WO2003023534A1

WO2003023534A1 - An appliance emulator

Info

Publication number: WO2003023534A1
Application number: PCT/TR2001/000044
Authority: WO
Inventors: Alper Baykut; Halime Usta; Ilkin Tacan
Original assignee: Arçelik A.S.
Priority date: 2001-09-11
Filing date: 2001-09-11
Publication date: 2003-03-20
Also published as: TR200400481T1

Abstract

This invention relates to an appliance emulator (1) for controlling, montoring, analysisng, simulating and emulating a household appliance (10) e.g. a refrigerator, a washing machine, a dishwasher or an oven having a data acquisition and control board (20) which serves as a substructure and is easily configured or edited by the user, especially for design purposes.

Description

AN APPLIANCE EMULATOR

FIELD OF INVENTION

The present invention is related to a device that can control, monitor, analyse, simulate and emulate, the algorithms and the household appliances.

BACKGROUND OF THE INVENTION

Upon the request of the users, improved appliance efficiency is desired in order to reduce energy or other resource consumption and to provide data to adjust the appliance operating components to function in accordance with a desired operating profile. This enhances the importance of the control system of the appliances. As the sophistication of the control system increases, the quantity of wiring, sensors, actuators and systems used and the time spent to install all of them increase. In order to retain the operational reliability and manufacturing efficiency for a wide range of products, control system and all the related parts of the appliance must be tested for instance, by a simulator, before the production stage.

In known techniques, on/off control of components, variable parameter controls, data acquisition and obtaining information about the related household appliance can be performed separately. Since they are not synchronised with each other, results obtained from the household appliances cannot be reliable. In these techniques, first control board and appliance hardware is prepared; then an algorithm is developed according to this hardware. In order to progress the algorithm, appliance hardware must be updated for each time. This is a difficult and time-consuming process. In DE 4004097, a process for the operating and/or monitoring of household appliances equipped with electronic control systems for switching on is disclosed. The computer of the electronic control unit communicates with an external computer via data and control lines. The computer of the control unit sends initial values to the memory in the external computer and send values are processed into programs for the display of data for general operation and for the display of time- and condition-related program values. The external computer possesses means for storing input values in the memory section of the computer of the appliance control and consequently has an on-off effect on the program control of the appliance. By this application, all household appliances connected to the external computer can be operated and monitored from a central point.

In US 5818428 an appliance control system with a user configurable interface, particularly suitable for use in connection with appliances, is explained. Users can configure display screens either at a point of sale location or at home with, e.g., a personal computer.

In US 5721693, an improved electric home appliance real use state information collection and analysis apparatus capable of providing a product design reference data by collecting and analyzing user's real use state and home appliance surrounding environments, thus improving reliability of the product, which includes an electric home appliance microcomputer for controlling the entire functions of a certain electric home appliance and for detecting a real use state of a user's real electric home appliance; an UPA microcomputer for storing a user's use state data input from the electric home appliance microcomputer and the collected various surrounding environment data into a memory and for transmitting the data to another element; and a personal computer for receiving and analyzing the data transmitted from the UPA microcomputer via an RS-232 serial communication link, thus providing a product design reference data by collecting and analyzing user's real use state and home appliance surrounding environments, thus improving reliability of the product, is defined.

SUMMARY OF INVENTION

The object of the invention is to control, test, monitor, analyse, simulate and emulate all the operational steps and components of household appliances and acquire data synchronously as a unique system free from its hardware according to environment conditions and requirements of users.

DRAWINGS OF THE PREFERRED EMBODIMENT

An embodiment of the appliance simulator, which is realised in order to attain said object of the invention, is illustrated in the attached drawings, wherein;

Figure 1, is a view of a computer, a household appliance and the data acquisition and control board,

Figure 2, is a schematic view of the data acquisition and control board,

Figure 3, is a schematic view of an embodiment of the invention comprising the data acquisition and control board, and a computer, and a household appliance,

Figure 4, is a schematic view of an embodiment of the invention comprising a computer including the data acquisition and control board, and a household appliance,

Figure 5, is a schematic view of an embodiment of the invention comprising the data acquisition and control board integrated to a household appliance

Figure 6, is a schematic view of an embodiment of the invention comprising the data acquisition and control board and a household appliance without data entry means, a display unit and a control board Figure 7, is a schematic view of an embodiment of the invention comprising the data acquisition and control board and a household appliance including data entry means, display unit and control board

Figure 8, is a schematic view of an embodiment of the invention comprising the data acquisition and control board, an additional component, and an additional sensor

The components shown in the drawings have the following reference numbers;

1- Appliance emulator 10- Household appliance 11- Body

12- Sensor

13- Component 14,24,34- Display unit

15,25,35 - Data entry means

16- Control board

20- Data acquisition and control board

21,31- Input/output port 22,32- Data storage unit

23,33- Microprocessor

26- Communication module

27- Frequencymeter

28- Counter 29- Multiplexer 30- Computer DESCRIPTION OF THE PREFERRED EMBODIMENTS

Each household appliance (10) comprises a body (11), one or more components (13) which are the fixed and moving parts of the household appliance (10), and one or more sensors (12), such as flowmeter, thermocouple, pressure switch, hall sensors, etc on the body (11) for detecting or measuring the physical conditions inside and/or outside the household appliance (10). The sensors (12) and the components (13) are controlled according to algorithms that define processes or a set of the rules for running the household appliance (10) according to the user requests or environmental conditions.

In the present invention, an appliance emulator (1) is used. The appliance emulator (1) controls, tests, simulates and emulates the household appliance (10) with its components operating synchronously as a unique system. The appliance emulator (1) watches, collects, records and analyses the data from the household appliance (10) and/or external components (13), and/or external sensors (12) under all possible working conditions. The appliance emulator (1) gathers information about the household appliance (10), and manages the controllable parameters of the household appliance (10) like on / off positions. The appliance emulator (1) can simulate and/or emulate the whole and/or a part of the household appliance (10). This provides a flexible, productive, functional and easy working environment especially for designers. So the appliance emulator (1) creates a wide possibility of design by running the household appliance (10) freely from the hardware of the household appliance (10), such as the body (11), the components (13), the sensors (12) etc.

The operational steps of the household appliance (10) can be designed or changed easily by using the appliance emulator (1). The algorithm is not necessarily recorded on the appliance emulator (1) every time. The algorithm can be designed and simulated for all the possible working conditions by the appliance emulator (I)-

In the preferred embodiment of the present invention, the appliance emulator (1) comprises a data acquisition and control board (20), and a computer (30).

The computer (30) includes a display unit (34) for monitoring and/or controlling the components (13) and the sensors (12), an input/output port (31) for communication, a data storage unit (32) for storing data, a data entry means (35) for entering data as a file editor and/or user interface, and a microprocessor (33) for controlling the functions of the computer (30), processing and analysing the data obtained from the household appliance (10), controlling the household appliance (10) by using the algorithms, configuring the data acquisition and control board (20) via setting the type of the household appliance (10), defining the parameters, simulating the household appliance (10) without controlling them actually, emulating the household appliance (10) by using the computer (30).

The data acquisition and control board (20) serves as a substructure, which can be configured easily by the user according to the needs, the components (13), the sensors (12) and the type of the household appliance (10). In addition to serving as a substructure, the data acquisition and control board (20) is a cost efficient general-purpose interface between the computer (30) and the household appliance (10) to acquire data by communicating preferably in series, by using a serial bus The data acquisition and control board (20) includes one or more digital and/or analog input/output ports (21), one or more communication modules (26) and one or more microprocessors (23).

In another embodiment of the present invention, the appliance emulator (1) comprises a data acquisition and control board (20). In this embodiment household appliance (10) has a display unit (14) for monitoring, one or more data input means (15) for data input, and a control board (16). While the appliance emulator (1) is working, the data acquisition and control board (20) uses the display unit (14), the data entry means (15) and the control board (16) instead of the computer (30).

The data acquisition and control board (20) includes one or more digital and/or analog input/output ports (21), one or more communication modules (26), a data storage unit (22) for storing data, a microprocessor (23) for controlling the functions of the data acquisition and control board (20), processing and analysing the data obtained from the household appliance (10), controlling the household appliance (10) by using the algorithms, configuring the data acquisition and control board (16) via setting the type of the household appliance (10), and defining the parameters, simulating the household appliance (10) without controlling them actually, emulating the household appliance (10) by using the computer (30).

In a third embodiment of the present invention, the appliance emulator (1) comprises a data acquisition and control board (20). The data acquisition and control board (20) includes one or more digital and/or analog input/output ports (21), one or more communication modules (26), a data storage unit (22) for storing data, a display unit (24) for monitoring, one or more data entry means (25) for entering data as a file editor and/or user interface, and a microprocessor (23) for controlling the functions of the data acquisition and control board (20), processing and analysing the data obtained from the household appliance (10), controlling the household appliance (10) by using the algorithms, configuring the data acquisition and control board (20) via setting the type of the household appliance (10), and defining the parameters, simulating the household appliance (10) without controlling them actually, emulating the household appliance (10) by using the computer (30). In all of the embodiments the appliance emulator (1) may use an external display unit (14,24,34), an external data entry means (15,25,35) such as a button or a set of buttons like a keyboard (35) or an external data storage unit (22,32). The appliance emulator (1) may be connected to more than one household appliance (10).

In all of the embodiments, the data acquisition and control board (20) further comprises a frequencymeter (27), a counter (28) and a multiplexer (27). The frequencymeter (27) is used to generate a special frequency signal output to control a component (13). The frequencymeter (27) can be also configured to measure the frequency of a sensor (12) input. The counter (28) is used to evaluate the data obtained by the user. For instance it is used as a pulse counter for sensors (12) as input data. The multiplexer (29) is used to acquire data from the multi channel. The multiplexer (29) is particularly necessary when the data acquisition and control board (20) has less input/output ports (21) than the requested amount. The multiplexer (29) increases the number of the input/output ports (21).

The communication module (26) enables the commumcation between the data acquisition and control board (20) with the household appliance (10) using the serial bus with a special speed and protocol. Similarly for all other devices or parts like the computer (30), the sensors (12), the components (13); the communication module (26) also manage the communication between the data acquisition and control board (20) and said device or parts by using serial bus with a special protocol and speed. Said protocols can be the same or different for each different device or parts.

The data storage unit (22,32) is used to record the data. In the preferred embodiment a non-volatile memory unit is used. While the household appliance (10) is working, data are collected in the data storage unit (22,32). In fact data are always recorded to the data storage unit (22,32) instantaneously and can be accessed by the user whenever it is requested.

Algorithm define processes or a set of rules for running and controlling tlie household appliance (10) by arranging the working sequences, periods, limits of the components (13) and/or sensors (12) and/or the entire household appliance (10). The algorithms are composed of sub-algorithms for controlling the individual components (13), the sensors (12) etc.

The user can edit/modify the algorithms for the appliance emulator (1) by using the data entry means (15,25,35). The display unit (14,24,34) can be also used as file editor and can be used for displaying the outputs. While preparing the algorithms, user can use loops, cases, sequence structures, mathematics and logic with all the related operators. By using these operators, blocks are combined and algorithms work together. In the preferred embodiment ASCII format is used in algorithms.

In order to develop new algorithms, user can build some special libraries in the data storage unit (22,32). These libraries contain sub algorithms or data about the different types of household appliance (10). There are some favourite sub- algorithms, which can be called by other algorithms continuously. Each library is designed according to block type and has help boxes for directing the user. The user connects these blocks to the others and develops new algorithms and follows the results. According to their duties or working type or working levels algorithms are classified; such as, temperature sensor class, switch class, position sensor class, time class, monitoring class. These specified classes are sub divided into other classes. For instance monitoring class is divided into, measured values monitoring class, regulated values monitoring class, and etc. The appliance emulator (1) has different operation modes; such as configuration mode, control mode, data acquisition mode, analysis mode, simulation mode and emulation mode. The appliance emulator (1) can work in any one of the modes or a combination of thereof. In the configuration mode, the appliance emulator (1) is configured according to the household appliance (10). In the control mode, the appliance emulator (1) controls the component (13) and monitors the sensors (12) of the household appliance (10). In the data acquisition mode, appliance emulator (1) acquires, monitors and records the data obtained from the household appliance (10) while it is working. In the analysis mode, the appliance emulator (1) analyses the data recorded. In the simulation mode, the appliance emulator (1) simulates the algorithm of the household appliance (10) by the computer (30) without controlling the component (13) actually. In the emulation mode, the appliance emulator (1) emulates the household appliance (10). The household appliance (10) can be emulated by using the computer (30), by using the control board (16) or both by using the computer (30) and the control board (16). In all modes, user can edit the algorithms.

In the configuration mode, the user configures the appliance emulator (1) according to the type of the household appliance (10) with special values recorded in the initial configuration file, without the configuration mode, the appliance emulator (1) cannot be used. In this file, there are special codes for household appliance (10), and the appliance emulator (1). The configuration file includes the requested port numbers for the frequencymeter (2), and/or the counter (3), and/or the input/output ports (21,31), and/or the multiplexer (4). By using these ports the data acquisition and control board (16), communicates, controls and audits the algorithm, the sensors, and the components (13). All the data files include necessary but different groups of data like; component positions, sensor readings etc. In order not to mix all this data, every group is recorded separately from each other in data files, and is recorded in a defined order with respect to the configuration file. The configuration file includes some special knowledge such as, tl e maximum and minimum values, measurement units, transformation functions or polynomials about the related components and algorithm. Because any output from the data acquisition and control board () must be transformed by a polynomial transformation function or by a look up table for calibrating the data that will be obtained according to the user requests.

In the control mode, the appliance emulator (1) controls the appliance by using the algorithms. In control mode the household appliance (1) is monitored i.e. on/off positions, the outputs of the sensors (12) etc. and the data is recorded in a suitable format according to the user requests. So the parameters of the components (13) and the sensors (12) can be modified easily at any instant. This allows the optimisation of the component (13) and sensor (12) settings.

In the control mode, the user follows the data read from the sensors (12), and controls the status of the components (13) like on/off positions by using and changing the dynamic parameters related with the algorithm. While the appliance emulator (1) monitors the algorithms and components (13), data are collected and recorded in an output data file at the same time. There are digital, analog input and output files with special extensions like (.log). In addition to digital and/or analogue inputs and digital and/or analogue outputs, there are frequency and counter inputs and/or outputs. All the data are recorded to the previously defined files with respect to the related port numbers on the data acquisition and control board (20).

In the data acquisition mode, the appliance emulator (1) is directly connected to the household appliance (10). The appliance emulator (1) displays and acquires the data from the household appliance (10). Therefore the user can observe all the variations about the components (13) and sensors (12) for any type of the household appliance (10), and acquire data by using the data acquisition and control board (20). The acquired data including date, time, component (13) positions, and sensor (12) readings, is stored in the data storage unit (22,32) and/or in the computer (30).

In the analysis mode, tlie data acquired from the household appliance (10) is analysed. This data includes information regarding to the observations of the sensors (12) and the components. While the household appliance (10) is not working, the appliance emulator (1) can analyse the previously recorded data. Since the previous data was recorded in special files, they are kept in the data storage unit (22,32) and can be analysed by choosing one of the signal processing techniques, statistical tools, filtering or data analysis, etc. The user monitors the data through the display panel (14,24,34).

In the simulation mode, the computer (30) animates the household appliance (10) without any physical connection to the household appliance (10). In the simulation mode, the household appliance (10) is not working and there are no data acquisition or control activities. Configuration files, algorithms and data stored in data storage unit (22,32) are used for simulating the household appliance (10). The user can change the sensor (12) input data using an interface like the computer (30) and follow the outcomes of the algorithm.

In the emulation mode, the appliance emulator (1) runs the algorithms stored either on the control board (16) or the appliance emulator (1). In the emulation mode, data is recorded, and analysed instantaneously. All the data can be recorded in a data file. In the preferred embodiment, the control algorithm is recorded before the configuration mode to the data storage unit (22,32).

In the preferred embodiment, the appliance emulator (1) can perform the operation modes in a sequence or one by one according to the needs of the user. User can select his/her choice from a menu at the display panel (14,24,34). The menu let the user to select the type of the household appliance and operation. Then user can select all the other parameters under these modes.

In order to run the appliance emulator (1) the household appliance (10) and the appliance emulator (1) are connected to each other. Then the required configuration file and/or algorithms are entered. According to the user requirements, the required mode is chosen, and if required the files and/or algorithms are edited and recorded to the data storage unit (22,32), and the new parameters are defined to the appliance emulator (1) for the sensors (12) and the components (13) by using a configuration file including information about the input/output connection ports, and other requested parameters. Then the required data are monitored and/or acquired and/or recorded.

The appliance emulator (1) provides an economical, quick and flexible method for designing household appliance (10). The appliance emulator (1) allows the user to acquire, record and analyse the data from the household appliance (10) and to control the household appliance (10) simultaneously. The user can develop and test different scenarios via selecting the required hardware, such as components

(13), sensors (12) and editing/modifying algorithms for the household appliances (10) by using the appliance emulator (1), without any experimental set-up, testing and/or producing any prototypes. User also has the possibility to conduct the durability and performance tests of the component (13). The appliance emulator

(1) also has a diagnostic capability for identifying the faults by applying different test methods and presents helpful tips for the technicians while servicing the household appliance (10).

Claims

1- An appliance emulator (1) for controlling, monitoring, analysing, simulating, emulating a household appliance (10) such as a refrigerator, a washing machine, a dishwasher or an oven, etc. which includes one or more sensors (12) for detecting or measuring the physical conditions inside and/or outside the household appliance (10), and one or more components (13) for instance a compressor, a motor, a pump etc., which comprises;

a data acquisition and control board (20), comprising at least one input/output port (21) for sending and receiving the data from the household appliance (10) and a computer (30), a communication module (26) for enabling the communication between the household appliance (10) and the computer (30), and a microprocessor (23) for data acquiring and/or processing; and

the computer (30) comprising, data entry means (35) for entering data and/or editing new/alternative algorithms for controlling the sensors (12), the components (13) or the household appliance (10) by the user, a data storage unit (32) for storing the input/output data that are obtained from the household appliance (10), the processing tools required for analysing or processing the data and compiling tools for running the algorithms, a display unit (34) for presenting the input/output data obtained by running the algorithms, and monitoring the data received or analysed from the household appliance (10) and/or the stored data in the data storage unit (32), a microprocessor (33) for controlling the functions of the computer (30), for processing and analysing the data obtained from the household appliance (10), for controlling the household appliance (10) by using the new/alternative algorithms edited by the user directly from the computer (30) and enabling the evaluation or selection of the control algorithm for the household appliance (10), for configuring the data acquisition and control board (20) via setting the type of the household appliance (10), and defining the parameters for the input/output ports (21,31), i.e. the type of the sensor (12) or the component (13) it is connected to, time, the maximum or minimum working values, the measurement units used in and the transformation functions for converting the obtained data to the understandable outputs, for simulating the sensors (12), and/or components (13) and/or the household appliance (10) with the computer (30) without controlling them actually, for emulating the sensors (12), and/or components (13) and/or the household appliance (10) by using the computer (30).

2- An appliance emulator (1) for controlling, monitoring, analysing, simulating, emulating a household appliance (10) such as a refrigerator, a washing machine, a dishwasher or an oven etc. which includes one or more sensors (12) for detecting or measuring the physical conditions inside and/or outside of the household appliance (10), one or more components (13) such as a compressor, a motor, a pump or a door, a display panel (14) for presentation of the input/output data obtained by running the algoritlims, monitoring the data received or analysed from the household appliance (10), a control board (16) for controlling the household appliance (10), and one or more data entry means (15) for data entry and for editing the control algorithms for the household appliance (10), which comprises;

a data acquisition and control board (20) including at least one input/output port (21) for sending and receiving the data between the household appliance (10) and the data acquisition and control board (20), a communication module (26) for enabling the communication between the household appliance (10) and the data acquisition and control board (20), a data storage unit (22) for storing the input/output data that are obtained from the household appliance (10), processing tools required for analysing or processing the data and compiling tools for running the algoritlims, a microprocessor (23) for acquiring, processing and analysing the data obtained from the household appliance (10), for directly controlling the household appliance (10) by using the new/alternative algorithms edited by the user and enabling the evaluation or selection of the optimum algorithm for the household appliance (10), for configuring the data acquisition and control board (20) via setting the type of the household appliance (10), defining the parameters for the input/output ports (21), i.e. the type of the sensor (12) or the component (13) it is connected to, time, the maximum or minimum working values, the measurement units used in and the transformation functions for converting the obtained data to the understandable outputs, for simulating the sensors (12), and/or components (13) and/or the household appliance (10) with the computer (30) without controlling them actually, for emulating the sensors (12), and/or components (13) and/or the household appliance (10) by using the computer (30).

3- An appliance emulator (1) for controlling, monitoring, analysing, simulating, emulating a household appliance (10) such as a refrigerator, a washing machine, a dishwasher or an oven etc, which includes one or more sensors (12) for detecting or measuring the physical conditions inside and/or outside of the household appliance (10), and one or more components (13) e.g. a compressor, a motor, a pump or a door which comprises; a data acquisition and control board (20), including at least one input/output port (21) for sending and receiving the data between the household appliance (10) and the data acquisition and control board (20), a communication module (26) for enabling the communication between the household appliance (10) and the data acquisition and control board (20), one or more than one data entry means (25) for entering data and/or editing new/alternative algorithms for controlling tl e sensors (12), the components

(13) or the household appliance (10) by the user, a data storage unit (22) for storing the input/output data that are obtained from and send to the household appliance (10), and the processing tools required for analysing or processing the data, compiling tools for running the algorithms, a display unit (24) for presentation of the input/output data obtained by running the algorithms, monitoring or analysing the data received from the household appliance (10) and/or the stored in the data storage unit (22), a microprocessor (23) for acquiring, processing and analysing the data obtained from the household appliance (10), for directly controlling the household appliance (10) by using the new/alternative algorithms edited by the user and enabling the evaluation or selection of the optimum algorithm for the household appliance (10), for configuring the data acquisition and control board (20) via setting the type of the household appliance (10), defining the parameters for the input/output ports (21), i.e. the type of the sensor (12) or the component (13) it is connected to, time, the maximum or minimum working values, the measurement units used in and the transformation functions for converting the obtained data to the understandable outputs, for simulating the sensors (12), and/or components (13) and/or the household appliance (10) with the computer (30) without controlling them actually, for emulating the sensors (12), and/or components (13) and/or the household appliance (10) by using the computer (30).

4-The appliance emulator (1) as in any one of claims 1 to 3, characterised in that, the data acquisition and control board (20) comprises a multiplexer (29) for acquiring the data from multi channels by increasing tlie number of the input/output port (21 ,31 ) .

5 -The appliance emulator (1) as in any one of claims 1 to 4, characterised in that, the data acquisition and control board (20) comprises a frequencymeter (27) for generating special frequency signals to control the components (13).

6-The appliance emulator (1) as in any one of claims 1 to 5, characterised in that, the data acquisition and control board (20) comprises a counter (28) for realising and enumerating the data.

7-The appliance emulator (1) as in any one of claims 1 or 3, characterised in that, the data acquisition and control board (20) comprises a data storage unit (22) for recording input/output data.

8-The appliance emulator (1) as in claim 1, characterised in that, the data acquisition and control board (20) is integrated into the computer (30).

9-The appliance emulator (1) as in claim 2, characterised in that, the data acquisition and control board (20) is integrated into the household appliance (10). 10-The appliance emulator (1) as in any one of claims 1 to 9, characterised in that, the data acquisition and control board (20) acquires data from an additional sensor (12) or component (13) other than that which the household appliance (10) has.