • D06F2105/62Stopping or disabling machine operation

Definitions

  • the invention relates to a method to estimate a load behavior in a laundry treatment machine. Furthermore, the invention relates to a laundry treatment machine with a control unit to estimate a load behavior.
  • the laundry treatment machine is a washing machine or a drying machine or a combined washing and drying machine.
  • the estimation of a load inertia at the beginning of a washing cycle has a key role to set the amount of resources such as water, detergent, bleach and softener and the amount of energy in order to achieve a good washing performance without wasting resources and energy.
  • the load inertia is caused by the laundry within the drum of the laundry treatment machine and varies in a wide range.
  • the washing unit is suspended to the cabinet by a set of springs and dampers.
  • This mechanical system is adjusted to have a resonance frequency at a relatively low angular speed between 150 rpm and 300 rpm.
  • the angular speed of the drum has to cross this resonance region without interference between the tub and the cabinet. Due to an increase of the drum size and a loading capacity of the laundry treatment machine the available space between the tub and the cabinet decreased. As a consequence, a precise estimation of a load unbalance is required in order to avoid a mechanical impact between the tub and the cabinet when the resonance region is crossed.
  • US 2005/204482 A1 discloses a method to estimate a load inertia and a load unbalance. The estimation is based on an angular speed signal and a torque signal during an acceleration of the drum or during superimposition of a dither signal to a substantially constant angular speed in order to excite the mechanical system of the laundry treatment machine.
  • the inertia and/or the load torque is determined based on two operations of the laundry treatment machine with two different speed controller parameters and bandwidths of the speed controller.
  • the speed controller regulates the angular speed of the drive motor an is part of the speed control loop.
  • T em * 1 denotes the first torque signal
  • ⁇ ⁇ 1 ⁇ denotes the derivative of the first angular speed signal
  • T em * 2 denotes the second torque signal
  • ⁇ ⁇ 2 ⁇ denotes the derivative of the second angular speed signal
  • T ⁇ L denotes the load torque
  • ⁇ t denotes the total inertia of the laundry treatment machine with regard to a rotation around the rotational axis.
  • the inertia J m of the laundry treatment machine is known from construction data or can be measured by running a test without a distributed load inside the drum.
  • the load torque can be determined, for example according to equation (1) and/or equation (2) and/or by means of a load observer as soon as the total inertia ⁇ t is estimated according to equation (3) and the load torque observer is parametrized accordingly.
  • the load torque observer enables an accurate and continuous estimation of the load torque.
  • the load torque observer can be easily implemented into a control unit of a laundry treatment machine. Additional hardware components, like sensors, are not required.
  • the advantages of the inventive method are as follows:
  • the load inertia and the total inertia can be evaluated at a constant angular speed, for example at 100 rpm, in order to avoid the use of an acceleration ramp and to avoid the risk of a mechanical impact between the tub and the cabinet.
  • the method can be used to estimate the dry load at the beginning of the washing cycle without using an acceleration ramp in order to set the amount of resources and energy.
  • the inertia estimation can be used to stop the drying cycle at a desired moisture retention.
  • the inventive method can be used to estimate the wet load at the end of the washing cycle without using an acceleration ramp.
  • the estimated load torque and an estimation of the load unbalance based thereon can be automatically adapted with the estimated total inertia.
  • the inventive method can be used in a laundry treatment machine with a large drum and can be easily implemented in existing control units.
  • the estimation of the inertia and/or the load torque is not affected by friction or by the speed controller setting.
  • the estimation of the inertia and/or the load torque just requires an operation of the laundry treatment machine at a constant angular speed without the need of an acceleration ramp such that the inertia and/or the load torque can be estimated in an easy and quick manner.
  • a method according to claim 2 ensures an easy, reliable and accurate estimation of the load behavior.
  • the desired angular speed or the target speed is constant.
  • the resulting speed fluctuations or speed oscillations depend on the bandwidth of the speed controller and/or on the controller parameters of the speed controller, on the mass of the load and on the total inertia.
  • a change of the speed controller parameters that changes the bandwidth of the speed controller at a constant desired angular speed results in a change of the speed oscillations and of the drive torque.
  • the angular speed oscillations about the constant desired angular speed could be, as example, within +- 10 rpm, or within +- 5 rpm, or within +- 2 rpm.
  • a method according to claim 3 ensures an easy, reliable and accurate estimation of the load behavior.
  • the mass of the load can be estimated in an easy and accurate manner depending on the load torque.
  • a method according to claim 4 ensures an easy, reliable and accurate estimation of the load behavior.
  • a method according to claim 5 ensures an easy, reliable and accurate estimation of the load behavior.
  • the total inertia can be easily estimated according to equation (3).
  • the load inertia can be easily estimated according to equation (4).
  • a method according to claim 6 ensures an easy, reliable and accurate estimation of the load behavior.
  • the signals are transformed into a frequency domain, in particular by computing a Fourier Transformation (FT). This transformation enables to determine respective first harmonics of the signals.
  • the first harmonics are used for the subsequent determination of the inertia and/or the load torque.
  • the determination of the inertia and/or the load torque is not affected by noise signals.
  • the first harmonics comprise information about the frequency, the amplitude and the phase of the signals. At least one of the frequency, the amplitude and the phase are used for the subsequent estimation of the inertia and/or the load torque.
  • a method according to claim 7 ensures an easy, reliable an accurate estimation of the load behavior.
  • the first harmonics of the signals are calculated for example by a Fourier Transformation (FT).
  • the first harmonics comprise information about the frequency, the amplitude and the phase of the signals. At least one of the frequency, the amplitude and the phase are used for the subsequent estimation of the inertia and/or the load torque.
  • a method according to claim 8 ensures an easy, reliable and accurate estimation of the load behavior.
  • the angular position and/or the drive torque of the drive motor can either be measured or estimated.
  • the angular position is used to calculate an observer error.
  • a method according to claim 9 ensures an easy, reliable and accurate estimation of the load behavior.
  • the observer error is used to estimate and/or correct internal states of the load torque observer.
  • the internal states of the load torque observer are in particular the observed angular position, an observed angular acceleration and the load torque.
  • the observer error is multiplied with observer coefficients or observer gains. The observer coefficients are used to adapt the accuracy and the behavior of the load torque observer.
  • a method according to claim 10 ensures an easy, reliable and accurate estimation of the load behavior.
  • the observer error is multiplied with observer coefficients or observer gains in order to calculate observer signals. These observer signals are used to estimate and/or correct the internal states of the observer.
  • a first observer signal is calculated by multiplying a derivative of the observer error with a first observer coefficient.
  • a second observer signal is calculated by multiplying the observer error with a second observer coefficient.
  • a third observer signal is calculated by multiplying the observer error with a third observer coefficient and by integrating the resulting signal.
  • the load torque depends on the sum of the first observer signal, the second observer signal and the third observer signal.
  • a method according to claim 11 ensures an easy, reliable and accurate estimation of the load behavior.
  • An observed angular acceleration and in consequence the observed angular position depends on the total inertia of the laundry treatment machine and the load.
  • the total inertia is estimated according to equation (3).
  • the total inertia can be adapted during the operation of the laundry treatment machine, if necessary. For example, the total inertia increases depending on the wetness of the laundry.
  • a method according to claim 12 ensures an easy, reliable and accurate estimation of the load behavior.
  • Sensorless drive motors are well known and do not comprise an angular position sensor and an angular speed sensor.
  • the angular position of the drive motor is estimated, for example by means of a position and/or speed estimator or a position and/or speed observer.
  • the load torque observer is preferably provided with an estimated angular position of the drive motor.
  • a method according to claim 13 ensures an easy, reliable and accurate estimation of the load behavior.
  • the load torque observer is provided with the desired drive torque of the drive motor.
  • An output signal of the speed controller is used to estimate the drive torque.
  • This output signal characterizes the desired electromagnetic drive torque of the drive motor and can be used to estimate the drive torque and/or the load torque which acts on the drum.
  • Fig. 1 shows a laundry treatment machine, namely a washing machine 1 with a cabinet 2 and a washing unit 3.
  • the washing unit 3 comprises a tub 4 and a drum 5.
  • the tub 4 is mounted to the cabinet 2 via dampers 6 and springs 7.
  • the drum 5 is mounted in a rotatable manner to the tub 4.
  • the drum 5 is connected via a drive shaft 8 with a drive motor 9.
  • the drive motor 9 is mounted at a backside of the tub 4.
  • the drive motor 9 rotates the drum 5 around a horizontal rotational axis 10.
  • the washing machine 1 comprises several lifters 11 to move the laundry.
  • the lifters 11 are mounted in equal angular distances to an inner side of the drum 5.
  • the washing machine 1 comprises a control unit 12 to control the operation of the washing machine 1.
  • the drive motor 9 has an angular position ⁇ , an angular speed ⁇ and an angular acceleration ⁇ . Due to the stiff drive shaft 8 the angular position, the angular speed and the angular acceleration of the drum 5 corresponds to the angular position ⁇ , the angular speed ⁇ and the angular acceleration ⁇ . In case of belt driven motor, the pulley ratio will be used to evaluate the angular position, the angular speed and the angular acceleration of the drum starting from the angular position, the angular speed and the angular acceleration of the motor.
  • the load L namely the laundry inside the drum 5 produces a load torque T L .
  • T L ⁇ mgr sin ⁇ + ⁇
  • m denotes the real mass of the load L
  • g denotes the gravitational acceleration
  • r denotes the drum radius
  • denotes the angular relative position of the load L inside the drum, namely an angle between the position of the load L and a drum reference position.
  • the angular positions ⁇ and ⁇ and the mass m are unknown.
  • the gravitational acceleration g and the drum radius r are known.
  • the drive motor 9 creates a drive torque T em which accelerates the drum 5.
  • the drive torque T em is superimposed by the load torque T L .
  • the control unit 12 comprises a speed controller 13, a torque controller 14, a first coordinate transformation 15, a pulse width modulator 16, a position and speed observer 17, a second coordinate transformation 18 and a load torque observer 19.
  • the torque controller 14 is part of an inner control loop or a torque control loop to control the drive torque T em of the drive motor 9.
  • the torque controller 14 is a PI controller.
  • the torque controller 14 is provided with a desired drive torque T em * and the drive motor currents which are denoted in common with i abc .
  • the drive motor currents i abc are transformed by means of the second coordinate transformation 18 into a dq coordinate system.
  • the corresponding currents are denoted in common with i dq .
  • the torque controller 14 creates in the dq coordinate system desired voltages which are denoted in common with v * dq .
  • the voltages v * dq are transformed by means of the first coordinate transformation 15 into desired voltages in an abc coordinate system which are denoted in common with v abc .
  • the voltages v abc are provided to the pulse width modulator 16 which creates via a switch circuit currents i a , i b , i c to operate the drive motor 9 with a torque T em which corresponds to the desired torque T em * .
  • the drive motor 9 is designed sensorless, namely without a speed sensor and a torque sensor. Therefore, the position and speed observer 17 is used to produce an estimated angular position ⁇ and an estimated angular speed ⁇ .
  • the position and speed observer 17 is provided with the voltages v abc and the currents i abc .
  • the estimated angular position ⁇ is provided to the first coordinate transformation 15 and the second coordinate transformation 18.
  • the speed controller 13 is part of an outer control loop or a speed control loop.
  • the speed controller 13 is provided with the difference of a desired angular speed ⁇ ⁇ and the estimated angular speed ⁇ .
  • the output signal of the speed controller 13 is the desired drive torque T em * .
  • the load torque observer 19 evaluates an estimated load torque T ⁇ L .
  • the load torque observer 19 is provided with the desired drive torque T em * and the estimated angular position ⁇ as input signals.
  • the load torque observer 19 calculates an observer error e obs which is the difference of the estimated angular position ⁇ and an observed angular position ⁇ obs .
  • the observer coefficients are for example set to
  • the load torque observer 19 calculates an observed angular speed ⁇ obs by integrating the observed angular acceleration ⁇ obs . Furthermore, the load torque observer 19 calculates the observed angular position ⁇ obs by integrating the observed angular speed ⁇ obs .
  • step S 1 the speed controller 13 is parametrized with first controller parameters P 1 .
  • the speed controller 13 is a PI controller.
  • a second step S 2 the drum 5 is accelerated by means of the drive motor 9 as example from 0 rpm to 100 rpm.
  • a third step S 3 the drum 5 is rotated with an essentially constant drum speed ⁇ .
  • the control unit 12 transforms the desired drive torque T em * and the estimated angular speed ⁇ into the frequency domain by calculating a Fourier Transformation.
  • the first harmonic of the desired drive torque T em * is stored in the control unit 12 and is denoted T em * 1 .
  • the first harmonic information for example the frequency, the amplitude and the phase, of the estimated angular speed ⁇ are used to get an estimated angular acceleration which is denoted ⁇ ⁇ 1 ⁇ .
  • the estimated angular acceleration ⁇ ⁇ 1 ⁇ is stored in the control unit 12.
  • step S 4 the speed controller 13 is parametrized with second controller parameters P 2 .
  • a fifth step S 5 the drum 5 is rotated with an essentially constant drum speed ⁇ .
  • the control unit 12 transforms the desired drive torque T em * and the estimated angular speed ⁇ into the frequency domain by calculating a Fourier Transformation.
  • the first harmonic of the desired drive torque T em * is stored in the control unit 12 and is denoted T em * 2 .
  • the first harmonic information for example the frequency, the amplitude and the phase, of the estimated angular speed ⁇ are used to get an estimated angular acceleration which is denoted ⁇ ⁇ 2 ⁇ .
  • the estimated angular acceleration ⁇ ⁇ 2 ⁇ is stored in the control unit 12.
  • Equation (15) is illustrated in fig. 7 .
  • Fig. 8 illustrates the estimated load torque T ⁇ L .
  • the load inertia ⁇ L , the load torque T ⁇ L , the mass m ⁇ and the angular load position ⁇ characterize the behavior of the load L and can be used for several purposes, for example to adapt the maximum spinning speed, to compensate the load L by filling the balancers 11 with water, to estimate the dry load at the beginning of the washing cycle and to set properly the required amount of water and/or detergent, to estimate the wet load at the beginning of the spinning cycle and to estimate the remaining moisture retention during a drying process.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Control Of Washing Machine And Dryer (AREA)

Abstract

A method to estimate a load behavior in a laundry treatment machine comprises the step of determining an inertia (Ĵ<sub>t</sub>, Ĵ<sub>L</sub>) and/or a load torque caused by a load depending on a first torque signal Tem*1, a second torque signal Tem*2, a derivative ω˙1^ of a first angular speed signal and a derivative ω˙2^ of a second angular speed signal. These signals are based on a first operation and a second operation of the laundry treatment machine, wherein a controller of the laundry treatment machine is operated with different controller parameters (P<sub>1</sub>, P<sub>2</sub>). The method enables to estimate the load behavior in an easy, reliable and accurate manner.

Description

  • The invention relates to a method to estimate a load behavior in a laundry treatment machine. Furthermore, the invention relates to a laundry treatment machine with a control unit to estimate a load behavior. For example, the laundry treatment machine is a washing machine or a drying machine or a combined washing and drying machine.
  • The estimation of a load inertia at the beginning of a washing cycle has a key role to set the amount of resources such as water, detergent, bleach and softener and the amount of energy in order to achieve a good washing performance without wasting resources and energy. The load inertia is caused by the laundry within the drum of the laundry treatment machine and varies in a wide range.
  • The washing unit is suspended to the cabinet by a set of springs and dampers. This mechanical system is adjusted to have a resonance frequency at a relatively low angular speed between 150 rpm and 300 rpm. During the spinning phase, the angular speed of the drum has to cross this resonance region without interference between the tub and the cabinet. Due to an increase of the drum size and a loading capacity of the laundry treatment machine the available space between the tub and the cabinet decreased. As a consequence, a precise estimation of a load unbalance is required in order to avoid a mechanical impact between the tub and the cabinet when the resonance region is crossed.
  • US 2005/204482 A1 discloses a method to estimate a load inertia and a load unbalance. The estimation is based on an angular speed signal and a torque signal during an acceleration of the drum or during superimposition of a dither signal to a substantially constant angular speed in order to excite the mechanical system of the laundry treatment machine.
  • It is an object of the present invention to provide a method to estimate a load behavior in a laundry treatment machine in an easy, reliable and accurate manner.
  • This object is achieved by a method comprising the steps of claim 1. According to the inventive method the inertia and/or the load torque is determined based on two operations of the laundry treatment machine with two different speed controller parameters and bandwidths of the speed controller. The speed controller regulates the angular speed of the drive motor an is part of the speed control loop. The first operation can be described by T ^ L + T em 1 = J ^ t ω ˙ 1 ^
    Figure imgb0001
    and the second operation can be described by T ^ L + T em 2 = J ^ t ω ˙ 2 ^
    Figure imgb0002
    wherein
    T em * 1
    Figure imgb0003
      denotes the first torque signal,
    ω ˙ 1 ^
    Figure imgb0004
      denotes the derivative of the first angular speed signal,
    T em * 2
    Figure imgb0005
      denotes the second torque signal,
    ω ˙ 2 ^
    Figure imgb0006
      denotes the derivative of the second angular speed signal,
    L   denotes the load torque and
    t   denotes the total inertia of the laundry treatment machine with regard to a rotation around the rotational axis.
  • Based on equations (1) and (2) the total inertia can be evaluated by J ^ t = T em 1 T em 2 ω ˙ 1 ^ ω ˙ 2 ^
    Figure imgb0007
  • The load inertia can be evaluated by J ^ L = J ^ t J m
    Figure imgb0008
    wherein
  • ĴL
    denotes the load inertia and
    Jm
    denotes the inertia of the laundry treatment machine.
  • The inertia Jm of the laundry treatment machine is known from construction data or can be measured by running a test without a distributed load inside the drum.
  • Furthermore, in case that the load inertia is evaluated according to equation (4), the load torque can be determined, for example according to equation (1) and/or equation (2) and/or by means of a load observer as soon as the total inertia t is estimated according to equation (3) and the load torque observer is parametrized accordingly.
  • The load torque observer enables an accurate and continuous estimation of the load torque. The load torque observer can be easily implemented into a control unit of a laundry treatment machine. Additional hardware components, like sensors, are not required.
  • The advantages of the inventive method are as follows:
    The load inertia and the total inertia can be evaluated at a constant angular speed, for example at 100 rpm, in order to avoid the use of an acceleration ramp and to avoid the risk of a mechanical impact between the tub and the cabinet. The same applies for the estimation of a load unbalance based on the load torque. The method can be used to estimate the dry load at the beginning of the washing cycle without using an acceleration ramp in order to set the amount of resources and energy. In case of a combined washing and drying machine or a drying machine the inertia estimation can be used to stop the drying cycle at a desired moisture retention. Furthermore, the inventive method can be used to estimate the wet load at the end of the washing cycle without using an acceleration ramp. The estimated load torque and an estimation of the load unbalance based thereon can be automatically adapted with the estimated total inertia. The inventive method can be used in a laundry treatment machine with a large drum and can be easily implemented in existing control units. The estimation of the inertia and/or the load torque is not affected by friction or by the speed controller setting. Furthermore, the estimation of the inertia and/or the load torque just requires an operation of the laundry treatment machine at a constant angular speed without the need of an acceleration ramp such that the inertia and/or the load torque can be estimated in an easy and quick manner.
  • A method according to claim 2 ensures an easy, reliable and accurate estimation of the load behavior. The desired angular speed or the target speed is constant. The resulting speed fluctuations or speed oscillations depend on the bandwidth of the speed controller and/or on the controller parameters of the speed controller, on the mass of the load and on the total inertia. A change of the speed controller parameters that changes the bandwidth of the speed controller at a constant desired angular speed results in a change of the speed oscillations and of the drive torque. The angular speed oscillations about the constant desired angular speed could be, as example, within +- 10 rpm, or within +- 5 rpm, or within +- 2 rpm.
  • A method according to claim 3 ensures an easy, reliable and accurate estimation of the load behavior. The mass of the load can be estimated in an easy and accurate manner depending on the load torque. The unbalance mass can be estimated by m ^ = max T ^ L g r
    Figure imgb0009
    wherein
  • denotes the mass of the load which corresponds to the unbalance mass,
    max(T̂L)
    denotes the maximum of the load torque,
    g
    denotes the gravitational acceleration and
    r
    denotes the drum radius.
  • A method according to claim 4 ensures an easy, reliable and accurate estimation of the load behavior. The angular load position can be estimated by solving T ^ L = m ^ g r sin Θ ^ + σ ^
    Figure imgb0010
    wherein
  • Θ̂
    denotes the angular drum position in relation to a reference position,
    σ̂
    denotes the angular relative load position inside the drum,
    T̂L
    denotes the load torque,
    denotes the mass of the load which corresponds to the unbalance mass,
    g
    denotes the gravitational acceleration and
    r
    denotes the drum radius.
  • The angular load position can be described by α ^ = θ ^ + σ ^ ,
    Figure imgb0011
    wherein
    • α̂ denotes the angular position of the load in relation to the reference position
    • such that T ^ L = m ^ g r cos α ^
      Figure imgb0012
      since the load torque has a maximum value, if α̂ = 90°.
  • A method according to claim 5 ensures an easy, reliable and accurate estimation of the load behavior. The total inertia can be easily estimated according to equation (3). Furthermore, the load inertia can be easily estimated according to equation (4).
  • A method according to claim 6 ensures an easy, reliable and accurate estimation of the load behavior. The signals are transformed into a frequency domain, in particular by computing a Fourier Transformation (FT). This transformation enables to determine respective first harmonics of the signals. The first harmonics are used for the subsequent determination of the inertia and/or the load torque. The determination of the inertia and/or the load torque is not affected by noise signals. The first harmonics comprise information about the frequency, the amplitude and the phase of the signals. At least one of the frequency, the amplitude and the phase are used for the subsequent estimation of the inertia and/or the load torque.
  • A method according to claim 7 ensures an easy, reliable an accurate estimation of the load behavior. By using the first harmonics of the signals the estimation of the inertia and/or the load torque is not affected by noise signals. The first harmonics of the signals are calculated for example by a Fourier Transformation (FT). The first harmonics comprise information about the frequency, the amplitude and the phase of the signals. At least one of the frequency, the amplitude and the phase are used for the subsequent estimation of the inertia and/or the load torque.
  • A method according to claim 8 ensures an easy, reliable and accurate estimation of the load behavior. The angular position and/or the drive torque of the drive motor can either be measured or estimated. The angular position is used to calculate an observer error.
  • A method according to claim 9 ensures an easy, reliable and accurate estimation of the load behavior. The observer error is used to estimate and/or correct internal states of the load torque observer. The internal states of the load torque observer are in particular the observed angular position, an observed angular acceleration and the load torque. The observer error is multiplied with observer coefficients or observer gains. The observer coefficients are used to adapt the accuracy and the behavior of the load torque observer.
  • A method according to claim 10 ensures an easy, reliable and accurate estimation of the load behavior. The observer error is multiplied with observer coefficients or observer gains in order to calculate observer signals. These observer signals are used to estimate and/or correct the internal states of the observer. A first observer signal is calculated by multiplying a derivative of the observer error with a first observer coefficient. A second observer signal is calculated by multiplying the observer error with a second observer coefficient. Furthermore, a third observer signal is calculated by multiplying the observer error with a third observer coefficient and by integrating the resulting signal. The load torque depends on the sum of the first observer signal, the second observer signal and the third observer signal.
  • A method according to claim 11 ensures an easy, reliable and accurate estimation of the load behavior. An observed angular acceleration and in consequence the observed angular position depends on the total inertia of the laundry treatment machine and the load. The total inertia is estimated according to equation (3). The total inertia can be adapted during the operation of the laundry treatment machine, if necessary. For example, the total inertia increases depending on the wetness of the laundry.
  • A method according to claim 12 ensures an easy, reliable and accurate estimation of the load behavior. Sensorless drive motors are well known and do not comprise an angular position sensor and an angular speed sensor. Hence, the angular position of the drive motor is estimated, for example by means of a position and/or speed estimator or a position and/or speed observer. The load torque observer is preferably provided with an estimated angular position of the drive motor.
  • A method according to claim 13 ensures an easy, reliable and accurate estimation of the load behavior. The load torque observer is provided with the desired drive torque of the drive motor. An output signal of the speed controller is used to estimate the drive torque. This output signal characterizes the desired electromagnetic drive torque of the drive motor and can be used to estimate the drive torque and/or the load torque which acts on the drum.
  • Furthermore, it is an object of the present invention to provide a laundry treatment machine which enables to estimate a load behavior in an easy, reliable and accurate manner.
  • This object is achieved by a laundry treatment machine with the features of claim 14. The advantages of the laundry treatment machine according to the invention correspond to the advantages already described in connection with the method according to the invention.
  • Further features, advantages and details of the invention will be apparent from the following description of an embodiment which refers to the accompanying drawings.
  • Fig. 1
    shows a schematic view of a laundry treatment machine with a drum, a drive motor and a control unit,
    Fig. 2
    shows a schematic cross sectional view of the drum with a load located inside the drum,
    Fig. 3
    shows a block diagram of a controller and a load torque observer implemented in the control unit,
    Fig. 4
    shows a block diagram of the load torque observer in Fig. 3,
    Fig. 5
    shows a flow chart of a method to estimate a total inertia of the laundry treatment machine and the load with respect to a rotation of the drum around a rotational axis,
    Fig. 6
    shows a time diagram of an angular speed and a drive torque of the drive motor during a first operation and a second operation of the laundry treatment machine in order to estimate the total inertia according to the flow chart in Fig. 5,
    Fig. 7
    shows a first torque signal and a first angular acceleration signal during a first operation and a second torque signal and a second angular acceleration signal during a second operation of the laundry treatment machine as well as a torque difference signal and an acceleration difference signal depending on the angular position of the drum in order to estimate the total inertia, and
    Fig. 8
    shows an estimated load torque depending on an angular position of the drum.
  • Fig. 1 shows a laundry treatment machine, namely a washing machine 1 with a cabinet 2 and a washing unit 3. The washing unit 3 comprises a tub 4 and a drum 5. The tub 4 is mounted to the cabinet 2 via dampers 6 and springs 7.
  • The drum 5 is mounted in a rotatable manner to the tub 4. The drum 5 is connected via a drive shaft 8 with a drive motor 9. The drive motor 9 is mounted at a backside of the tub 4. The drive motor 9 rotates the drum 5 around a horizontal rotational axis 10.
  • The washing machine 1 comprises several lifters 11 to move the laundry. The lifters 11 are mounted in equal angular distances to an inner side of the drum 5.
  • Furthermore, the washing machine 1 comprises a control unit 12 to control the operation of the washing machine 1. The drive motor 9 has an angular position Θ, an angular speed ω and an angular acceleration ω̇. Due to the stiff drive shaft 8 the angular position, the angular speed and the angular acceleration of the drum 5 corresponds to the angular position Θ, the angular speed ω and the angular acceleration ω̇. In case of belt driven motor, the pulley ratio will be used to evaluate the angular position, the angular speed and the angular acceleration of the drum starting from the angular position, the angular speed and the angular acceleration of the motor.
  • The load L, namely the laundry inside the drum 5 produces a load torque TL. In case that the angular speed of the drum 5 is higher than a satelization speed the load torque TL can be described by T L = mgr sin θ + σ
    Figure imgb0013
    wherein
    m  denotes the real mass of the load L,
    g  denotes the gravitational acceleration,
    r  denotes the drum radius,
    Figure imgb0014
      denotes the angular position of the drum in relation to a reference position Θ0, and
    σ   denotes the angular relative position of the load L inside the drum, namely an angle between the position of the load L and a drum reference position.
  • The angular position α of the load L can be described by α = Θ + σ
    Figure imgb0015
    wherein
  • α
    denotes the angular position of the load L in relation to the reference position θ0.
  • The angular positions σ and α and the mass m are unknown. The gravitational acceleration g and the drum radius r are known. The load torque TL has a maximum value if α = 90° such that T L = mgr cos α .
    Figure imgb0016
  • The drive motor 9 creates a drive torque Tem which accelerates the drum 5. The drive torque Tem is superimposed by the load torque TL.
  • The control unit 12 comprises a speed controller 13, a torque controller 14, a first coordinate transformation 15, a pulse width modulator 16, a position and speed observer 17, a second coordinate transformation 18 and a load torque observer 19.
  • The torque controller 14 is part of an inner control loop or a torque control loop to control the drive torque Tem of the drive motor 9. For example, the torque controller 14 is a PI controller. The torque controller 14 is provided with a desired drive torque T em *
    Figure imgb0017
    and the drive motor currents which are denoted in common with iabc. The drive motor currents iabc are transformed by means of the second coordinate transformation 18 into a dq coordinate system. The corresponding currents are denoted in common with idq. The torque controller 14 creates in the dq coordinate system desired voltages which are denoted in common with v* dq. The voltages v* dq are transformed by means of the first coordinate transformation 15 into desired voltages in an abc coordinate system which are denoted in common with vabc. The voltages vabc are provided to the pulse width modulator 16 which creates via a switch circuit currents ia, ib, ic to operate the drive motor 9 with a torque Tem which corresponds to the desired torque T em *
    Figure imgb0018
    .
  • The drive motor 9 is designed sensorless, namely without a speed sensor and a torque sensor. Therefore, the position and speed observer 17 is used to produce an estimated angular position Θ̂ and an estimated angular speed ω̂. The position and speed observer 17 is provided with the voltages vabc and the currents iabc. The estimated angular position Θ̂ is provided to the first coordinate transformation 15 and the second coordinate transformation 18.
  • The speed controller 13 is part of an outer control loop or a speed control loop. The speed controller 13 is provided with the difference of a desired angular speed ω and the estimated angular speed ω̂. The output signal of the speed controller 13 is the desired drive torque T em *
    Figure imgb0019
    .
  • The load torque observer 19 evaluates an estimated load torque L. The load torque observer 19 is provided with the desired drive torque T em *
    Figure imgb0020
    and the estimated angular position Θ̂ as input signals. The load torque observer 19 calculates an observer error eobs which is the difference of the estimated angular position Θ̂ and an observed angular position Θobs.
  • The load torque observer 19 calculates three observer signals k1, k2 and k3. These observer signals can be described by: k 1 = K 1 s e obs
    Figure imgb0021
    k 2 = K 2 e obs
    Figure imgb0022
    k 3 = K 3 / s e obs
    Figure imgb0023
    wherein
    • k1 denotes a first observer coefficient,
    • k2 denotes a second observer coefficient,
    • k3 denotes a third observer coefficient,
    • s denotes a derivator, and
    • 1/s denotes an integrator.
  • The observer coefficients are for example set to
    • K1 = 64,
    • K2 = 13, and
    • K3=5.
  • The estimated load torque L can be calculated by T ^ L = k 1 + k 2 + k 3
    Figure imgb0024
  • The load torque observer 19 calculates an observed angular acceleration ω̇obs by ω ˙ obs = 1 J ^ t T em * T ^ L
    Figure imgb0025
    wherein
    • t is the total inertia of those parts of the washing machine 1 which rotate around the rotational axis 10, in particular of the drum 5 with the balancers 11, of the drive shaft 8, of the drive motor 9, and of the load L. The total inertia can be described by J ^ t = J ^ L + J m
      Figure imgb0026
      wherein
    • L denotes the load inertia and Jm denotes the inertia of the washing machine 1. The inertia of the washing machine 1 is known from construction data.
  • The load torque observer 19 calculates an observed angular speed ω obs by integrating the observed angular acceleration ω̇ obs . Furthermore, the load torque observer 19 calculates the observed angular position Θobs by integrating the observed angular speed ωobs .
  • In the following the estimation of the total inertia t is described in detail:
    In step S1 the speed controller 13 is parametrized with first controller parameters P1. For example, the speed controller 13 is a PI controller.
  • In a second step S2 the drum 5 is accelerated by means of the drive motor 9 as example from 0 rpm to 100 rpm.
  • Afterwards, in a third step S3 the drum 5 is rotated with an essentially constant drum speed ω. During the third step S3 the control unit 12 transforms the desired drive torque T em *
    Figure imgb0027
    and the estimated angular speed ω̂ into the frequency domain by calculating a Fourier Transformation. The first harmonic of the desired drive torque T em *
    Figure imgb0028
    is stored in the control unit 12 and is denoted T em * 1
    Figure imgb0029
    . Furthermore, the first harmonic information, for example the frequency, the amplitude and the phase, of the estimated angular speed ω̂ are used to get an estimated angular acceleration which is denoted ω ˙ 1 ^
    Figure imgb0030
    . The estimated angular acceleration ω ˙ 1 ^
    Figure imgb0031
    is stored in the control unit 12.
  • Afterwards, in a step S4 the speed controller 13 is parametrized with second controller parameters P2.
  • Afterwards, in a fifth step S5 the drum 5 is rotated with an essentially constant drum speed ω. During the step S5 the control unit 12 transforms the desired drive torque T em *
    Figure imgb0032
    and the estimated angular speed ω̂ into the frequency domain by calculating a Fourier Transformation. The first harmonic of the desired drive torque T em *
    Figure imgb0033
    is stored in the control unit 12 and is denoted T em * 2
    Figure imgb0034
    . Furthermore, the first harmonic information, for example the frequency, the amplitude and the phase, of the estimated angular speed ω̂ are used to get an estimated angular acceleration which is denoted ω ˙ 2 ^
    Figure imgb0035
    . The estimated angular acceleration ω ˙ 2 ^
    Figure imgb0036
    is stored in the control unit 12.
  • In a subsequent sixth step S6 the total inertia can be calculated by J ^ t = T em * 1 T em * 2 ω ˙ 1 ^ ω ˙ 2 ^
    Figure imgb0037
  • The estimated total inertia t is used to parametrize the load torque observer 19. Equation (15) is illustrated in fig. 7.
  • After parameterization the load torque observer 19 can be used in a seventh step to observe and estimate the load torque L. Furthermore, the load inertia can be calculated by J ^ L = J ^ t J m
    Figure imgb0038
    and the estimated mass m̂ of the load or the unbalance mass can be calculated by m ^ = max T ^ L gr
    Figure imgb0039
  • The angular position Θ̂ of the load L is already known. Fig. 8 illustrates the estimated load torque L.
  • The load inertia L, the load torque L, the mass and the angular load position Θ̂ characterize the behavior of the load L and can be used for several purposes, for example to adapt the maximum spinning speed, to compensate the load L by filling the balancers 11 with water, to estimate the dry load at the beginning of the washing cycle and to set properly the required amount of water and/or detergent, to estimate the wet load at the beginning of the spinning cycle and to estimate the remaining moisture retention during a drying process.

Claims (14)

  1. Method to estimate a load behavior in a laundry treatment machine with the steps of:
    - providing a laundry treatment machine (1) with a drum (5), a drive motor (9) to rotate the drum (5) around a rotational axis (10) and a controller (13) to regulate an angular speed of the drive motor (9),
    - performing a first operation of the laundry treatment machine (1) with a load (L) inside the drum (5), wherein the controller (13) is operated with first controller parameters (Pi),
    - determining a first torque signal T em * 1
    Figure imgb0040
    and a derivative ω ˙ 1 ^
    Figure imgb0041
    of a first angular speed signal of the drive motor (9) based on the first operation,
    - performing a second operation of the laundry treatment machine (1) with the load (L) inside the drum (5), wherein the controller (13) is operated with second controller parameters (P2),
    - determining a second torque signal T em * 2
    Figure imgb0042
    and a derivative ω ˙ 2 ^
    Figure imgb0043
    of a second angular speed signal of the drive motor (9) based on the second operation, and
    - determining an inertia (t, ĴL ) and/or a load torque (L ) caused by the load (L) depending on the first torque signal T em * 1
    Figure imgb0044
    , the second torque signal T em * 2
    Figure imgb0045
    , the derivative ω ˙ 1 ^
    Figure imgb0046
    of the first angular speed signal and the derivative ω ˙ 2 ^
    Figure imgb0047
    of the second angular speed signal, wherein the load torque (L ) is determined by means of a load torque observer (19).
  2. Method according to claim 1, characterized in
    that at least one of the first operation and the second operation is performed at a constant desired target angular speed (ω), while in particular a real speed (ω) oscillates according to the controller parameters (P1, P2) and the load (L).
  3. Method according to claim 1 or 2, characterized
    by the step of determining a mass () of the load (L) depending on the load torque (L ).
  4. Method according to at least one of the preceding claims, characterized
    by the step of determining an angular load position () of the load (L) depending on the load torque (L ).
  5. Method according to at least one of the preceding claims, characterized
    by the step of determining a total inertia (t ) of the laundry treatment machine (1) and the load (L), wherein in particular a load inertia (L ) is the difference between the total inertia (Ĵt) and a machine inertia (Ĵm).
  6. Method according to at least one of the preceding claims, characterized in
    that the first torque signal T em * 1
    Figure imgb0048
    , the second torque signal T em * 2
    Figure imgb0049
    the first angular speed signal and the second angular speed signal are transformed into a frequency domain.
  7. Method according to at least one of the preceding claims, characterized in
    that a respective first harmonic of the first torque signal T em * 1
    Figure imgb0050
    , of the second torque signal T em * 2
    Figure imgb0051
    , of the first angular speed signal and of the second angular speed signal are used to determine the inertia (t, ĴL ) and/or the load torque (L ).
  8. Method according to at least one of the preceding claims, characterized in
    that the load torque observer (19) is provided with an angular position (Θ̂) of the drive motor (9) and/or a drive torque T em *
    Figure imgb0052
    of the drive motor (9).
  9. Method according to at least one of the preceding claims, characterized in
    that the load torque observer (19) determines an observer error (eobs ) depending on an angular position (Θ̂) of the drive motor (9) and an observed angular position (Θobs ).
  10. Method according to at least one of the preceding claims, characterized in
    that the load torque observer (19) determines observer signals (ki, k2, k3) depending on an observer error (eobs ) and observer coefficients (K1, K2, K3) to determine the load torque (L ) and/or an observed angular position (Θobs ).
  11. Method according to at least one of the preceding claims, characterized in
    that the load torque observer (19) determines an observed angular position (Θobs ) depending on a total inertia (t ) of the laundry treatment machine (1) and the load (L).
  12. Method according to at least one of claims 8 to 11, characterized in that the drive motor (9) is designed sensorless and the angular position (Θ̂) of the drive motor (9) is estimated, in particular by means of a position observer (17).
  13. Method according to at least one of claims 8 to 12, characterized in that the drive torque T em *
    Figure imgb0053
    of the drive motor (9) is estimated and/or is the desired drive torque T em *
    Figure imgb0054
    and the output of the controller (13).
  14. Laundry treatment machine with
    - a drum (5),
    - a drive motor (9) to rotate the drum (5) around a rotational axis (10), and
    - a control unit (12) to estimate a load behavior with a controller (13) to regulate an angular speed of the drive motor (9), wherein the control unit (12) is designed such that
    -- a first operation of the laundry treatment machine (1) with a load (L) inside the drum (5) is performed, wherein the controller (13) is operated with first controller parameters (Pi),
    -- a first torque signal T em * 1
    Figure imgb0055
    and a derivative ω ˙ 1 ^
    Figure imgb0056
    of a first angular speed signal of the drive motor (9) are determined based on the first operation,
    -- a second operation of the laundry treatment machine (1) with the load (L) inside the drum (5) is performed, wherein the controller (13) is operated with second controller parameters (P2),
    -- a second torque signal T em * 2
    Figure imgb0057
    and a derivative ω ˙ 2 ^
    Figure imgb0058
    of a second angular speed signal of the drive motor (9) are determined based on the second operation, and
    -- an inertia (t , L ) and/or a load torque (L ) caused by the load (L) is determined depending on the first torque signal T em * 1
    Figure imgb0059
    , the second torque signal T em * 2
    Figure imgb0060
    , the derivative ω ˙ 1 ^
    Figure imgb0061
    of the first angular speed signal and the derivative ω ˙ 2 ^
    Figure imgb0062
    of the second angular speed signal, wherein the load torque (L ) is determined by means of a load torque observer (19).
EP22164092.3A 2020-03-02 2020-03-02 Method to estimate a load behavior in a laundry treatment machine Pending EP4036300A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050204482A1 (en) 2003-04-28 2005-09-22 Emerson Electric Co. Method and system for operating a clothes washing machine
DE102008055091A1 (en) * 2008-12-22 2010-06-24 BSH Bosch und Siemens Hausgeräte GmbH Method for controlling a laundry distribution operation of a household appliance for the care of laundry
EP2607535A2 (en) * 2011-12-20 2013-06-26 Whirlpool Corporation Method of operating a laundry treating appliance and appliance implementing it
US20190112745A1 (en) * 2017-10-17 2019-04-18 Fisher & Paykel Appliances Limited Laundry appliance and operating method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050204482A1 (en) 2003-04-28 2005-09-22 Emerson Electric Co. Method and system for operating a clothes washing machine
DE102008055091A1 (en) * 2008-12-22 2010-06-24 BSH Bosch und Siemens Hausgeräte GmbH Method for controlling a laundry distribution operation of a household appliance for the care of laundry
EP2607535A2 (en) * 2011-12-20 2013-06-26 Whirlpool Corporation Method of operating a laundry treating appliance and appliance implementing it
US20190112745A1 (en) * 2017-10-17 2019-04-18 Fisher & Paykel Appliances Limited Laundry appliance and operating method

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