Claims:WE CLAIM:
1. An autonomous clutch-less drive mechanism for a vertical axis washing machine, the clutch-less drive mechanism comprising:
a first motor adapted to rotate a perforated drum of the vertical axis washing machine in a plurality of operating modes; and
a second motor adapted to rotate a pulsator of the vertical axis washing machine independent of the first motor in the plurality of operating modes;
wherein the first motor and the second motor are arranged in the vertical axis washing machine in one of a first operating configuration and a second operating configuration such that the first motor is located in line to the second motor in the first operating configuration and the first motor is located perpendicular to the second motor in the second operating configuration.

2. The autonomous clutch-less drive mechanism as claimed in claim 1, wherein the first motor and the second motor are selected from a group comprising of a brushless DC motor, induction motor, and switched reluctance motor.

3. The autonomous clutch-less drive mechanism as claimed in claim 1, wherein:
the first motor is adapted to cause an orbital movement of the perforated drum; and
the second motor is adapted to cause a wobble movement of the pulsator.

4. The autonomous clutch-less drive mechanism as claimed in claim 1, comprises:
a first controller to control operating parameters of the first motor in the plurality of operating modes; and
a second controller to control operating parameters of the second motor independent of the first controller in the plurality of operating modes.

5. The autonomous clutch-less drive mechanism as claimed in claim 3, wherein the operating parameters include a speed of rotation, a direction of rotation, and torque.

6. The autonomous clutch-less drive mechanism as claimed in claim 1, comprises:
a first pulley mechanism coupled to the first motor and the perforated drum; and
a second pulley mechanism coupled to the second motor and the pulsator such that the rotation of the first motor is independent of the rotation of the second motor.
7. The autonomous clutch-less drive mechanism as claimed in claim 6, wherein:
the first pulley mechanism comprises:
a first driving pulley; and
a first belt coupled to the first driving pulley and the first motor to rotate the perforated drum in a direction of the rotation of the first motor; and
the second pulley mechanism comprises:
a second driving pulley; and
a second belt coupled to the second driving pulley and the second motor to rotate the pulsator in a direction of the rotation of the second motor.

8. The autonomous clutch-less drive mechanism as claimed in claim 1, comprises:
an auxiliary motor adapted to rotate an auxiliary pulsator of the vertical axis washing machine independent of the first motor and the second motor, the auxiliary motor is arranged in the vertical axis washing machine in one of the first operating configuration and the second operating configuration such that the auxiliary motor is located perpendicular to the first motor in the first operating configuration and the auxiliary motor is located in line to the first motor in the second operating configuration.

9. The autonomous clutch-less drive mechanism as claimed in claim 8, comprises:
an auxiliary controller to control operating parameters of the auxiliary motor independent of the first controller and the second controller in the plurality of operating modes.

10. The autonomous clutch-less drive mechanism as claimed in claim 1, wherein:
in one operating mode, the first motor and the second motor are rotated in opposite directions;
in one operating mode, the first motor and the second motor are rotated in same direction;
in one operating mode, the first motor is rotated continuously in a first direction and the second motor is rotated in stepped manner in a second direction;
in one operating mode, the second motor is rotated continuously in a first direction and the first motor is rotated in stepped manner in a second direction;
in one operating mode, the first motor is rotated while the second motor is at a halt; and
in one operating mode, the second motor is rotated while the first motor is at a halt.

11. A vertical axis washing machine comprising:
a perforated drum;
a pulsator rotatably mounted in the perforated drum;
a first shaft connected to the perforated drum;
a second shaft connected to the pulsator; and
an autonomous clutch-less drive mechanism comprising:
a first motor adapted to rotate the perforated drum in a plurality of operating modes, the first shaft is connected to the first motor to rotate the perforated drum in response to rotation of the first motor; and
a second motor adapted to rotate the pulsator independent of the first motor in the plurality of operating modes, the second shaft is connected to the second motor to rotate the pulsator in response to rotation of the second motor; and
wherein the first motor and the second motor are arranged in the vertical axis washing machine in one of a first operating configuration and a second operating configuration such that the first motor is located in line to the second motor in the first operating configuration and the first motor is located perpendicular to the second motor in the second operating configuration.

12. The vertical axis washing machine as claimed in claim 11, wherein:
the second shaft is rotatably arranged inside the first shaft; and
the first shaft and the second shaft are aligned with a vertical axis of the washing machine.

13. The vertical axis washing machine as claimed in claim 11, wherein the autonomous clutch-less drive mechanism comprises:
a first controller to control operating parameters of the first motor in the plurality of operating modes; and
a second controller to control operating parameters of the second motor independent of the first controller in the plurality of operating modes.

14. The vertical axis washing machine as claimed in claim 11, wherein the autonomous clutch-less drive mechanism comprises:
a first pulley mechanism coupled to the first motor and the first shaft; and
a second pulley mechanism coupled to the second motor and the second shaft such that the rotation of the first motor is independent of the rotation of the second motor.

15. The vertical axis washing machine as claimed in claim 11, comprises:
an auxiliary pulsator rotatably and concentrically mounted on the pulsator, the auxiliary pulsator having a diameter lesser than a diameter of the pulsator and connected to the second shaft.

16. The vertical axis washing machine as claimed in claim 15, wherein the autonomous clutch-less drive mechanism comprises:
an auxiliary motor adapted to rotate an auxiliary pulsator of the vertical axis washing machine independent of the first motor and the second motor, the second shaft is connected to the auxiliary motor to rotate the auxiliary pulsator in response to rotation of the auxiliary motor, the auxiliary motor is arranged in the vertical axis washing machine in one of the first operating configuration and the second operating configuration such that the auxiliary motor is located perpendicular to the first motor in the first operating configuration and the auxiliary motor is located in line to the first motor in the second operating configuration.

17. The vertical axis washing machine as claimed in claim 16, wherein the autonomous clutch-less drive mechanism comprises:
an auxiliary controller to control operating parameters of the auxiliary motor independent of the first controller and the second controller in the plurality of operating modes.
, Description:AUTONOMOUS CLUTCH-LESS DRIVE SYSTEM FOR VERTICAL AXIS WASHING MACHINE AND THE VERTICAL AXIS MACHINE THEREOF
DESCRIPTION
TECHNICAL FIELD
The present disclosure generally relates a vertical axis washing machine and, in particular, relates to an autonomous clutch-less drive system for the vertical axis washing machine and the vertical axis washing machine thereof.
BACKGROUND
A vertical axis washing machine, commonly known as the top load washing machine, is very popular for washing and drying of clothes. FIG. 1 illustrates a conventional vertical axis washing machine 100. The vertical axis washing machine 100 has a housing including a tub 102 for receiving water and a perforated drum 104 within the tub 102 for receiving fabrics to be washed in the water. The perforated drum 104 is mounted on the upper end of a drive shaft (or pulsator shaft) 106, which extends upwards within the tub 102. A hollow sleeve or spin shaft (or drum shaft) 108 extends upwards within the tub 102 around the drive shaft 106. The spin shaft 108 is connected to the drum 104 and the drive shaft is connected to a pulsator 110. The pulsator 110 is rotatably mounted in the perforated drum 104. The spin shaft 108 and the drive shaft 106 are further connected to a motor 112 and a clutch system 114 to control the rotation of the drum 104 and the pulsator 110.
During a wash mode or wash cycle, the motor 112 initially rotates in a first direction (clockwise or anti-clockwise). This leads to rotation of the drive shaft 106, which rotates the pulsator 110, while the clutch system 114 holds the spin shaft 108 stationary so that a limited wobble-type motion or turbulence is imparted to the drum 104 for cleaning the fabrics. During spin mode or spin cycle, the clutch system 114 coupled with the motor 112 engages the spin shaft 108 with the drive shaft 106 in order to spin the drum 104 in a single direction, for centrifugal extraction of liquid from the fabrics. When the motor 112 is turned off at the end of centrifugal extraction, the clutch system 114 quickly stops the rotation of both the drum 104 and the pulsator 110.
During spin mode or spin cycle, the motor 112 rotates the drum 104 at peak speed. Due to gear ratios, the motor 112 rotates the drum 104 and the pulsator 110, which in turn creates centrifugal forces on the fabrics/clothes due to which water is thrown out through holes or perforations in the drum 104 into the tub 102. When the spin mode is finished, a pump (not shown in the figure) drains the water from the tub 102. During rinse mode or rinse cycle, the motor 112 rotates the drum 104 to rinse the fabrics with clean water. The rinse cycle is a quick cycle that requires no detergent and runs automatically after most other wash cycles. With fabrics/clothes, the drum 104 spins to ensure that a sufficient amount of dirty water is out. However, in order to get an acceptable quality wash, the intake of water in the vertical axis washing machine 100 is high by almost 20% compared to equivalent capacity front load machines.
Now, the motor 112 is typically a single-phase induction motor, which is a constant speed motor. However, the speed of the induction motor can only be controlled by sacrificing the cost of a decrease in efficiency by using a voltage control drive, and low electrical power factor by using a variable-frequency drive (VFD). The variable speed requisite in such conventional machines, during wash and spin mode for the drum and pulsator, is thus, rendered purely as a mechanical function of a planetary gear system (included within the clutch assembly) that accompanies the washing machines. Motor speed remains largely a constant value at around 1300 rotations per minute (RPM), throughout the wash or spin cycle.
Further, the clutch system 114 includes multiple parts such as epicyclic gear train or gearbox 116, ratchet 118, inner shaft (not shown in the figure), outer shaft (not shown in the figure), drum case 120, brake lever 122, clutch lever 124, belt 126, clutch pulley 128, motor pulley 130, spring lever brake (not shown in the figure), clutch lever brake (not shown in the figure), nut (not shown in the figure), bolt (not shown in the figure), water seal (not shown in the figure) (inner and outer water seals), oil-less bearing (not shown in the figure), coupler connector (not shown in the figure), pawl (not shown in the figure), case gear (not shown in the figure), guide carrier (not shown in the figure), etc. However, the parts are majorly made of plastics (including gears and ratchets) and therefore are highly prone to wear & tear over time and are unreliable. On the contrary, parts made of metals make the washing machine heavy and noisy. In addition, when the gearbox 116 is locked up, both the drive shaft 106 that drives the pulsator 110 and the spin shaft 108 that drives the drum 104, spin at the speed half as that of the motor 112 due to a speed reduction of 2 times, which is achieved in default in both wash and spin modes, by a difference in pulley diameters of the motor pulley 130 and the clutch pulley 128. As such, the speed of rotation of the pulsator 110 is reduced further 5.33 times in wash mode due to clutch system 114 apart from the default 2 times reduction, thereby causing a total 10.66 times speed reduction.
Further during wash mode, the drum 104 remains stationary while the pulsator 110 rotates in alternate directions at around 120 RPM. During spin mode, the clutch system 114 engages both the spin shaft 108 and the drive shaft 106, and the motor 112 suddenly ramps up or increases the speed and rotates both the drum 104 and the pulsator 110 at a maximum rpm, i.e., say 650 RPM in a single direction. This creates unbalance issues as sufficient time is not allotted to redistribute the wet fabrics along the periphery of the drum 104, which is a pre-requisite for an effective spin cycle. In addition, as the pulsator 110 is incapable of making an independent motion relative to the drum 104, the turbulence created during the wash mode is very limited. This leads to poor wash quality. Further, there is high power consumption to achieve the desired wash quality as the program time needs to be increased.
Various solutions are available that overcome these deficiencies. In one solution, by way of example as described in CN1093196C, a tub via a rotating tub shaft is connected with a dehydrating motor and an agitator is connected to a stirring shaft through a washing motor in an automatic vertical axis washing machine. The washing motor is an outer rotor type, having a large diameter than the dehydrating motor. The dehydrating motor is an inner rotor type and is located outside the washing motor. The solution does not require a clutch mechanism or the speed reduction mechanism, and independently control the rotation of the tub and the agitator.
In another solution, by way of example as described in CN106787541A, a washing machine comprises an outer cylinder, an inner cylinder, an impeller and a driving device. The driving device comprises an annular reluctance rotor, a permanent magnetic rotor, and a stator. The stator, the reluctance rotor and the permanent magnetic rotor are nested in turn from the inside to the outside and rotatable mutually. Among the stator, the reluctance rotor and the permanent magnetic rotor, each two of them which are adjacent are separated by an air gap. The stator comprises a stator core and a first winding and a second winding. The first winding and the second winding are winded around the stator core and mutually exclusive. The first winding and the second winding respectively correspond to the reluctance rotor and the permanent magnetic rotor, so as to respectively and exclusively drive the reluctance rotor and the permanent magnetic rotor to rotate, wherein, the reluctance rotor and the permanent magnetic rotor are respectively and relatively and fixedly connected with the inner cylinder and the impeller respectively and exclusively to drive the inner cylinder and the impeller to rotate. According to the washing machine, a manner of non-mechanical differential rotational speed and non-clutch is adopted so that dual power washing and dehydration are realized, system integration degree is high, energy consumption is low and clean ratio is high.
In another solution, by way of example as described in CN103051284A, a motor for a washing machine with a dual rotor-dual stator structure with no independent clutch is used and along with selectively using an impeller and a dewatering tank. A driving signal is generated according to a washing control signal, and the motor for the washing machine is controlled to be driven. A transducer, three-phase alternating current is generated under the control of the motor control portion, and the three-phase alternating current is output to the thirteenth phase stator coil for driving the outer rotor of the motor to rotate and output to the twenty-third phase stator coil for driving the inner rotor of the motor to rotate. A first rotor driving control portion, which is arranged between the transducer and the twenty-third phase stator coil, blocks or permits the three-phase alternating current to pass under the control of the motor control portion, and the rotation direction of the inner rotor is controlled.
In another solution, by way example, as described in US6445101B2, a clutchless motor drive system for a vertical axis washing machine comprises an electric motor including a rotor shaft, a first main winding and a second main winding. The first and second main windings are selectively energizable to operate the motor at first and second speeds, and at least one of the windings is a permanent split capacitor winding. A transmission is coupled to the rotor shaft, and the rotor shaft engages the transmission without employing a clutch mechanism.
However, these solutions require complex systems in place of clutch systems and are therefore increase the cost of manufacturing of the vertical washing machines, with little few improvements in reliability. Further, these solutions employ a single motor having outrunner construction. This limits the maximum torque speed capability of the motor, as a rotor having a large diameter is required, thereby necessitating the requirement of the motor having a higher power rating. In addition, these solutions depend on the drain retractor motor to achieve water draining.
Thus, there exists a need for a solution to overcome the above-mentioned deficiencies.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified format that is further described in the detailed description of the present disclosure. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter. In accordance with the purposes of the disclosure, the present disclosure as embodied and broadly described herein describes an autonomous clutch-less drive system for a vertical axis washing machine, and the vertical axis washing machine thereof.
In accordance with the embodiment, an autonomous clutch-less drive system for a vertical axis washing machine is disclosed. The autonomous clutch-less drive system includes a first motor adapted to rotate a perforated drum of the vertical axis washing machine in a plurality of operating modes. The autonomous clutch-less drive system includes a second motor adapted to rotate a pulsator of the vertical axis washing machine independent of the first motor in the plurality of operating modes. The first motor and the second motor are arranged in the vertical axis washing machine in one of a first operating configuration and a second operating configuration. In the first operating configuration, the first motor is located in line to the second motor and in the second operating configuration the first motor is located perpendicular to the second motor.
In accordance with the embodiment, a vertical axis washing machine is disclosed. The vertical axis washing machine comprises a perforated drum. The vertical axis washing machine comprises a pulsator rotatably mounted in the perforated drum. The vertical axis washing machine comprises a first shaft connected to the perforated drum and a second shaft connected to the pulsator. The vertical axis washing machine further comprises an autonomous clutch-less drive mechanism comprising of a first motor and a second motor. The first motor is adapted to rotate the perforated drum in a plurality of operating modes. As such, the first shaft is connected to the first motor to rotate the perforated drum in response to rotation of the first motor. The second motor is adapted to rotate the pulsator independent of the first motor in the plurality of operating modes. As such, the second shaft is connected to the second motor to rotate the pulsator in response to rotation of the second motor. The first motor and the second motor are arranged in the vertical axis washing machine in one of a first operating configuration and a second operating configuration. In the first operating configuration, the first motor is located in line with the second motor. In the second operating configuration, the first motor is located perpendicular to the second motor.
The advantages of the present disclosure include, but not limited to, enabling controlling of the two motors independently since the two motors are operating independently of each other. Further, the two motors can be located in-line or perpendicular to each other, depending on available space. These mounting arrangements or operating configurations will provide flexibility and stability to the washing machine. Further, such mounting arrangements eliminates the use of drain-pump motor/clutch retractor motor used in conventional vertical axis washing machines and the same can be effectively replaced by a solenoid valve for draining the water. This further leads to a cost benefit.
These aspects and advantages will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF FIGURES
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 illustrates a sectional view of a vertical axis washing machine as known in the art;
FIG. 2 illustrates a block diagram of a vertical axis washing machine comprising an autonomous clutch-less drive system, in accordance with some embodiments of the present disclosure;
FIG. 3A and FIG. 3B illustrate sectional views of the vertical axis washing machine comprising the autonomous clutch-less drive system, in accordance with some embodiments of the present disclosure;
FIG. 4A illustrates a bottom view of the vertical axis washing machine comprising a first configuration of the autonomous clutch-less drive system, in accordance with one embodiment of the present disclosure;
FIG. 4B schematically illustrates a bottom view of the vertical axis washing machine comprising a second configuration of the autonomous clutch-less drive system, in accordance with other embodiment of the present disclosure;
FIG. 5A and FIG. 5B illustrate various views of the vertical axis washing machine comprising the autonomous clutch-less drive system in the second configuration, in accordance with other embodiment of the present disclosure; and
FIG. 6 illustrates a sectional view of the autonomous clutch-less drive system, in accordance with some embodiments of the present disclosure;
FIG. 7 illustrates a block diagram of the vertical axis washing machine comprising the autonomous clutch-less drive system, in accordance with some other embodiments of the present disclosure; and
FIG. 8 illustrates a bottom view of a vertical axis washing machine comprising a first configuration of the autonomous clutch-less drive system, in accordance with one other embodiment of the present disclosure.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
DETAILED DESCRIPTION
For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the disclosure relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
FIG. 2 illustrates a block diagram of a vertical axis washing machine 200, the construction and operation of which is well known in the art, and in which the present invention is implemented. The vertical axis washing machine 200, also known as top-loading washing machine, comprises an autonomous clutch-less drive system 202, in accordance with some embodiments of the present disclosure. FIG. 3A & FIG. 3B illustrates a sectional view of the vertical axis washing machine 200 comprising the autonomous clutch-less drive system 202, in accordance with some embodiments of the present disclosure.
Referring to FIG. 2, FIG. 3A, and FIG. 3B, the vertical axis washing machine 200 comprises a cabinet housing 201 including a tub 204 adapted to be filled with wash water or rinse water through a fill tube (not shown) in response to user selection of various control buttons located on a control panel (not shown) of the vertical axis washing machine 200. The vertical axis washing machine 200 includes a perforated drum 206 and a pulsator 208. The perforated drum 206 is mounted within the tub 204 to receive fabrics or clothes. The pulsator 208 is rotatably mounted within the perforated drum 206 such that the fabrics are subjected to washing action by the pulsator 208 after the introduction of water and the user-selection of the control button. After each wash or rinse cycle, the perforated drum 206 is rotated about a vertical axis AA’ at high speed in order to extract water from the fabrics during the spin mode. The water is drained into a sump (not shown) and pumped to a drain (not shown) by a pump assembly (not shown).
The perforated drum 206 and the pulsator 208 are independently driven by the autonomous clutch-less drive system 202. The autonomous clutch-less drive system 202 includes a first motor 210 adapted to rotate the perforated drum 206 in a plurality of operating modes. The first motor 210 is adapted to cause an orbital movement of the perforated drum 206. The first motor 210 is selected from a group comprising of a brushless DC (BLDC) motor, induction motor, and switched reluctance motor. Typically, the BLDC motors can be constructed in different physical configurations such as single-phase, two-phase, or three-phase motors based on stator windings. In an example implementation of the present disclosure, three-phased BLDC motor with permanent magnet rotor operating at 1600 rotations per minute (RPM) to 3600 RPM is selected as the first motor 210. The first motor 210 is located below the tub 204. The first motor 210 can be securely mounted to the tub 204 using techniques as known in the art. The first motor 210 and the perforated drum 206 are connected through a first shaft (also referred to as spin shaft or drum shaft, and not shown in the figure) and a first pulley mechanism 214 such that the first shaft rotates the perforated drum 206 in response to a rotation of the first motor 210. The first pulley mechanism 214 is coupled to the first motor 210 and the first shaft.
The autonomous clutch-less drive system 202 includes a second motor 212 adapted to rotate the pulsator 208 independent of the first motor 210 in the plurality of operating modes. The second motor 212 is adapted to cause a wobble movement of the pulsator 208. As would be understood, the wobble movement of the pulsator 208 creates agitation and relative movement of clothes or fabric thereby attaining a decent wash quality. The second motor 212 is selected from a group comprising of a brushless DC (BLDC) motor, induction motor, and switched reluctance motor. Typically, the BLDC motors can be constructed in different physical configurations such as single-phase, two-phase, or three-phase motors based on stator windings. In an example implementation of the present disclosure, three-phased BLDC motor with permanent magnet rotor operating at 1600 RPM to 3600 RPM is selected as the second motor 212. The second motor 212 is located below the tub 204. The second motor 212 can be securely mounted to the tub 204 using techniques known in the art. The second motor 212 and the pulsator 208 are connected through a second shaft (also referred to as driveshaft or pulsator shaft, and not shown in the figure) and a second pulley mechanism 216 such that the second shaft rotates the pulsator 208 in response to a rotation of the second motor 212. The second pulley mechanism 216 is coupled to the second motor 212 and the second shaft.
The first motor 210 and the second motor 212 are arranged in the vertical axis washing machine 200, i.e., below the tub 204, in one of a first operating configuration and a second operating configuration. FIG. 4A and FIG. 4B illustrates a bottom view of the vertical axis washing machine 200 depicting the first motor 210 and the second motor 212 securely attached to the tub 204. Referring to FIG. 4A, the first operating configuration 402 is illustrated. In the first operating configuration, the first motor 210 is located in line with or opposite to the second motor 212. Referring to FIG. 4B, the second operating configuration 404 is illustrated. In the second operating configuration, the first motor 210 is located perpendicular to the second motor 212.
Such operating configurations or mounting arrangements provide the flexibility of manufacturing the vertical axis washing machine 200 and stability to the vertical axis washing machine 200 while in operation. Further, such operating configurations eliminate the use of drain-pump motor/clutch retractor motor (not shown) used in conventional vertical axis washing machines and the same can be effectively replaced by solenoid valve for draining the water. This further leads to a cost benefit. Further, the operating configuration of the first motor 210 and the second motor 212 in the autonomous clutch-less drive system 202 enables enhanced independent control over the rotation of the pulsator 208 and the perforated drum 206. This leads to improved wash quality, reduced water consumption, reduced wash time, reduced power consumption, and improved life of the washing machine as the wobble movement of the pulsator 208 is better controlled independently of the orbital movement of the perforated drum 206.
Further, the autonomous clutch-less drive system 202 includes a first controller 218 and a second controller 220. The first controller 218 controls operating parameters of the first motor 210 in the plurality of operating modes. The second controller 220 controls operating parameters of the second motor 212 independent of the first controller 218 in the plurality of operating modes. The operating parameters include a speed of rotation, a direction of rotation, and a torque. This enables controlling the two motors independently since the two motors are operating independently of each other. Each of the first controller 218 and the second controller 220 includes an intelligent power module (IPM), a microcontroller, and other associated electronic components to control the operating parameters of the first motor 210 and the second motor 212. As would be understood, the IPM is an advanced power switch device designed for high-speed switching drive. In one example implementation, the first controller 218 and the second controller 220 may be coupled with a main controller of the vertical axis washing machine 200. The main controller may control various functionalities of the vertical axis washing machine 200 such as filling the tub 204 with water, rinsing, washing, etc., in response to user selection of various control buttons located on a control panel (not shown) of the vertical axis washing machine 200. Based on the user selection, the main controller may provide input to the first controller 218 and the second controller 220 to control the first motor 210 and the second motor 212.
Further, in accordance with the embodiment, the plurality of operating modes enable controlling of one or more of the operating parameters of both the first motor 210 and the second motor 212. The plurality of operating modes are configured or enabled through the first controller 218 and the second controller 220. The plurality of operating modes can be defined as variants of wash mode or wash cycle and can be provided as control buttons located on the control panel for user selection.
In some operating modes, the speed of both the first motor 210 and the second motor 212 are controlled independently while the direction of rotation of both the first motor 210 and the second motor 212 is same. In some operating modes, the direction of rotation of both the first motor 210 and the second motor 212 is controlled independently while the speed of both the first motor 210 and the second motor 212 is same.
In one operating mode, the first motor 210 and the second motor 212 are rotated in opposite directions. Such operating mode is generally termed as wash mode. In such mode, the perforated drum 206 is rotated in a direction (either in clockwise direction or in anti-clockwise direction) due to the rotation of the first motor 210 while the pulsator 208 is rotated in opposite direction (either in anti-clockwise direction or in clockwise direction) due to the rotation of the second motor 212.
In one operating mode, the first motor 210 and the second motor 212 are rotated in the same direction. Such operating mode can be incorporated during a wash mode or a spin mode. In such mode, the perforated drum 206 is rotated in a direction (either in clockwise direction or in anti-clockwise direction) due to the rotation of the first motor 210 while the pulsator 208 is rotated in the same direction (either in clockwise direction or in anti-clockwise direction) due to the rotation of the second motor 212.
In one operating mode, the first motor 210 is rotated continuously in a first direction and the second motor 212 is rotated in a stepped manner in a second direction opposite to the first direction. As such, the perforated drum 206 rotates continuously in a direction (either in clockwise direction or in anti-clockwise direction) due to the rotation of the first motor 210 while rotation of the pulsator 208 is controlled in a stepped manner in opposite direction (either in anti-clockwise direction or in clockwise direction) due to the rotation of the second motor 212.
In one operating mode, the second motor 212 is rotated continuously in a first direction and the first motor 210 is rotated in a stepped manner in a second direction opposite to the first direction. As such, the pulsator 208 rotates continuously in a direction (either in clockwise direction or in anti-clockwise direction) due to the rotation of the second motor 212 while rotation of the perforated drum 206 is controlled in a stepped manner in opposite direction (either in anti-clockwise direction or in clockwise direction) due to the rotation of the first motor 210.
In one operating mode, the first motor 210 is rotated while the second motor 212 is at a halt. As such, the perforated drum 206 is rotated in any direction (either in a clockwise direction or in an anti-clockwise direction) due to the rotation of the first motor 210, while the pulsator 208 is stopped.
In one operating mode, the second motor 212 is rotated while the first motor 210 is at a halt. As such, the pulsator 208 is rotated in any direction (either in a clockwise direction or in an anti-clockwise direction) due to the rotation of the second motor 212, while the perforated drum 206 is stopped.
Thus, infinite motion capabilities are provided to the vertical axis washing machine 200 according to the plurality of operating modes, thereby controlling the wobble movement of the pulsator 208 independently of the perforated drum 206. This results in flexibility in the vertical axis washing machine 200 in achieving a quality washing performance by enabling improved agitation of the fabrics by virtue of higher freedom of rotational movement of the pulsator 208 and the perforated drum 206 with respect to each other during the wash mode. This leads to ease of washing of different types of fabrics due to better agitation and relative movement of the fabrics without any limitation, thereby enhancing user-experience such as improved wash quality, reduced water consumption, reduced wash time, reduced power consumption, and improved life of the washing machine.
FIG. 5A illustrates a side view of the vertical axis washing machine 200 comprising the autonomous clutch-less drive system 202 in second operating configuration, in accordance with other embodiment of the present disclosure. FIG. 5B illustrates an isometric view of the vertical axis washing machine 200 comprising the autonomous clutch-less drive system 202 in second operating configuration, in accordance with other embodiment of the present disclosure.
Referring to FIG. 5A and FIG. 5B, the autonomous clutch-less drive system 202 includes the first pulley mechanism 214 coupled to the first motor 210 and the perforated drum 206. The first pulley mechanism 214 comprises a first driving pulley 502 and a first belt 504. The first belt 504 is coupled to the first driving pulley 502 and the first motor 210. The first driving pulley 502 and the first belt 504 can be coupled and can be securely mounted below the tub 204 using techniques as known in the art.
The autonomous clutch-less drive system 202 includes the second pulley mechanism 216 coupled to the second motor 212 and the pulsator 208. The second pulley mechanism 216 comprises a second driving pulley 506 and a second belt 508. The second belt 508 is coupled to the second driving pulley 506 and the second motor 212. The second driving pulley 506 and the second belt 508 can be coupled and can be securely mounted below the tub 204 using techniques as known in the art.
FIG. 6 illustrates the autonomous clutch-less drive system 202, in accordance with other embodiment of the present disclosure. A first shaft 602, (also referred to as spin shaft or drum shaft) connects the first motor 210 with the perforated drum 206 such that the first shaft 602 rotates the perforated drum 206 in response to rotation of the first motor 210. As described earlier, the autonomous clutch-less drive system 202 includes the first pulley mechanism 214 coupled to the first motor 210 and the perforated drum 206. As such, the first pulley mechanism 214 is coupled to the first shaft 602 and the first motor 210. The first belt 504 is coupled to the first driving pulley 502 and the first motor 210 to rotate the perforated drum 206 in a direction of the rotation of the first motor 210 through the first shaft 602.
Further, a second shaft 604 (also referred to as driveshaft or pulsator shaft) connects the second motor 212 with the pulsator 208 such that the second shaft 604 rotates the pulsator 208 in response to rotation of the second motor 212. The second shaft 604 is rotatably arranged concentrically inside the first shaft 602 and therefore the first shaft 602 is a hollow shaft and the second shaft 604 is a solid shaft. Thus, the first shaft 602 and the second shaft 604 extend upwards within the tub such that the first shaft 602 extends around the second shaft 604. The first shaft 602 and the second shaft 604 are aligned with the vertical axis AA’ of the washing machine 200. The perforated drum 206 and the pulsator 208 are mounted on an upper end of the shafts and the first motor 210 and the second motor 212 are mounted on a lower end of the shaft.
As described earlier, the autonomous clutch-less drive system 202 includes the second pulley mechanism 216 coupled to the second motor 212 and the pulsator 208 such that the rotation of the first motor 210 is independent of the rotation of the second motor 212. As such, the second pulley mechanism 216 is coupled to the second shaft 604 and the second motor 212. The second belt 508 is coupled to the second driving pulley 506 and the second motor 212 to rotate the pulsator 208 in a direction of the rotation of the second motor 212 through the second shaft 604.
Thus, the separate pulley mechanisms for the motors, i.e., the first motor 210 and the second motor 212, alleviate any constraints of the motors as well as existing clutch based conventional system. The pulley reduction ratio is 1:10 times the motor pulley to drum & pulsator pulley ratios. As such, each of the operating parameters can be controlled, i.e., increased or decreased, by changing the size of the pulley mechanisms. This further leads to having infinite motion capabilities. In addition, the vertical axis washing machine 200 including the autonomous clutch-less drive system 202 reduces the number of mechanical components used in the transmission. This improves the life of the vertical axis washing machine 200. Further, the use of such mechanism will impart extensive wobble movement of the pulsator 208 to the fabrics as compared to conventional mechanism, resulting in high wash quality.
FIG. 7 illustrates a block diagram of the vertical axis washing machine 200 in accordance with some other embodiments of the present disclosure. In such some other embodiments, the vertical axis washing machine 200 includes an auxiliary pulsator 700 having a diameter lesser than a diameter of the pulsator 208. The auxiliary pulsator 700 is rotatably and concentrically mounted on the pulsator 208 and is connected to the second shaft 604. As such, the autonomous clutch-less drive system 202 includes an auxiliary motor 702 connected to the second shaft 604 to rotate the auxiliary pulsator 700. The auxiliary motor 702 is adapted to rotate the auxiliary pulsator 700 independent of the first motor 210 and the second motor 212.
The auxiliary motor 702 is selected from a group comprising of a brushless DC (BLDC) motor, induction motor, and switched reluctance motor. Typically, the BLDC motors can be constructed in different physical configurations such as single-phase, two-phase, or three-phase motors based on stator windings. In an example implementation of the present disclosure, three-phased BLDC motor with permanent magnet rotor operating at 1600 RPM to 3600 RPM is selected as the auxiliary motor 702. The auxiliary motor 702 is located below the tub 204. The auxiliary motor 702 can be securely mounted to the tub 204 using techniques as known in the art.
In accordance with the present embodiments, the auxiliary motor 702 is arranged in the vertical axis washing machine 200, i.e., below the tub 204, in one of the first operating configuration and the second operating configuration. In the first operating configuration, the auxiliary motor 702 is located perpendicular to the first motor 210. In the second operating configuration, the auxiliary motor 702 is located in line with the first motor 210.
As such, FIG. 8 illustrates a bottom view of a vertical axis washing machine 800 depicting the first motor 210, the second motor 212, and the auxiliary motor 702 securely attached to the tub 204. Referring to FIG. 8, the first operating configuration is illustrated. In the first operating configuration, the first motor 210 is located in line with or opposite to the second motor 212. The auxiliary motor 702 is located perpendicular to the first motor 210.
In addition, the autonomous clutch-less drive system 202 includes an auxiliary controller 704 to control operating parameters of the auxiliary motor 702 independent of the first controller 218 and the second controller 220 in the plurality of operating modes. In an example implementation, the auxiliary controller 704 may be coupled with the main controller of the vertical axis washing machine 200. In an example implementation of operating mode, the direction of rotation of both the first motor 210 and the auxiliary motor 702 are same. In another example implementation of operating mode, the direction of rotation of both the second motor 212 and the auxiliary motor 702 are the same.
Based on experimental results, table 1 summarizes the quantifiable advantages of the mechanism as described according to present embodiments over conventional mechanism in a typical top load washing machine with 6.5kg capacity in a controlled ambient test environment of 25°C and 1 atm pressure.
Table 1
S. No Parameters Conventional Mechanism Mechanism in accordance with present embodiments Improvement in percentage
1 Wash time (Minutes) 45 25 +46%
2 Water consumption (Litres) 100 70 +30%
3 Wash quality (%) 83 95 +12.6%
4 Power consumption (Wh) 78 50 +36%
5 Life of washing machine transmission (years) 6 12 +50%

Thus, as can be gathered from above, the autonomous clutch-less drive system 202 provides various advantages such as improved wash quality, reduced water consumption, reduced wash time, reduced power consumption, and improved life of the washing machine due to controlling the movement of the pulsator 208 independently of the perforated drum 206.
While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. Clearly, the present disclosure may be otherwise variously embodied, and practiced within the scope of the following claims.