Appliance control system with cycle selection detection Number:6,813,911 from the United States Patent and Trademark Office (PTO) owispatent

Title: Appliance control system with cycle selection detection

Abstract: An appliance controller includes a control knob assembly and detection mechanism having various mechanical and electrical components that are configured to detect the position of the knob assembly and produce a position signal indicative of the knob assembly position. The position signal is provided to the appliance controller that produces a control signal in response thereto. The control signal is used to initiate various appliance functions based on the specific position of the knob assembly. In one form, the detection mechanism includes a variable resistor assembly that is comprised of a wiper and resistor pad arrangement. In another form, the detection mechanism includes a shaft encoder mechanism that is comprised of a light transmitter and receiver, and an associated apertured disc secured to the knob assembly.

Patent Number: 6,813,911 Issued on 11/09/2004 to Peterson,   et al.

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Inventors:	Peterson; Gregory A. (South Barrington, IL); Stultz; Peter F. (Elgin, IL)
Assignee:	Emerson Electric Company (St. Louis, MO)
Appl. No.:	197178
Filed:	July 17, 2002

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Current U.S. Class:	68/12.27
Field of Search:	68/12.27,12.02 134/113 34/596

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References Cited [Referenced By]

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U.S. Patent Documents

	3110777		November 1963		Rast
	3531791		September 1970		Wells
	3804297		April 1974		Jurjans
	4676077		June 1987		Hirooka et al.
	4763493		August 1988		Nishite et al.
	4803854		February 1989		Kikuchi et al.
	4982468		January 1991		Takahashi et al.
	5279134		January 1994		Nonogaki et al.
	6626013		September 2003		Ohta et al.
	6671916		January 2004		Herr et al.
	2001/0042391		November 2001		Wobkemeier
	2002/0138918		October 2002		Johnson

Foreign Patent Documents

	0 661 908		Jul., 1995		EP
	2 116 297		Sep., 1983		GB
	3-242196		Oct., 1991		JP

Primary Examiner: Stinson; Frankie L.
Attorney, Agent or Firm: Maginot, Moore & Beck

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Parent Case Text

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This application claims the benefit of and/or priority to U.S. provisional application Ser. No. 60/310,695 filed Aug. 6, 2001, entitled "Appliance Control System."

CROSS-REFERENCE TO RELATED APPLICATIONS

Cross-reference is made to U.S. patent application entitled "Appliance Control System With Power Controller" by Peterson, Ser. No. 10/xxx,xxx and attorney docket number 1007-0551; U.S. patent application entitled "Appliance Control System With Hyperspin Mode" by Peterson, Ser. No. 10xxx,xxx and attorney docket number 1007-0552; U.S. patent application entitled "Appliance Control System With Auxiliary Inputs" by Peterson and Stultz, Ser. No. 10xxx,xxx and attorney docket number 1007-0553; U.S. patent application entitled "Appliance Control System With LED Operation Indicators" by Peterson and Stultz, Ser. No. 10xxx,xxx and attorney docket number 1007-0555; U.S. patent application entitled "Appliance Control System With Network Accessible Programmable Memory" by Peterson, Ser. No. 10xxx,xxx and attorney docket number 1007-0556; U.S. patent application entitled "Appliance Control System With Knob Control Assembly" by Peterson and Stultz, Ser. No. 10xxx,xxx and attorney docket number 1007-0557; and U.S. patent application entitled "Appliance Control System With Solid State Appliance Controller" by Peterson, Ser. No. 10xxx,xxx and attorney docket number 1007-0558; all of which are commonly assigned and filed on even date herewith.

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Claims

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What is claimed is:

1. An appliance control system which is operable in a user cycle selection mode and a cycle operation mode, comprising: a housing; a display device supported by said housing; a user cycle selector at least partially positioned within said housing; a printed circuit board supported by said housing; a circuit configured to (i) operate said display device during said user cycle selection mode to indicate position status of said user cycle selector; and (ii) operate said display device during said cycle operation mode to indicate cycle progression status of said appliance control system, said circuit includes a circuit pattern assembly supported by said printed circuit board; and a wiper assembly positioned within said housing; wherein said user cycle selector is movable from a first selector position to a second selector position in relation to a circuit pattern assembly, wherein said circuit is configured to operate said display device to indicate a first position status which corresponds to said first selector position when said wiper assembly is positioned in contact with said circuit pattern assembly at a first orientation, and wherein said circuit is configured to operate said display device to indicate a second position status which corresponds to said second selector position when said wiper assembly is positioned in contact with said circuit pattern assembly at a second orientation.

2. The appliance control system of claim 1, wherein: said user cycle selector includes a control shaft, said wiper assembly includes a carrier member and a wiper, said wiper is supported on said carrier member, said carrier member has a shaft hole defined therein, and said control shaft extends through said shaft hole.

3. The appliance control system of claim 2, wherein said carrier member is rotatably secured to said printed circuit board.

4. The appliance control system of claim 3, wherein: said printed circuit board has a shaft passage extending therethrough, said shaft passage defines an interior peripheral edge portion, said carrier member includes a hub having a hub groove defined therein, and said interior peripheral edge portion is located in said hub groove.

5. The appliance control system of claim 2, wherein said user cycle selector further includes a user knob secured to an end of said control shaft.

6. The appliance control system of claim 2, wherein: said control shaft defines a first keyed surface, said shaft passage defines a second keyed surface, and said first keyed surface aligns with said second keyed surface when said control shaft extends through said shaft passage.

7. The appliance control system of claim 1, wherein said display device includes a plurality of light emitting diodes.

8. An appliance control system which is operable in a user cycle selection mode and a cycle operation mode, comprising: a display device; a user cycle selector which is movable from a first selector position to a second selector position; a wiper assembly; and a circuit configured to (i) operate said display device during said user cycle selection mode to indicate position status of said user cycle selector; and (ii) operate said display device during said cycle operation mode to indicate cycle progression status of said appliance control system, said circuit includes a circuit pattern assembly; wherein said circuit is configured to operate said display device to indicate a first position status which corresponds to said first selector position when said wiper assembly is positioned in contact with said circuit pattern assembly at a first orientation, and wherein said circuit is configured to operate said display device to indicate a second position status which corresponds to said second selector position when said wiper assembly is positioned in contact with said circuit pattern assembly at a second orientation.

9. The appliance control system of claim 8, wherein: said user cycle selector includes a control shaft, said wiper assembly includes a carrier member and a wiper, said wiper is supported on said carrier member, said carrier member has a shaft hole defined therein, and said control shaft extends through said shaft hole.

10. The appliance control system of claim 9, further comprising a printed circuit board, wherein said carrier member is rotatably supported on said printed circuit board.

11. The appliance control system of claim 10, wherein: said printed circuit board has a shaft passage extending therethrough, said shaft passage defines an interior peripheral edge portion, said carrier member includes a hub having a hub groove defined therein, and said interior peripheral edge portion is located in said hub groove.

12. The appliance control system of claim 9, wherein said user cycle selector further includes a user knob secured to an end of said control shaft.

13. The appliance control system of claim 9, wherein: said control shaft defines a first keyed surface, said shaft passage defines a second keyed surface, and said first keyed surface aligns with said second keyed surface when said control shaft extends through said shaft passage.

14. The appliance control system of claim 8, wherein said display device includes a plurality of light emitting diodes.

15. An appliance control system which is operable in a user cycle selection mode and a cycle operation mode, comprising: a user cycle selector; a wiper assembly, wherein movement of said user cycle selector causes movement of said wiper assembly; and a circuit pattern assembly positioned in contact with said wiper assembly; wherein switching of said appliance control system from said user cycle selection mode to said cycle operation mode when said wiper assembly is positioned in contact with said circuit pattern assembly at a first orientation causes a first selected cycle of said cycle operation mode to be performed by said appliance control system, and wherein switching of said appliance control system from said user cycle selection mode to said cycle operation mode when said wiper assembly is positioned in contact with said circuit pattern assembly at a second orientation causes a second selected cycle of said cycle operation mode to be performed by said appliance control system.

16. The appliance control system of claim 15, wherein: said first selected cycle includes a delicate cycle, said second selected cycle includes a permanent press cycle.

17. The appliance control system of claim 15, wherein: said first selected cycle includes a cotton cycle, and said second selected cycle includes a delicate cycle.

18. The appliance control system of claim 15, wherein: said user cycle selector includes a control shaft, and said wiper assembly includes a carrier member and a wiper, said wiper is supported on said carrier member, said carrier member has a shaft hole defined therein, and said control shaft extends through said shaft hole.

19. The appliance control system of claim 18, further comprising a printed circuit board, wherein said carrier member is rotatably supported on said printed circuit board.

20. The appliance control system of claim 19, wherein: said printed circuit board has a shaft passage extending therethrough, said shaft passage defines an interior peripheral edge portion, said carrier member includes a hub having a hub groove defined therein, and said interior peripheral edge portion is located in said hub groove.

21. The appliance control system of claim 18, wherein said user cycle selector further includes a user knob secured to an end of said control shaft.

22. The appliance control system of claim 18, wherein: said control shaft defines a first keyed surface, said shaft passage defines a second keyed surface, and said first keyed surface aligns with said second keyed surface when said control shaft extends through said shaft passage.

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Description

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FIELD OF THE INVENTION

The present invention relates generally to appliances, and more particularly, to a control system for an appliance.

BACKGROUND

Appliances such as washing machines, dryers, ovens, and the like, typically include a plurality of knobs, dials, input pads, switches and/or the like. Such knobs, dials, input pads, switches and/or the like function as user inputs, user input controls, controls, controllers and/or the like. In most instances, the controls provide for discrete selection of various modes, cycles, states, choices, parameters, and/or the like of the appliance.

In the case of washing machines, a main knob or dial is utilized for selecting the laundry cycle and a length of time of the selected cycle. The rotational position of the main knob is correlated to particular cycle/time selections and thus determines a selection. The main knob or dial typically additionally incorporates a mechanical timer mechanism. The other knobs also utilize rotational position to select and/or indicate the selection.

Such knobs and/or dials heretofore have been constructed utilizing analog components. Analog components provide the desired discrete selection capability and provide tactile feel associated with the chosen selection. The knobs and/or dials, however, can suffer failure for various reasons such as mechanical breakdown or fatigue. Shaft or rotational position may be difficult if not impossible for the appliance to determine with worn components. Additionally, mechanical knobs and/or dials are relatively heavy. It would thus be desirable to have an appliance controller that is not mechanical but still provides the same functionality as heretofore mechanical input devices. More particularly, it would be desirable to have an electronic appliance controller such as a knob or dial that at least partially electronically provides detection of selected position.

SUMMARY

An appliance controller comprises a control knob assembly that at least partially electronically detects, determines and/or monitors rotational position to determine user selection.

An appliance controller comprises a control knob assembly and detection mechanism having various mechanical and electrical components that are configured to detect the position of the knob assembly and produce a position signal indicative of the knob assembly position. The position signal is provided to the appliance controller that produces a control signal in response thereto. The control signal is used to initiate various appliance functions based on the specific position of the knob assembly.

In one form, the subject invention provides an appliance control system that is operable in a user cycle selection mode and a cycle operation mode. The appliance control system includes a housing, a display device supported by the housing, a user cycle selector at least partially positioned within the housing, a printed circuit board supported by the housing; a circuit configured to (i) operate the display device during the user cycle selection mode to indicate position status of the user cycle selector; and (ii) operate the display device during the cycle operation mode to indicate cycle progression status of the appliance control system, the circuit includes a circuit pattern assembly supported by the printed circuit board, and a wiper assembly positioned within the housing. The user cycle selector is movable from a first selector position to a second selector position in relation to a circuit pattern assembly, wherein the circuit is configured to operate the display device to indicate a first position status which corresponds to the first selector position when the wiper assembly is positioned in contact with the circuit pattern assembly at a first orientation, and wherein the circuit is configured to operate the display device to indicate a second position status which corresponds to the second selector position when the wiper assembly is positioned in contact with the circuit pattern assembly at a second orientation.

In another form, the subject invention provides an appliance control system that is operable in a user cycle selection mode and a cycle operation mode. The appliance control system includes a display device, a user cycle selector that is movable from a first selector position to a second selector position, a wiper assembly, and a circuit configured to (i) operate the display device during the user cycle selection mode to indicate position status of the user cycle selector; and (ii) operate the display device during the cycle operation mode to indicate cycle progression status of the appliance control system, the circuit including a circuit pattern assembly. The circuit is configured to operate the display device to indicate a first position status which corresponds to the first selector position when the wiper assembly is positioned in contact with the circuit pattern assembly at a first orientation. The circuit is further configured to operate the display device to indicate a second position status which corresponds to the second selector position when the wiper assembly is positioned in contact with the circuit pattern assembly at a second orientation.

In a further form, the subject invention provides an appliance control system that is operable in a user cycle selection mode and a cycle operation mode. The appliance control system includes a user cycle selector, a wiper assembly, wherein movement of the user cycle selector causes movement of the wiper assembly, and a circuit pattern assembly positioned in contact with the wiper assembly. The switching of the appliance control system from the user cycle selection mode to the cycle operation mode when the wiper assembly is positioned in contact with the circuit pattern assembly at a first orientation causes a first selected cycle of the cycle operation mode to be performed by the appliance control system. The switching of the appliance control system from the user cycle selection mode to the cycle operation mode when the wiper assembly is positioned in contact with the circuit pattern assembly at a second orientation causes a second selected cycle of the cycle operation mode to be performed by the appliance control system.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following descriptions of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a washing machine embodying the various aspects of the various inventions shown and described herein;

FIG. 2 is a block diagram of the washing machine of FIG. 1;

FIG. 3 is a block diagram of an exemplary power supply for the washing machine of FIG. 1;

FIG. 4 is another block diagram of the exemplary power supply;

FIG. 5 is an electrical schematic of the exemplary power supply;

FIG. 6 is a flowchart of an exemplary manner of operation of the exemplary power supply;

FIG. 7 is a block representation of the appliance control system showing a plurality of auxiliary inputs;

FIG. 8 is a further representation of the appliance control system of FIG. 7;

FIG. 9 is a simplified electrical schematic of the representation of FIGS. 7 and 8;

FIG. 10 is a partial electrical schematic of the appliance control system in accordance with the principles presented herein;

FIG. 11 is a partial electrical schematic of the appliance control system;

FIG. 12 is a partial electrical schematic of the appliance control system;

FIG. 13 is a flowchart of an exemplary manner of operation of the auxiliary inputs of the present invention;

FIG. 14 is a block diagram representation of a hyperspin feature in accordance with an aspect of the present invention;

FIG. 15 is another block diagram representation of the hyperspin feature;

FIG. 16 is another block representation of the hyperspin feature;

FIG. 17 is a partial electrical schematic of the hyperspin portion of the appliance control system;

FIG. 18 is a partial electrical schematic of the motor portion;

FIG. 19 is a flowchart of an exemplary manner of operation of the hyperspin feature in accordance with the principles of the present invention;

FIG. 20 is a block representation of a communication feature in accordance with the principles of the present invention;

FIG. 21 is a block representation of water control features of the present invention;

FIG. 22 is a partial electrical schematic of the appliance control system showing the water control features and the user cycle selection input;

FIG. 23 is one part of a partial electrical schematic of the appliance control system showing the LEDs;

FIG. 24 is another part of the partial electrical schematic of the appliance control system of FIG. 23;

FIG. 25 is a front elevational view of the main controller module that is used in the washing machine of FIG. 1;

FIG. 26 is a bottom elevational view of the main controller module of FIG. 25;

FIG. 27 is a rear elevational view of the main controller module of FIG. 25;

FIG. 28 is an exploded perspective view of the main controller module of FIG. 25;

FIG. 29 is an assembled perspective view of part of the user selector assembly of the main controller module of FIG. 25;

FIG. 30 is an exploded perspective view of various parts of the user selector assembly of the main controller module of FIG. 25;

FIG. 31 is a front elevational view of the housing of the main controller module of FIG. 25;

FIG. 32 is a cross sectional view taken along the line 32--32 of FIG. 31 of the housing of the main controller module of FIG. 25;

FIG. 33 is a rear elevational view of the housing of the main controller module of FIG. 25;

FIG. 34 is a front perspective view of the housing of the main controller module of FIG. 25;

FIG. 35 is a rear perspective view of the housing of the main controller module of FIG. 25;

FIG. 36 is a rear elevational view of the escutcheon of the main controller module of FIG. 25;

FIG. 37 is a side elevational view of the escutcheon of the main controller module of FIG. 25;

FIG. 38 is a cross sectional view of the escutcheon of the main controller module of FIG. 25 taken along the line 38--38 of FIG. 36;

FIG. 39 is a perspective view of the second spring of the main controller module of FIG. 25;

FIG. 40 is a side elevational view of the second spring of the main controller module of FIG. 25;

FIG. 41 is a first side elevational view of the control shaft of the main controller module of FIG. 25;

FIG. 42 is a second side elevational view of the control shaft of the main controller module of FIG. 25;

FIG. 43 is an enlarged view of the part of FIG. 42 that is encircled and labeled FIG. 43;

FIG. 44 is a cross sectional view of the reduced diameter portion of the control shaft of the main controller module of FIG. 25 taken along the line 44--44 of FIG. 42;

FIG. 45 is a first side elevational view of the first spring of the main controller module of FIG. 25;

FIG. 46 is a second side elevational view of the first spring of the main controller module of FIG. 25;

FIG. 47 is a front elevational view of the wiper assembly of the main controller module of FIG. 25;

FIG. 48 is a rear elevational view of the wiper assembly of the main controller module of FIG. 25;

FIG. 49 is a side elevational view of the wiper assembly of the main controller module of FIG. 25;

FIG. 50 is an elevational view of the circuit pattern assembly of the main controller module of FIG. 25;

FIG. 51 is an elevational view of the front side of the first printed circuit board and the front side of the second printed circuit board of the main controller module of FIG. 25 (note that after assembly of the main controller module, the second printed circuit board is positioned under the first printed circuit board, however for clarity of viewing, FIG. 51 shows the second printed circuit board pivoted to a location adjacent to the first printed circuit board);

FIG. 52 is an elevational view of the back side of the first printed circuit board and the back side of the second printed circuit board of the main controller module of FIG. 25 (note that for clarity of viewing, FIG. 52 shows the second printed circuit board pivoted in a manner similar to that shown in FIG. 51);

FIG. 53 is an elevational view of an informational overlay of the main controller module of FIG. 25;

FIG. 54 is an enlarged fragmentary view of the informational overlay of FIG. 53;

FIG. 55 is a schematic diagram of a first alternative shaft position detection mechanism which can be used in the main controller module and/or any of the auxiliary input units of the appliance control system of the present invention;

FIG. 56 is a schematic diagram of a second alternative shaft position detection mechanism which can be used in the main controller module and/or any of the auxiliary input units of the appliance control system of the present invention; and

FIG. 57 is a perspective view of a dryer embodying the various aspects of the various inventions shown and described herein.

Corresponding reference characters indicate corresponding parts throughout the several views.

DETAILED DESCRIPTION

Referring to FIG. 1, there is depicted a washing machine, generally designated 5, representing one form of a laundry appliance. The washing machine 5 has a frame 36 that houses a receptacle or tub 32 that is configured to receive laundry therein for washing. The tub 32 is accessed via a pivoting door or lid 38 in the frame 36. The tub 32 is mounted in the frame 36 so as to revolve or spin, typically (and as shown) around a vertical axis 46. The tub 32 is in communication with a motor 26 that is likewise mounted in the frame 36, and which is operative to spin the tub 32 in a controlled manner as described below.

The washing machine 5 also has a control panel frame 40 that houses an appliance control system 10. External to the control panel frame 40 and part of the appliance control system 10 is a main controller module 300 and a plurality of auxiliary inputs 44 (typically in the form of knob, switches, or the like). The controller module 300 provides operating mode/cycle indication and/or control of the operating mode/cycle for/of the washing machine 5. Power for the washing machine 5 is provided via a power cord 48 that is configured to be plugged into an appropriate source of electricity, typically a 120 volt AC source or a 240 volt AC source (not shown). The general operation of the washing machine 5, with respect to the loading, washing, and unloading of laundry, is typical of washing machines.

The appliance control system 10 also includes a communication port 50 that allows the washing machine 5 to be coupled to or in communication with an external device, network, or the like. The communication port 50 may take the form of an RS-232 port, a telephone-type port, or the like. Particularly, the communication port 50 allows the washing machine 5 to be in communication with a test/diagnostic device, a public and/or private network such as the Internet, another laundry appliance, or other device.

Referring to FIG. 2 there is depicted a block diagram of the washing machine 5. The washing machine 5 includes the appliance control system (ACS) 10, the motor 26, the door or lid switch 28, a water temperature sensor 30, the receptacle or tub 32, and water supply solenoid valves 34. The ACS 10 is operative to control various aspects/features/functions of the washing machine 5 as explained in greater detail below, and to indicate the various cycles of the washing machine 5. The ACS 10 includes various sections, modules, portions, or the like the nature and manner of operation of which will be described below. As indicated above, the motor 26 is operative to rotate the tub 32 during the various cycles or modes of the washing machine 5. The tub 32 is adapted to hold an amount of laundry and water for washing. The lid switch 28 is operative to interrupt or stop the motor 26 or cause the washing machine 5 to not continue its operating cycle when the lid 38 is opened during operation. The lis switch 28 also prevents the start of a cycle if the lid 38 is initially open. Therefore, the lid 38 must be closed in order for the washing machine 5 to begin an operating cycle. The water temperature sensor 30 is operative to provide water temperature data to the ACS 10 regarding temperature of the water going into the tub 32 or already in the tub 32 in order to provide the proper/appropriate washing water temperature. The water supply solenoids/valves 34 are operative to control the flow of hot and/or cold water into the tub 32.

The ACS 10 includes an auxiliary user interface selector 12 for the washing machine. The auxiliary user interface selector 12 is adapted/configured via appropriate circuitry, logic, and/or components to allow a user to select various washing machine parameters. Particularly, the auxiliary user interface selector 12 is operative to allow the user to select various washing machine parameters or operating cycle options (options) of various washing machine cycles or modes. A power control system 14 is provided in the ACS 10 that is operative, configured, and/or adapted via appropriate circuitry, logic, and/or components to provide power to the various components of the washing machine 5. More particularly, the power control system 14 is operative to provide a standby or low power and/or an operating power to the various components of the washing machine 5.

The ACS 10 also has a hyperspin control system 16 that is operative, configured, and/or adapted via appropriate circuitry, logic and/or components to provide a hyperspin feature or function. The hyperspin feature/function permits the tub 32 to spin or rotate at a speed that is greater than a normal tub rotation speed, typically during a drying cycle of the washing machine 5. The ACS 10 further has a main controller module 300 that is operative, configured, and/or adapted to allow the user to select various operating modes, cycles or the like of the washing machine 5. The main controller module 300 includes a selector display 20. The selector display 20 is operative, configured, and/or adapted via appropriate circuitry, logic, and/or components to provide information regarding the user selection. The selector display 20 is also operative to indicate or show the progression of the user selection as the washing machine performs the user selection. The selector display 20 includes a plurality of light emitting devices 307 as will be discussed below

The ACS 10 further includes a communication interface 22. The communication interface 22 is operative, configured, and/or adapted via appropriate circuitry, logic, and/or components to allow the washing machine 5 to interface with external components, circuitry, logic, networks, or the like. As well, the communication interface 22 allows remote access to various features, functions, or the like of the washing machine 5. Lastly, the ACS 10 includes sensor ports 24 that are adapted to allow connection with various sensors and/or data inputs of the washing machine 5.

Power Supply

Referring to FIG. 3 there is depicted a block diagram representation of the power control system 14 and other components and/or circuitry/logic of the washing machine 5. The washing machine 5 receives line electricity from a source of electricity that is typically a 120 volt AC or 240 volt AC electricity source (not shown) designated line electricity in. The AC electricity supplied to the washing machine 5 from line electricity in will hereinafter be termed line electricity, regardless of its source and voltage. The line electricity is received by the washing machine 5 via the power cord 48 (see FIG. 1).

The line electricity is supplied via the power control system 14 to line electricity conditioning circuitry/logic 56 that is operative via appropriate circuitry, logic, and/or components to provide the line electricity to line electricity components 58 of the washing machine 5. The line electricity components 58 include the motor 26 (direct use), the lid switch 28 (as pass-through) and any other washing machine component that directly or indirectly utilizes the line electricity to operate.

The power control system 14 is operative via appropriate circuitry, logic, and/or components to power or run operating power components 52 and standby low power components 54 of the washing machine 5. The operating power components 52 include relays, transistors, triacs, silicon controlled rectifiers (SCRs), and the like. The standby low power components 54 include integrated circuits (ICs), auxiliary input units, clocks, and the like.

The power control system 14 includes operating power circuitry/logic 66 that is operative to produce, generate, or derive operating power (electricity) from the line electricity for powering the operating power components 52. As well, the power control system 14 includes standby low power circuitry/logic 64 that is operative to produce, generate, or derive standby and/or low power (electricity) from the line electricity for powering the standby and/or low power components 54.

The operating power circuitry/logic 66 provides operating power to the operating power components 52 when the washing machine 5 is in use. The standby low power circuitry/logic 64 provides standby power to the standby power components 54 when the washing machine 5 is not in use but still plugged into the line electricity as well as to low power components 54 when the washing machine is in use. It should be noted that the power control system 14 does not utilize a transformer to generate and/or derive the operating power or the standby low power for the washing machine 5. This is accomplished by utilizing electronic component signal conditioning.

The standby low power provides electricity in a small or low amount in the neighborhood of less than one watt, but which may be generated in any amount necessary for a standby state and a low power state of the washing machine 5. In one embodiment, the generated standby low power electricity is approximately five (5) volts at a particular current that yields standby power in the milliwatts. In an embodiment of a washing machine ACS, whose circuitry/logic is described in detail below, the standby low power produced by the standby power circuitry/logic 64 is around 500 milliwatts. It should be understood that the standby low power produced by the standby low power circuitry/logic 64 is determined by the standby operating conditions, parameters, or the like of the particular standby low power components 54 of the washing machine 5.

The operating power provides electricity in an amount necessary to operate, actuate, or use the various operating power components 52. Thus, the operating power generated by the operating power circuitry/logic 66 is in accordance with design characteristics of the washing machine 5. However, in one embodiment, the operating power circuitry/logic 66 is operative to produce twenty-four (24) volts of operating electricity.

The power control system 14 also includes line cross circuitry/logic 62 that is operative, configured, and/or adapted to generate, produce, or derive a line cross signal from the line electricity. The line cross signal is represented by the arrow 72 and is provided to a processor 60 of the washing machine 5. The processor 60 may be a processing unit, microprocessor, processing means, or the like. The processor 60 utilizes the line cross signal for timing purposes.

The power control system 14 is operative in one of two modes or states of operation. One state or mode of operation may be termed an idle or standby mode, while the other state or mode of operation may be termed a run or operating mode. In the idle mode of operation, the standby power circuitry/logic 64 provides standby power to the standby power components 54, while the operating power circuitry/logic 66 is prevented from supplying operating power to the operating power components. In the run mode of operation, the operating power circuitry/logic 66 provides operating power to the operating power components. At the same time (while in the run mode of operation) the standby low power circuitry/logic 64 provides standby power to the standby low power components. This is because the standby low power components 54 are a necessary part of the operation of the washing machine 5. For this reason, the standby power may also be termed low power while the standby power components may be termed low power components. The standby power circuitry/logic 64 may thus be considered as supplying standby power to standby components when the washing machine 5 is plugged in but not operating, and as supplying low power to low power components when the washing machine is operating. The standby components may not necessarily be the same as the low power components.

When the washing machine 5 is receiving the line electricity, and not in use (the idle or standby mode), the washing machine 5 is operative to generate standby power via the standby power circuitry/logic 64 for the standby power components 54. When a user turns actuates the washing machine 5, without regard to the particular operating mode (the run mode), the washing machine 5 needs operating power as generated by the operating power circuitry/logic 66. The particular components of the operating power components 52 that require operating power is dependent upon the operating mode of the washing machine 5.

The power control system 14 regulates the application of the operating power to the operating power components 52 via switch/switching circuitry/logic 68. In accordance with an aspect of the present invention, the switch/switching circuitry/logic 68 (hereinafter switching circuitry 68 for short) is operative to switch in or apply the operating power from the operating power circuitry/logic 66 to the operating power components 52 when appropriate or necessary for the operation of the washing machine 5, or control of the application of the operating power from the operating power circuitry/logic 66 to and for the appropriate operating power components 52. This may include intermittently applying the operating power to the operating power components 52.

The switching circuitry 68 is regulated or controlled by a control signal that is provided to the switching circuitry 68 by a processor 60 via a control line 70. The control signal actuates the switching circuitry 68, causing the operating power circuitry/logic 66 generating the operating power for the operating power components 52 to be supplied or applied to the operating power components 52. In accordance with one embodiment, the operating power for the electronic components is twenty-four (24) volts, but may be any operating voltage that is appropriate. The control signal is provided to the switching circuitry 68 when the washing machine 5 is actuated into a run or operating mode. This is typically accomplished through user actuation of a control knob/on/off switch of the washing machine 5. Particularly, the washing machine 5 is actuated into a washing cycle or operation via a user actuating a control input of the washing machine 5. In one form, the control signal is pulsed.

Referring now to FIG. 4, there is depicted a more detailed block diagram of the washing machine 5 and, more particularly, of the power control system 14. The washing machine 5 includes various sensors and data inputs generally designated 78 that provide sensor signals and data input to the processor 60. The processor 60 utilizes these sensor signals and data inputs for various purposes and signal generation as discussed herein. The washing machine 5 also includes a control input 76 that represents user-actuated inputs. Signals from the control input 76 are forwarded to the processor 76. The sensor/data input 78 and/or the control input 76 provides data to the processor 60 that the processor 60 may use to generate the control signal for the power control system 14.

In addition to the various components, features and/or functions described in conjunction with FIG. 3, the power control system 14 includes clamp circuitry/logic 74 that is provided in conjunction with the standby/low power circuitry/logic 64. The clamp circuitry/logic 74 is operative to set and the power level of the standby/low power circuitry/logic 64 or prevent over power of the standby/low power circuitry/logic 64.

It should be appreciated that various components of the washing machine 5, such as the motor 26, utilize the line electricity (typically 120 volts or 240 volts) for operation. This is not the same as the operating power generated by the operating power circuitry/logic. The washing machine 5 utilizes the operating power for actuation of the various relays, solenoids, and the like. These relays, solenoids, and the like, actuate the motor, water valves, and other like components of the washing machine 5 of which some then utilize the line electricity for operation. Additionally, the line electricity is utilized in conjunction with various switches, such as safety switches (e.g. the lid switch 28), that provide a signal to the processor 60 regarding the state of the particular switch. Where necessary, these switches and the like are explained in detail herein.

As indicated above, the operating power from the operating power circuitry/logic 66 is applied or supplied to the operating power components 52 through the switching circuitry 68, with the switching circuitry 68 controlled by a control signal or control signals from the processor 60. In one form, the switching circuitry 68 includes signal conditioning circuitry/logic 80 that receives the control signal via the control signal line 70 from the processor 60. The switching circuitry/logic 68 also includes a silicon controlled rectifier (SCR) 82 (or any other similar operating/functioning device) that is in communication with the signal conditioning circuitry/logic 80 and with the operating power circuitry/logic 66. The SCR 82 is thus operative to switch in or allow the operating power from the operating power circuitry/logic 66 to be applied or supplied to the various operating power components 52 (run mode) upon being triggered (receiving) the conditioned control signal from the signal conditioning circuitry/logic 80. The processor 60 produces a control signal that is provided to the signal conditioning circuitry/logic 80 and then to the SCR 82 when it is appropriate for the operating power to be supplied to the operating power components. Particularly, the processor 60 provides the control signal when the user actuates the washing machine 5 into a run mode (selects a run mode cycle or the like of the washing machine 5). The SCR 82 thus switches in or allows the switching in of the operating power into the circuitry/logic of the washing machine 5.

Because the operating power is needed when the appliance is started (i.e. the run mode), a start/stop signal, represented by the start/stop block 158, is provided to the controller 158 for use in producing the control signal and providing the control signal to the SCR 172. The start/stop signal is preferably provided through the operational mode indicator/cycle indicator of the laundry appliance. As well, other components of the laundry appliance, represented by the component input block 156, may provide a signal or signals for use in producing the control signal.

In one form, the processor 60 continues to provide a control signal to the signal conditioning circuitry/logic 80 during any run mode cycle of the washing machine 5 or while operating power is required. The signal conditioning circuitry/logic 80 thus continues to provide the control signal to the SCR 82 in like manner and the SCR 82, in turn, stays on to keep the operating power from the operating power circuitry/logic 66 to the operating power components 52.

Alternatively, in another form, the processor 60 provides a control signal to the signal conditioning circuitry/logic 80 that stops the application of a conditioned control signal from the signal conditioning circuitry/logic 80 to the SCR 82. The SCR 82 is thus responsive to the "off" control signal to shut off the application of the operating power from the operating power circuitry/logic 66 to the operating power components 52.

Referring now to FIG. 5, there is shown a specific exemplary embodiment of a power control system 14 in accordance with the present principles. The power control system 14 of FIG. 5 is shown in electrical schematic form. The power control system of FIG. 5 operates and/or functions in the manner set forth above.

The power control system 14 receives incoming electricity from a Line In electricity source. Particularly, line electricity (hot) from an electricity source (e.g. a wall plug) is provided at P14, terminal 1, wherein it is provided to other components via the terminal 84 ("L"). Neutral is coupled at P14, terminal 2, where neutral is equated with ground. A variable resistor VR1 of sufficient resistance and voltage rating is provided between the line electricity and the neutral for short circuit protection.

The line cross circuitry/logic 62 is coupled to the line electricity for providing a line cross signal R on line 86. Line 86 is in communication with the processor 60 (not shown in FIG. 5). The line cross circuitry/logic 62 includes a transistor Q14 that is biased by the line electricity such that the collector (terminal 3) provides the line cross signal. As mentioned above, the line cross signal R is utilized by the processor 60 to indicate phase of the line electricity. The line cross signal is also utilized by the processor for clocking purposes. In particular, the transistor Q14 (an NPN transistor) is alternatively switched on and off by the alternating current of the line electricity to provide the line cross signal R at line 86.

The power control system 14 includes a bank of capacitors 88 that are in communication with and charged by the line electricity. In accordance with an aspect of the present invention, only one of the capacitors, C7, however, is normally dischargeable after charging, since the terminal (terminal 1) that is opposite the terminal (terminal 2) that is in communication with the line in electricity, completes a circuit. Particularly, the capacitor C7 is dischargeable through the diode D5 and a five (5) volt power supply circuitry/logic formed, in part, by the diode D1 and the capacitor C4. This forms the standby/low power circuitry/logic 64. The standby/low power circuitry/logic 64 may include more than one capacitor (C7) if desired or necessary.

The standby or low power circuitry/logic 64 is thus always operative when the washing machine 5 is plugged into the line electricity. Clamping circuitry 74 is provided in communication with the standby/low power circuitry/logic 64 to keep the standby/low power circuitry/logic (the five volt power circuitry/logic) at a constant voltage level.

While the other capacitors C12 and C13 of the capacitor bank 88 normally charge, they are not normally able to discharge, and thus form a normally open circuit. The SCR 82, however, is provided that is operative to provide a discharge path for the capacitors C12 and C13 upon the application of a control signal to the SCR 82. The control signal is provided via control line 70 from the processor 60 to the control signal conditioning circuitry/logic 80. The control signal is then applied to the gate (terminal 2) of a transistor Q6 (a PNP transistor) of the control signal conditioning circuitry/logic 80 wherein a control signal is taken from the collector (terminal 3) and applied to the control input (terminal 2) of the SCR 82.

When the SCR 82 is turned on (allowed to conduct) by the application of the control signal from the transistor Q6, a discharge path is created for the capacitors C12 and C13. The capacitors C12 and C13 discharge through the diode D9 that, together with capacitor C10, provides a rectified (DC) operating voltage of twenty-four (24) volts., This, in part, constitutes the operating power circuitry/logic 66. Thus, only when a control signal is applied to the circuitry/logic, does the operating power become applied/supplied to the proper components of the washing machine 5.

It should be appreciated that operating power circuitry/logic 66 may include any number of capacitors as desired or necessary. Further, it should be appreciated that the various values of resistors and capacitors of the power control system 14 are subject to modification as desired.

With reference to FIG. 6, an exemplary manner of operation of the present power control system will be described in conjunction with the flowchart thereof, the flowchart generally designated 90. Initially, the washing machine is plugged into a source of suitable electricity (line electricity), step 92. This is typically a wall outlet (not shown) of a home, business, or the like such as is known that supplies 120 or 240 volt AC power. When the power control system is receiving line electricity, the phase of the line electricity is monitored, step 94. The power control system monitors the phase of the line electricity for clocking purposes of and the like.

The washing machine monitors and/or determines if the washing machine is to be or is in an idle mode or a run mode, step 96. If in the idle mode, the power control system generates idle mode (low) power, step 98. The idle mode power is provided to the idle mode (low/standby) power circuitry/logic, step 100. The power control system continues to generate and provide idle mode power as long as the washing machine is plugged in, step 102.

In step 96, if the washing machine is or is to be in a run mode, the power control system generates run mode (operating) power, step 104, and generates idle mode (operating) power 98 (and additionally performs steps 100 and 102). In step 106, the generated run mode power is provided to the run power components. The power control system determines whether a stop signal has been produced or not, step 108. If a stop signal has been produced, then run mode power is ceased, and the power control system/washing machine returns to the idle/run mode decision step (step 96), step 110. If a stop signal has not been produced, then run mode power is generated (back to step 104) until a stop signal is produced.

With respect to the operation of the power supply, idle mode power is preferably always generated when the washing machine is plugged in. This allows the integrated circuits and the like to be powered up for clocking and other purposes. Not all of the integrated circuits may necessarily be provided idle mode (standby or low) power. Further, run mode (operational) power is typically provided only when the washing machine is turned on by the user (a run mode or cycle is chosen).

Auxiliary Inputs

As seen in FIG. 1 the appliance control system (ACS) 10 of the washing machine 5 has a plurality of auxiliary input units 44. Each auxiliary input unit 44 is operative to allow the selection or adjusting of various parameters of and/or related to the washing machine 5. In particular, the auxiliary input units 44 allow a user to select various options or parameters for the operating mode of the washing machine (the operating mode being separately selected by the user via the main controller module 300 of the ACS 10. The options may be water temperature, rinse options, load size, speed, fabric type, or the like depending on the particular make and/or model of the washing machine.

Referring now to FIGS. 7 and 8, there is shown a representation of the plurality of auxiliary inputs or input units, generally designated 44 of the ACS 10. In accordance with an aspect of the present invention, the plurality of auxiliary input units 44 are connected in series, with a first auxiliary input unit 112 coupled to and in communication with an auxiliary input port 114 of the ACS 10. Since the auxiliary input units 44 are typically mounted on the control panel 40 (see FIG. 1) the auxiliary input units 44 are remote from the majority of the electronic circuitry/logic of the ACS 10. The majority of the electronic circuitry/logic of the ACS 10 is thus provided on one or just several PC boards. Providing a port on one of the PC boards, provides a convenient way to coupled the auxiliary input units 44 to the remainder of the electronic circuitry/logic of the ACS 10.

An output of the first auxiliary input unit 112 is coupled to the auxiliary input port 114 and thus in communication with the processor 60 via two wires or conductors 122 and 124. An output of a second auxiliary input unit 118 is coupled to and in communication with an input of the first auxiliary input unit 112 via two wires 126 and 128. Any intermediate or middle auxiliary input units (not shown but represented by ".cndot..cndot..cndot." in FIGS. 7 and 8) are likewise coupled to and in communication with a previously adjacent auxiliary input unit. The last auxiliary input unit 120 is coupled to and in communication with the intermediary auxiliary input units via two wires 130 and 132. The series connection of auxiliary input units 44 form a daisy-chain and, more particularly, a two-wire daisy-chain or serial connection. Any amount of auxiliary input units 44 is thus daisy-chainable.

Each auxiliary input unit 112, 118, and 120 has a respective knob, dial, or the like 134, 136, and 138. The knobs 134, 136, and 138 allow for the user-selection of the various adjusting parameters of the appliance. The knobs may be discrete, position type switches or may be variable position controls. In either case each knob 134, 136, and 138 allows a user to select a position that corresponds to a particular option of two or more possible options. Typically one auxiliary input unit is dedicated to a particular option such as water temperature. As an example and referring to FIG. 7, the auxiliary input unit 120 has two user-selectable options, positions, or settings labeled A and B. The indicator (arrow) on the knob 138 points to selection A. In accordance with an aspect of the present invention, position A has a unique parameter value associated therewith, while position B also has a unique parameter value associated therewith. The unique parameter value of the position or setting of the knob 138 (or the auxiliary input unit 120) is provided as a parameter value signal to the adjacent auxiliary input unit, here the auxiliary input unit 118). The auxiliary input unit 118 has three user-selectable options, positions, or settings labeled C, D, and E. Each position C, D, and E has a unique parameter value associated therewith. In accordance with an aspect of the present invention, the unique parameter value of the position or setting of the knob 136 (or the auxiliary input unit 118) is combined with the unique parameter value of the auxiliary input unit 120 and provided as a combined parameter value signal to the adjacent auxiliary input unit closest to the auxiliary input port 114, here the auxiliary input unit 112). The auxiliary input unit 112 has three user-selectable options, positions, or settings labeled F, G, and H. Each position F, G, and H has a unique parameter value associated therewith. In accordance with an aspect of the present invention, the unique parameter value of the position or setting of the knob 134 (or the auxiliary input unit 112) is combined with the combined unique parameter value of the auxiliary input units 120 and 118 and provided as an aggregate parameter value signal to the auxiliary input port 114, and thus the processor 60. The processor 60, under control of program instructions contained in the memory 116 analyzes the aggregate parameter value signal to determine the particular option selected for each auxiliary input unit. The unique aggregate parameter value is thus used to determine the parameter value for each auxiliary input unit 44. Once the particular parameter value is known for each auxiliary input unit 44, the particular option or setting for each auxiliary input unit is known.

Referring particularly to FIG. 8, the plurality of auxiliary input units 44 are shown in side view. Each knob 134, 136, and 138 is connected to a respective shaft 140, 142, and 144 that is retained in a respective body 146, 148, and 150. Each knob and shaft combination, 134/146, 136/148, and 138/150 is rotatable relative to its respective body 146, 148, and 150. Additionally each knob/shaft combination, 134/146, 136/148, and 138/150 includes a respective detent plate 152, 154, and 156. Each detent plate 152, 154, and 156 is fixed relative to its respective knob/shaft combination, 134/146, 136/148, and 138/150. Each knob 134, 136, and 138 includes a plurality of grooves or notches on an underside thereof such that the knob and detent plate combinations 134/152, 136/154, and 138/156, co-act with one another during rotation of the knob/shaft combination, 134/146, 136/148, and 138/150. This provides a tactile feedback for a user during rotation thereof.

In FIGS. 10-12, there is depicted electrical schematics of an embodiment of a portion of the ACS 10. In FIG. 10, the processor 60 of the ACS 10 is shown as a Hitachi HB/3664 microcontroller (labeled U1), but which can be any suitable processor or processor unit. The various electrical components and connections to the processor 60 are shown. For instance, a clocking circuit 158 is depicted that provides clock signals for the processor 60, wherein the OSC 1 of the clock circuitry 158 is coupled to pin 11 (OSC1) and the OSC 2 of the clock circuitry 158 is coupled to pin 10 (OSC2).

In FIG. 11, the auxiliary input port 114 is formed of a first channel input labeled P2, terminal 1, and a second channel input labeled P2, terminal 2. The first and second channels receive as inputs the two wires (122 and 124) of the first auxiliary input unit 112. Preferably, the first and second input terminals are in the form of a receptacle that is adapted/configured to receive a mating plug as a termination of the two wires 122 and 124. A third terminal, labeled P2, terminal 3, may be provided as part of the receptacle and is coupled to electrical ground. In this case, a third wire may be provided from each auxiliary input unit, or as one conductor of a two conductor wire from the auxiliary input unit. The first and second channels, P2 terminal 1 and P2 terminal 2 are coupled to or in communication with the processor 60 in order to provide the aggregate parameter value signal to the processor 60 from the auxiliary input units 44.

In FIG. 12, the memory 116 that stores the program instructions for the ACS 10 and the washing machine 5 in general, includes a serial data line input/output, labeled SDA (pin 5) for communication with the processor 60 and a serial clock line input, labeled SCL (pin 6) for receipt of clocking signals from the processor 60. In this manner, the program instructions may be transferred to the processor 60, while the memory 116 may also be written to by the processor 60. In accordance with an aspect of the present invention that is described in greater detail below