US20220145510A1

US20220145510A1 - Washing machine appliance and method of determining the remaining moisture content of a load of clothes

Info

Publication number: US20220145510A1
Application number: US17/095,631
Authority: US
Inventors: Grafton Cook
Original assignee: Haier US Appliance Solutions Inc
Current assignee: Haier US Appliance Solutions Inc
Priority date: 2020-11-11
Filing date: 2020-11-11
Publication date: 2022-05-12

Abstract

A washing machine appliance includes a wash basket that is rotatably mounted within a wash tub and is selectively rotated by a motor assembly. A controller is operably coupled to a water supply and the motor assembly and is configured to estimate a dry load weight of the load of clothes, determine a cloth type of the load of clothes, determine a remaining moisture content of the load of clothes based at least in part on the dry load weight and the cloth type, and transmit the remaining moisture content to a dryer appliance for improved operation.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to laundry appliances, and more particularly, to washing machine appliances and methods of improving dryer operation based on washing machine performance.

BACKGROUND OF THE INVENTION

Laundry appliances, such as washing machine appliances and dryer appliances, are commonly used to wash and dry, respectively, a load of clothes. Specifically, washing machine appliances generally include a wash tub for containing water or wash fluid and a wash basket rotatably mounted within the wash tub for receiving the load of clothes. These washing machines are typically equipped to operate in one or more modes or cycles, such as wash, rinse, and spin cycles. After the washing machine processes are complete, the load of clothes is moved over the to the dryer, which includes a cabinet with a drum rotatably mounted therein and a heating assembly that supplies heated air into a chamber of the drum, e.g., through a duct mounted to a back wall of the drum, to facilitate a drying process.
During a spin or drain cycle of a washing machine appliance, a drain pump assembly may operate to discharge water from within sump. Notably, not all the water or wash fluid added into the tub is extracted from the load of clothes during the spin and drain cycle. As a result, the load of clothes subsequently transferred from the washing machine appliance to a corresponding dryer appliance has some amount of residual water or moisture, referred to as the remaining moisture content (RMC). Conventional dryer appliances operate independently of the corresponding washing machine appliance and do not compensate for the remaining moisture content of a load of clothes transferred from the washing machine appliance.
Accordingly, a laundry system with features for improved washing and/or drying performance would be desirable. More specifically, a laundry system that includes a washing machine appliance that provides useful information to a dryer appliance for overall improved system operation would be particularly beneficial.
BRIEF DESCRIPTION OF THE INVENTION
Advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
In one exemplary embodiment, a washing machine appliance is provided. The washing machine appliance includes a wash tub positioned within a cabinet, a wash basket rotatably mounted within the wash tub and defining a wash chamber configured for receiving a load of clothes, a water supply for selectively adding water to the wash tub, a motor assembly mechanically coupled to the wash basket for selectively rotating the wash basket, and a controller operably coupled to the water supply and the motor assembly. The controller is configured to estimate a dry load weight of the load of clothes, determine a cloth type of the load of clothes, and determine a remaining moisture content of the load of clothes based at least in part on the dry load weight and the cloth type.
In another exemplary embodiment, a method of operating a washing machine appliance is provided. The washing machine appliance includes a wash basket rotatably mounted within a wash tub, a water supply for selectively adding water to the wash tub, and a motor assembly mechanically coupled to the wash basket for selectively rotating the wash basket. The method includes estimating a dry load weight of a load of clothes, determining a cloth type of the load of clothes, and determining a remaining moisture content of the load of clothes based at least in part on the dry load weight and the cloth type.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a schematic representation of a laundry appliance system that includes a washing machine appliance, a dryer appliance, and an external communication system according to an exemplary embodiment of the present subject matter.

FIG. 2 provides a perspective view of the exemplary washing machine appliance of FIG. 1 with the door of the exemplary washing machine appliance shown in an open position.

FIG. 3 provides a side cross-sectional view of the exemplary washing machine appliance of FIG. 1.

FIG. 4 provides a perspective view of the exemplary dryer appliance of FIG. 1 with portions of a cabinet of the dryer appliance removed to reveal certain components of the dryer appliance.

FIG. 5 provides a method of operating a washing machine appliance according to an exemplary embodiment of the present subject matter.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As used herein, the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a 10 percent margin.
FIG. 1 illustrates a laundry appliance system 50 according to exemplary embodiments of the present subject matter. As shown, laundry appliance system 50 generally includes a washing machine appliance 52 and a dryer appliance 54, for washing and drying clothes, respectively. Each of washing machine appliance 52 and dryer appliance 54 will be described below according to exemplary embodiments of the present subject matter. Specifically, these figures illustrate various views of washing machine 52 and dryer appliance 54 in order to facilitate discussion regarding the use and operation of laundry system 50. However, it should be appreciated that the specific appliance configurations illustrated and described are only exemplary, and the scope of the present subject matter is not limited to the configurations set forth herein. Furthermore, it should be appreciated that like reference numerals may be used to refer to the same or similar features between washing machine 52 and dryer appliance 54.
Referring still to FIG. 1, a schematic diagram of an external communication system 60 will be described according to an exemplary embodiment of the present subject matter. In general, external communication system 60 is configured for permitting interaction, data transfer, and other communications between and among washing machine 52, dryer appliance 54, and/or a user of such appliances. For example, this communication may be used to provide and receive operating parameters, cycle settings, performance characteristics, user preferences, or any other suitable information for improved performance of laundry system 50.
As illustrated, each of washing machine appliance 52 and dryer appliance 54 may include a controller 62 (described in more detail below). External communication system 60 permits controllers 62 of washer appliance 52 and dryer appliance 54 to communicate with external devices either directly or through a network 64. For example, a consumer may use a consumer device 66 to communicate directly with washing machine 52 and/or dryer appliance 54. Alternatively, these appliances may include user interfaces for receiving such input (described below). For example, consumer devices 66 may be in direct or indirect communication with washing machine 52 and dryer appliance 54, e.g., directly through a local area network (LAN), Wi-Fi, Bluetooth, Zigbee, etc. or indirectly through network 64. In general, consumer device 66 may be any suitable device for providing and/or receiving communications or commands from a user. In this regard, consumer device 66 may include, for example, a personal phone, a tablet, a laptop computer, or another mobile device.
In addition, a remote server 68 may be in communication with washing machine 52, dryer appliance 54, and/or consumer device 66 through network 64. In this regard, for example, remote server 68 may be a cloud-based server 68, and is thus located at a distant location, such as in a separate state, country, etc. In general, communication between the remote server 68 and the client devices may be carried via a network interface using any type of wireless connection, using a variety of communication protocols (e.g. TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g. HTML, XML), and/or protection schemes (e.g. VPN, secure HTTP, SSL).
In general, network 64 can be any type of communication network. For example, network 64 can include one or more of a wireless network, a wired network, a personal area network, a local area network, a wide area network, the internet, a cellular network, etc. According to an exemplary embodiment, consumer device 66 may communicate with a remote server 68 over network 64, such as the internet, to provide user inputs, transfer operating parameters or performance characteristics, etc. In addition, consumer device 66 and remote server 68 may communicate with washing machine 52 and dryer appliance 54 to communicate similar information.
External communication system 60 is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system 60 provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more laundry appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.
Referring now also to FIGS. 2 and 3, washing machine appliance 52 will be described according to an exemplary embodiment of the present subject matter. Specifically, these figures illustrate an exemplary embodiment of a vertical axis washing machine appliance 52. Specifically, FIGS. 1 and 2 illustrate perspective views of washing machine appliance 52 in a closed and an open position, respectively. FIG. 3 provides a side cross-sectional view of washing machine appliance 52. Washing machine appliance 52 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined.
While described in the context of a specific embodiment of vertical axis washing machine appliance 52, it should be appreciated that vertical axis washing machine appliance 52 is provided by way of example only. It will be understood that aspects of the present subject matter may be used in any other suitable washing machine appliance, such as a horizontal axis washing machine appliance. Indeed, modifications and variations may be made to washing machine appliance 52, including different configurations, different appearances, and/or different features while remaining within the scope of the present subject matter.
Washing machine appliance 52 has a cabinet 102 that extends between a top portion 104 and a bottom portion 106 along the vertical direction V, between a first side (left) and a second side (right) along the lateral direction L, and between a front and a rear along the transverse direction T. As best shown in FIG. 3, a wash tub 108 is positioned within cabinet 102, defines a wash chamber 110, and is generally configured for retaining wash fluids during an operating cycle. Washing machine appliance 52 further includes a primary dispenser 112 (FIG. 2) for dispensing wash fluid into wash tub 108. The term “wash fluid” refers to a liquid used for washing and/or rinsing articles during an operating cycle and may include any combination of water, detergent, fabric softener, bleach, and other wash additives or treatments.
In addition, washing machine appliance 52 includes a wash basket 114 that is positioned within wash tub 108 and generally defines an opening 116 for receipt of articles for washing. More specifically, wash basket 114 is rotatably mounted within wash tub 108 such that it is rotatable about an axis of rotation A. According to the illustrated embodiment, the axis of rotation A is substantially parallel to the vertical direction V. In this regard, washing machine appliance 52 is generally referred to as a “vertical axis” or “top load” washing machine appliance 52. However, it should be appreciated that aspects of the present subject matter may be used within the context of a horizontal axis or front load washing machine appliance as well.
As illustrated, cabinet 102 of washing machine appliance 52 has a top panel 118. Top panel 118 defines an opening (FIG. 2) that coincides with opening 116 of wash basket 114 to permit a user access to wash basket 114. Washing machine appliance 52 further includes a door 120 which is rotatably mounted to top panel 118 to permit selective access to opening 116. In particular, door 120 selectively rotates between the closed position (as shown in FIGS. 1 and 3) and the open position (as shown in FIG. 2). In the closed position, door 120 inhibits access to wash basket 114. Conversely, in the open position, a user can access wash basket 114. A window 122 in door 120 permits viewing of wash basket 114 when door 120 is in the closed position, e.g., during operation of washing machine appliance 52. Door 120 also includes a handle 124 that, e.g., a user may pull and/or lift when opening and closing door 120. Further, although door 120 is illustrated as mounted to top panel 118, door 120 may alternatively be mounted to cabinet 102 or any other suitable support.
As best shown in FIGS. 2 and 3, wash basket 114 further defines a plurality of perforations 126 to facilitate fluid communication between an interior of wash basket 114 and wash tub 108. In this regard, wash basket 114 is spaced apart from wash tub 108 to define a space for wash fluid to escape wash chamber 110. During a spin cycle, wash fluid within articles of clothing and within wash chamber 110 is urged through perforations 126 wherein it may collect in a sump 128 defined by wash tub 108. Washing machine appliance 52 further includes a pump assembly 130 (FIG. 3) that is located beneath wash tub 108 and wash basket 114 for gravity assisted flow when draining wash tub 108.
An impeller or agitation element 132 (FIG. 3), such as a vane agitator, impeller, auger, oscillatory basket mechanism, or some combination thereof is disposed in wash basket 114 to impart an oscillatory motion to articles and liquid in wash basket 114. More specifically, agitation element 132 extends into wash basket 114 and assists agitation of articles disposed within wash basket 114 during operation of washing machine appliance 52, e.g., to facilitate improved cleaning. In different embodiments, agitation element 132 includes a single action element (i.e., oscillatory only), a double action element (oscillatory movement at one end, single direction rotation at the other end) or a triple action element (oscillatory movement plus single direction rotation at one end, single direction rotation at the other end). As illustrated in FIG. 3, agitation element 132 and wash basket 114 are oriented to rotate about axis of rotation A (which is substantially parallel to vertical direction V).
As best illustrated in FIG. 3, washing machine appliance 52 includes a motor assembly or a drive assembly 138 in mechanical communication with wash basket 114 to selectively rotate wash basket 114 (e.g., during an agitation or a rinse cycle of washing machine appliance 52). In addition, drive assembly 138 may also be in mechanical communication with agitation element 132. In this manner, drive assembly 138 may be configured for selectively rotating or oscillating wash basket 114 and/or agitation element 132 during various operating cycles of washing machine appliance 52.
More specifically, drive assembly 138 may generally include one or more of a drive motor 140 and a transmission assembly 142, e.g., such as a clutch assembly, for engaging and disengaging wash basket 114 and/or agitation element 132. According to the illustrated embodiment, drive motor 140 is a brushless DC electric motor, e.g., a pancake motor. However, according to alternative embodiments, drive motor 140 may be any other suitable type or configuration of motor. For example, drive motor 140 may be an AC motor, an induction motor, a permanent magnet synchronous motor, or any other suitable type of motor. In addition, drive assembly 138 may include any other suitable number, types, and configurations of support bearings or drive mechanisms.
Referring still to FIGS. 1 through 3, a control panel 150 with at least one input selector 152 (FIG. 1) extends from top panel 118. Control panel 150 and input selector 152 collectively form a user interface input for operator selection of machine cycles and features. A display 154 of control panel 150 indicates selected features, operation mode, a countdown timer, and/or other items of interest to appliance users regarding operation.
Operation of washing machine appliance 52 is controlled by a controller or processing device 62 that is operatively coupled to control panel 150 for user manipulation to select washing machine cycles and features. In response to user manipulation of control panel 150, controller 62 operates the various components of washing machine appliance 52 to execute selected machine cycles and features. According to an exemplary embodiment, controller 62 may include a memory and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with methods described herein. Alternatively, controller 62 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Control panel 150 and other components of washing machine appliance 52 may be in communication with controller 62 via one or more signal lines or shared communication busses.
During operation of washing machine appliance 52, laundry items are loaded into wash basket 114 through opening 116, and washing operation is initiated through operator manipulation of input selectors 152. Wash basket 114 is filled with water and detergent and/or other fluid additives via primary dispenser 112. One or more valves can be controlled by washing machine appliance 52 to provide for filling wash tub 108 and wash basket 114 to the appropriate level for the amount of articles being washed and/or rinsed. By way of example for a wash mode, once wash basket 114 is properly filled with fluid, the contents of wash basket 114 can be agitated (e.g., with agitation element 132 as discussed previously) for washing of laundry items in wash basket 114.
More specifically, referring again to FIG. 3, a water fill process will be described according to an exemplary embodiment. As illustrated, washing machine appliance 52 includes a water supply conduit 160 that provides fluid communication between a water supply source 162 (such as a municipal water supply) and a discharge nozzle 164 for directing a flow of water into wash chamber 110. In addition, washing machine appliance 52 includes a water fill valve or water control valve 166 which is operably coupled to water supply conduit 160 and communicatively coupled to controller 62. In this manner, controller 62 may regulate the operation of water control valve 166 to regulate the amount of water within wash tub 108. In addition, washing machine appliance 52 may include one or more pressure sensors 170 for detecting the amount of water and or clothes within wash tub 108. For example, pressure sensor 170 may be operably coupled to a bottom of wash tub 108 for detecting the water pressure within wash tub 108, which controller 62 may use to determine a cloth type, as described below.
After wash tub 108 is filled and the agitation phase of the wash cycle is completed, wash basket 114 can be drained, e.g., by drain pump assembly 130. Laundry articles can then be rinsed by again adding fluid to wash basket 114 depending on the specifics of the cleaning cycle selected by a user. The impeller or agitation element 132 may again provide agitation within wash basket 114. One or more spin cycles may also be used as part of the cleaning process. In particular, a spin cycle may be applied after the wash cycle and/or after the rinse cycle in order to wring wash fluid from the articles being washed. During a spin cycle, wash basket 114 is rotated at relatively high speeds to help wring fluid from the laundry articles through perforations 126. After articles disposed in wash basket 114 are cleaned and/or washed, the user can remove the articles from wash basket 114, e.g., by reaching into wash basket 114 through opening 116.
Referring now to FIG. 4, a perspective view of dryer appliance 54 is provided with a portion of a cabinet or housing 202 of dryer appliance 54 removed in order to show certain components of dryer appliance 54. While described in the context of a specific embodiment of dryer appliance 54, using the teachings disclosed herein it will be understood that dryer appliance 54 is provided by way of example only. Other dryer appliances having different appearances and different features may also be utilized with the present subject matter as well. Dryer appliance 54 defines a vertical direction V, a lateral direction L, and a transverse direction T. The vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular and form an orthogonal direction system.
Cabinet 202 includes a front panel 204, a rear panel 206, a pair of side panels 208 spaced apart from each other by front and rear panels 204 and 206, a bottom panel 210, and a top cover 212. Within cabinet 202 is a drum or container 216 mounted for rotation about a substantially horizontal axis, e.g., that is parallel or substantially parallel to the lateral direction L. Drum 216 defines a chamber 214 for receipt of articles, e.g., clothing, linen, etc., for drying. Drum 216 extends between a front portion and a back portion, e.g., along the lateral direction L.
A motor 220 is configured for rotating drum 216 about the horizontal axis, e.g., via a pulley and a belt (not shown). Drum 216 is generally cylindrical in shape, having an outer cylindrical wall or cylinder and a front flange or wall that defines an entry 222 of drum 216, e.g., at the front portion of drum 216, for loading and unloading of articles into and out of chamber 214 of drum 216. A plurality of tumbling ribs 224 are provided within chamber 214 of drum 216 to lift articles therein and then allow such articles to tumble back to a bottom of drum 216 as drum 216 rotates. Drum 216 also includes a back or rear wall, e.g., such that drum 216 is rotatable on its rear wall as will be understood by those skilled in the art. A duct 226 is mounted to the rear wall of drum 216 and receives heated air that has been heated by a heating assembly or system 240.
Motor 220 is also in mechanical communication with an air handler 230 such that motor 220 rotates air handler 230, e.g., a centrifugal fan. Air handler 230 is configured for drawing air through chamber 214 of drum 216, e.g., in order to dry articles located therein as discussed in greater detail below. In alternative exemplary embodiments, dryer appliance 54 may include an additional motor (not shown) for rotating air handler 230 independently of drum 216.
Drum 216 is configured to receive heated air that has been heated by a heating assembly 240, e.g., in order to dry damp articles disposed within chamber 214 of drum 216. Heating assembly 240 includes a heating element (not shown), such as a gas burner or an electrical resistance heating element, for heating air. As discussed above, during operation of dryer appliance 54, motor 220 rotates drum 216 and air handler 230 such that air handler 230 draws air through chamber 214 of drum 216 when motor 220 rotates. In particular, ambient air (identified herein generally by reference numeral 242) enters heating assembly 240 via an entrance 244 due to air handler 230 urging such ambient air into entrance 244. Such ambient air is heated within heating assembly 240 and exits heating assembly 240 as heated air 242. Air handler 230 draws such heated air through duct 226 to drum 216. The heated air enters drum 216 through an outlet 246 of duct 226 positioned at the rear wall of drum 216.
Within chamber 214, the heated air can accumulate moisture, e.g., from damp articles disposed within chamber 214. In turn, air handler 230 draws humid air through a trap duct 248 which contains a screen filter (not shown) which traps lint particles. Such humid air then passes through trap duct 248 and air handler 230 before entering an exhaust conduit 250. From exhaust conduit 250, such humid air passes out of dryer appliance 54 through a vent 252 defined by cabinet 202. After the clothing articles have been dried, they are removed from the drum 216 via entry 222. A door 260 provides for closing or accessing drum 216 through entry 222.
A user interface panel 270 is positioned on a cabinet backsplash and includes a cycle selector knob 272 that is in communication with a processing device or controller (such as a controller 62). Signals generated in controller 62 operate motor 220, air handler, 230, and heating assembly 240 in response to the position of selector knobs 272. User interface panel 270 may further conclude additional indicators, a display screen, a touch screen interface 174, etc. for providing information to a user of the dryer appliance 54 and receiving suitable operational feedback. Alternatively, a touch screen type interface, knobs, sliders, buttons, speech recognition, etc., mounted to cabinet backsplash or at any other suitable location to permit a user to input control commands for dryer appliance 54 and/or controller 62.
Controller 62 may include memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of dryer appliance 54. The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 62 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.
In general, controller 62 is in operative communication with various components of dryer appliance 54. In particular, controller 62 is in operative communication with motor 220 and heating assembly 240. Thus, upon receiving an activation signal from cycle selector knob 272, controller 62 can activate motor 220 to rotate drum 216 and air handler 230. Controller 62 can also activate heating assembly 240 in order to generate heated air for drum 216, e.g., in the manner described above.
Controller 62 is also in communication with a thermal or temperature sensor 280, e.g., a thermocouple or thermistor. Temperature sensor 280 is configured for measuring a temperature of heated air within duct 226. Temperature sensor 280 can be positioned at any suitable location within dryer appliance 54. For example, temperature sensor 280 may be positioned within or on duct 226. Controller 62 can receive a signal from temperature sensor 280 that corresponds to a temperature measurement of heated air within duct 226, e.g., a temperature measurement of heated air exiting duct 226 at outlet 246.
Now that the construction of system 50, washing machine 52, dryer appliance 54, and external communication system 60 have been presented according to exemplary embodiments, an exemplary method 300 of operating a system of laundry appliances will be described. Although the discussion below refers to the exemplary method 300 of operating system 50, and more particularly washing machine appliance 52, one skilled in the art will appreciate that the exemplary method 300 is applicable to the operation of any suitable washing machine appliance or laundry system. In exemplary embodiments, the various method steps as disclosed herein may be performed by controllers 62, remote server 68, and/or a separate, dedicated controller.
Referring generally to FIG. 5, a method of operating a washing machine appliance in a laundry system is provided. According to exemplary embodiments, method 300 includes, at step 310, estimating a dry load weight of a load of clothes within a washing machine appliance. For example, controller 62 of washing machine appliance 100 may be configured for estimating, calculating, or otherwise determining the dry load weight of load of clothes. In this regard, for example, the dry load weight may be the weight of the load of clothes, e.g., in pounds or kilograms. According to an exemplary embodiment, this step of estimating the dry load weight may be performed by initiating a dry load sensing procedure.
As used herein, the term “dry load sensing” and the like is generally intended to refer to any process for obtaining a weight of the load of clothes in a washing machine appliance prior to adding water. For example, according to an exemplary embodiment, the dry load sensing procedure may include rotating the wash basket at a predetermined spin speed and monitoring a force, torque, or inertia generated by or at the motor assembly used to rotate the wash basket at that predetermined spin speed. Controller 62 may use this information as well as other information to estimate or calculate the dry load weight, e.g., using regression equations, data correlation tables, other suitable algorithms or computations, etc.
According to an exemplary embodiment of the present subject matter, a method of determining a dry load weight may include monitoring basket speed basket speed (e.g., in revolutions per minute) and the motor power (e.g., in Watts) over time. In this regard, for example, washing machine appliance 52 may further include basket speed sensor 172 (FIG. 3), which may be any suitable sensor or sensors for monitoring the movement of wash basket 114 and determining a measured basket speed of wash basket 114. For example, according to the exemplary embodiments, basket speed sensor 172 is a Hall Effect sensor, an accelerometer, or an optical sensor. Using basket speed sensor 172, the dry load weight detection cycle generally includes a sequence of spin operations and corresponding measurements of the wash basket speed and motor power. For example, the dry load weight detection procedure may include accelerating wash basket 114 a predetermined acceleration rate while monitoring the motor power required to rotate wash basket 114 and the spin speed of wash basket 114. This method may further include maintaining the wash basket speed at this predetermined speed while monitoring motor torque, power, back EMF, etc.
It should be appreciated that any suitable measurement method, sampling rate, or measured variables may be used as a proxy for motor power and basket speed. For example, according to an exemplary embodiment, motor current is measured and used as a proxy for motor power. According to still other embodiments, obtaining the basket speed of the wash basket may include measuring a motor frequency, a back electromotive force (EMF) on the motor, or a motor shaft speed (e.g., using a tachometer). It should be appreciated that other systems and methods for monitoring motor power and/or basket speeds may be used while remaining within the scope of the present subject matter.
Step 320 may include determine a cloth type of the load of clothes. In this regard, controller 62 may implement any suitable actions in order to estimate, calculate, or otherwise determine the type of clothes in the wash chamber 110. As used herein, the term “cloth type” is used generally to describe the type of clothes within wash chamber 110. For example, the cloth type, may be synthetics, cottons, mixed loads, etc. Notably, these cloth types general absorb or retain different volumes of water. For example, cotton loads can absorb a large amount of water, while synthetics generally retain little or no water. By monitoring the amount of water that collects at the bottom of wash tub 108, controller 62 may determine the cloth type of a particular load. This method of determining cloth type may be referred to herein generally as a wet load sensing procedure.
According to an exemplary embodiment, washing machine appliance 52 may use pressure sensor 170 to perform a wet load sensing procedure, e.g., by determining water or wash fluid pressure within wash tub 108 and also to determine a cloth type of the load of clothes. For example, by monitoring the amount of water added into wash tub 108 relative to the pressure that water exerts on pressure sensor 170, the cloth type may be estimated. For example, controller 62 of washing machine appliance 52 may operate water control valve 166 to discharge a predetermined volume of water and monitor the water pressure using pressure sensor 170. After the water has been added, controller 62 may use the pressure measured by pressure sensor 170 to estimate the cloth type. For example, controller may determine that the water pressure falls within a certain predetermined range associated with a particular cloth type, exceeds some predetermined pressure threshold, etc.
After the dry load weight is obtained at step 310 (e.g., using the dry load sensing procedure) and the cloth type is obtained at step 320 (e.g., using the wet load sensing procedure), step 330 includes determining a remaining moisture content of the load of clothes based at least in part on the dry load weight and the cloth type. For example, according to an exemplary embodiment, the remaining moisture content may be calculated by subtracting the dry load weight from a wet load weight. The dry load weight may be determined, for example, as described above with respect to step 310.
According to exemplary embodiments, the wet load weight may be determined using a linear regression equation with the dry load weight and the cloth type as inputs. Specifically, the linear regression equation may take the form wet load weight=A+Bx+Cy, where A, B, and C are fixed constants, x is a quantitative value or representation correlated or corresponding to the dry load weight, and y is a quantitative value or representation correlated or corresponding to the cloth type. In this regard, for example, a saturated load of a certain type and size (e.g., eight pounds of towels) will give characteristic system feedback, i.e., a quantitative value, that is plugged into the transfer function to facilitate calculation of a wet weight. Although this linear regression equation only includes three terms associated with A, B, and C, it should be appreciated that the linear regression equation may be more complex, include any suitable number of terms, inputs, and fixed constants. These constants may be empirically determined, programmed by the manufacturer, calculated using other control algorithms, or determined in any other suitable manner. For example, according to another exemplary embodiment, estimating the wet load weight may include obtaining a manual load size input from a user of the washing machine appliance. According to still other exemplary embodiments, these fixed constants or coefficients may be obtained via a remote update, e.g., an over-the-air software update via network 64 and/or remote server 68.
According to exemplary embodiments, washing machine appliance 52 may be configured for performing a precise fill operation or procedure to fill wash tub 108 with the desired amount of water and monitor several operating or performance characteristics or parameters in the process. In this regard, the precise fill process is an automated procedure that supplies an ideal or optimal amount of water into the wash tub 108 for improved performance based at least in part on the quantity and type of clothes that are being washed. In this regard, for example, controller 62 may selectively regulate water control valve 166 in order to provide the ideal amount of water for a particular load size, e.g., by sensing the load during the water filling process. According to exemplary embodiments of the present subject matter, estimating the wet load weight may include the use of data obtained during the precise fill process. For example, this data may be incorporated as another variable in the linear regression equation described above, e.g., as another term associated with another constant for improved accuracy.
Step 340 includes transmitting the remaining moisture content to a dryer appliance. In this regard, for example, washing machine appliance 52 and dryer appliance 54 may be linked or correlated appliances that are located in the same laundry room or residence. These appliances understand that clothes cleaned by washing machine appliance 52 will be dried using dryer appliance 54. It should be appreciated that the remaining moisture content may be transmitted to dryer appliance 54 in any suitable manner. For example, the remaining moisture content may be obtained from remote server 68 or over network 64. In this regard, washing machine appliance 52 may transmit these washer operating parameters to the network 64 or remote server 68 when measured or selected, and dryer appliance 54 may periodically pull or download these parameters from the network 64. According to still other embodiments, dryer appliance 54 may be in direct wireless communication with washing machine appliance 52, e.g., via a Wi-Fi or Bluetooth connection. According to such an embodiment, the remaining moisture content may be transmitted directly from washing machine appliance 52 to dryer appliance 54. According to still other embodiments, washer operating parameters may be transferred in any other suitable manner, e.g., via user input, a wired connection, etc.
FIG. 5 depicts steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure. Moreover, although aspects of method 300 are explained using system 50 as an example, it should be appreciated that these methods may be applied to the operation of any suitable system of laundry appliances and a remote network or server.
The laundry systems and methods of operation described above include an algorithm for determining the remaining moisture content in a load of clothes after a wash cycle in a washing machine appliance. According to exemplary embodiments, the algorithm for determining remaining moisture content estimates the wet weight of clothes loads using data derived from the Precise Fill algorithm, as well as system parameters during the coast-down from the final spin. Another embodiment of the algorithm uses the precise fill data and the rate of change of basket speed to determine the remaining moisture in the load. The washing machine appliance may store the wet weight of the clothes and transmit the wet weight of the clothes to the dryer to improve the accuracy of dryer algorithms. This data can be compared to the dry weight derived by a dry load sense algorithm to estimate the amount of water carried forward into the dryer. This information will be transmitted to a connected dryer to improve drying performance. This remaining moisture content may then be transmitted to a connected dryer appliance, which may itself use this information to improve its operation algorithms, operating parameters, settings, etc. for improved overall performance.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

What is claimed is:

1. A washing machine appliance, comprising:

a wash tub positioned within a cabinet;

a wash basket rotatably mounted within the wash tub and defining a wash chamber configured for receiving a load of clothes;

a water supply for selectively adding water to the wash tub;

a motor assembly mechanically coupled to the wash basket for selectively rotating the wash basket; and

a controller operably coupled to the water supply and the motor assembly, the controller being configured to:

estimate a dry load weight of the load of clothes;

determine a cloth type of the load of clothes; and

determine a remaining moisture content of the load of clothes based at least in part on the dry load weight and the cloth type.

2. The washing machine appliance of claim 1, wherein estimating a dry load weight of the load of clothes comprises:

initiating a dry load sensing procedure after the load of clothes has been added to the wash tub but before the water is added to the wash tub.

3. The washing machine appliance of claim 2, wherein the dry load sensing procedure comprises:

rotating the wash basket at a predetermined spin speed; and

monitoring a force generated by the motor assembly to rotate the wash basket at the predetermined spin speed.

4. The washing machine appliance of claim 1, wherein determining a cloth type comprises:

initiating a wet load sensing procedure after the load of clothes has been added to the wash tub and the water is added to the wash tub.

5. The washing machine appliance of claim 4, further comprising a pressure sensor for monitoring a pressure of the water in the wash tub, and wherein the wet load sensing procedure comprises:

adding water to the wash tub;

monitoring the pressure within the wash tub using the pressure sensor; and

determining a cloth type based at least in part on an amount water added before the pressure reaches a predetermined pressure threshold.

6. The washing machine appliance of claim 1, wherein determining the remaining moisture content comprises subtracting the dry load weight from a wet load weight.

7. The washing machine appliance of claim 6, wherein the wet load weight is determined using a linear regression equation with the dry load weight and the cloth type as inputs.

8. The washing machine appliance of claim 7, wherein the linear regression equation is as follows:

wet load weight=A+Bx+Cy;

where: A, B, and C are fixed constants;

x is a quantitative value corresponding to the dry load weight; and

y is a quantitative value corresponding to the cloth type.

9. The washing machine appliance of claim 6, wherein estimating the wet load weight comprises obtaining a manual load size input from a user of the washing machine appliance.

10. The washing machine appliance of claim 1, wherein the controller is further configured to:

transmit the remaining moisture content to a dryer appliance.

11. The washing machine appliance of claim 1, wherein adding water to the wash tub comprises utilizing a precise fill process, and wherein estimating a wet load weight comprises using data obtained during the precise fill process.

12. A method of operating a washing machine appliance, the washing machine appliance comprising a wash basket rotatably mounted within a wash tub, a water supply for selectively adding water to the wash tub, and a motor assembly mechanically coupled to the wash basket for selectively rotating the wash basket, the method comprising:

estimating a dry load weight of a load of clothes;

determining a cloth type of the load of clothes; and

determining a remaining moisture content of the load of clothes based at least in part on the dry load weight and the cloth type.

13. The method of claim 12, wherein estimating a dry load weight of the load of clothes comprises:

14. The method of claim 13, wherein the dry load sensing procedure comprises:

rotating the wash basket at a predetermined spin speed; and

15. The method of claim 12, wherein determining a cloth type comprises:

16. The method of claim15, wherein the wet load sensing procedure comprises:

adding water to the wash tub;

monitoring a pressure within the wash tub using a pressure sensor; and

17. The method of claim 12, wherein determining the remaining moisture content comprises subtracting the dry load weight from a wet load weight.

18. The method of claim 17, wherein the wet load weight is determined using a linear regression equation with the dry load weight and the cloth type as inputs.

19. The method of claim 18, wherein the linear regression equation is as follows:

wet load weight=A+Bx+Cy;

where: A, B, and C are fixed constants;

x is a quantitative value corresponding to the dry load weight; and

y is a quantitative value corresponding to the cloth type.

20. The method of claim 12, further comprising:

transmitting the remaining moisture content to a dryer appliance.