LAUNDRY APPLIANCE AND METHODS OF MOTION-BASED DRYING DETECTION

Description

FIELD OF THE DISCLOSURE

The present subject matter relates generally to laundry appliances, such dryer or combined washer/dryer appliances, and methods for operating the same.

BACKGROUND OF THE DISCLOSURE

Laundry appliance, such as dryers or drying appliances, generally include a cabinet with a drum mounted therein. For dryers, a heater or heater assembly is also often provided to pass heated air through the chamber of the drum in order to dry moisture-laden articles disposed within the chamber. This may be provided in the context of a dedicated drying appliance or a combination washing and drying appliance, which may greatly increase the ease and convenience for cleaning clothing articles.

Operating cycles in conventional laundry appliances are initiated by a user of the appliance. For instance, the user must select the desired cycle type (e.g., cotton, mixed, etc.) and operating parameters before manually starting the wash or drying cycle by pressing a tactile “Start” button. In some instances, the user may be required to specify an end time for the cycle or select a cycle with a predetermined duration, which thus specifies an end time. Given the wide variation in particular loads or conditions, though, this can often result in a significant under or over drying of the articles. In turn, a user may be dissatisfied with the appliance performance or risk expending unnecessary money and energy.

Increasingly, cycles or options for automating certain aspects of appliance operation have been desired. These, in turn, may require dedicated sensor assemblies. For instance, a dedicated humidity sensor may be required to detect moisture within the articles or laundry chamber generally. Such sensor assemblies can increase the cost or complexity of the appliance (e.g., during assembly). Additionally or alternatively, such sensor assemblies may create another point for maintenance or decrease overall durability of the appliance.

As a result, it would be useful to provide an appliance or method of operation with features for automating certain aspects of, for instance, a drying cycle (e.g., without requiring a dedicated humidity sensor). Additionally or alternatively, it may be advantageous to provide a laundry appliance or method facilitating a robust, durable, cost-efficient, or accurate assembly.

BRIEF DESCRIPTION OF THE DISCLOSURE

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one exemplary aspect of the present disclosure, a laundry appliance is provided. The laundry appliance may include a cabinet, a tub, a laundry basket, a heater, and a controller. The tub may be positioned within the cabinet. The tub may define a tub outlet and a tub inlet. The laundry basket may be rotatably mounted within the tub. The laundry basket may define a chamber for receipt of articles for washing or drying. The heater may be configured to heat and remove moisture from air within the chamber. The controller may be operably coupled to the heater and configured to initiate a laundry operation. The laundry operation may include directing a dry cycle for the articles, directing the dry cycle comprising activating the heater according to the dry cycle. The laundry operation may also include receiving a plurality of motion signals during the dry cycle, evaluating the plurality of received motion signals, and determining a dry state of the articles based on the evaluation of the plurality of received motion signals. The laundry operation may further include modifying direction of the dry cycle based on the determined dry state.

In another exemplary aspect of the present disclosure, a method of operating a laundry appliance is provided. The method may include directing a dry cycle for articles for drying within a laundry basket of the laundry appliance. The method may also include directing the dry cycle comprising activating a heater mounted within a cabinet of the laundry appliance according to the dry cycle. The method may further include receiving a plurality of motion signals during the dry cycle and evaluating the plurality of received motion signals. The method may still further include determining a dry state of the articles based on the evaluation of the plurality of received motion signals. The method may yet further include modifying direction of the dry cycle based on the determined dry state.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 provides a perspective view of a laundry appliance in accordance with exemplary embodiments of the present disclosure.

FIG. 2 provides a side sectional view of the exemplary laundry appliance of FIG. 1.

FIG. 3 provides a schematic diagram of an exemplary heat pump dryer appliance and a conditioning system thereof in accordance with exemplary embodiments of the present disclosure.

FIG. 4 provides an exemplary measurement chart illustrating radial tub motion (e.g., vertical or horizontal displacement) over time during a dry cycle.

FIG. 5 provides a depiction of an example machine-learned model according to exemplary embodiments of the present disclosure.

FIG. 6 illustrates a method for operating a laundry appliance in accordance with exemplary embodiments of the present disclosure.

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

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components or systems. For example, the approximating language may refer to being within a 10 percent margin (i.e., including values within ten percent greater or less than the stated value). In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction (e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, such as, clockwise or counterclockwise, with the vertical direction V).

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows.

Except as explicitly indicated otherwise, recitation of a singular processing element (e.g., “a controller,” “a processor,” “a microprocessor,” etc.) is understood to include more than one processing element. In other words, “a processing element” is generally understood as “one or more processing element.” Furthermore, barring a specific statement to the contrary, any steps or functions recited as being performed by “the processing element” or “said processing element” are generally understood to be capable of being performed by “any one of the one or more processing elements.” Thus, a first step or function performed by “the processing element” may be performed by “any one of the one or more processing elements,” and a second step or function performed by “the processing element” may be performed by “any one of the one or more processing elements and not necessarily by the same one of the one or more processing elements by which the first step or function is performed.” Moreover, it is understood that recitation of “the processing element” or “said processing element” performing a plurality of steps or functions does not require that at least one discrete processing element be capable of performing each one of the plurality of steps or functions.

Referring now to the figures, an exemplary laundry appliance that may be used to implement aspects of the present subject matter will be described. Specifically, FIG. 1 is a perspective view of an exemplary horizontal axis washer/dryer appliance 100 (e.g., washer and condenser dryer combination appliance), referred to herein for simplicity as laundry appliance 100. FIG. 2 is a side sectional view of laundry appliance 100. As illustrated, laundry appliance 100 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. Laundry appliance 100 includes a cabinet 102 that extends between a top 104 and a bottom 106 along the vertical direction V, between a left side 108 and a right side 110 along the lateral direction, and between a front 112 and a rear 114 along the transverse direction T.

Referring to FIG. 2, a laundry basket 120 is rotatably mounted within cabinet 102 such that it is rotatable about an axis of rotation A. According to the illustrated embodiment, axis of rotation A is substantially parallel to a horizontal direction (e.g., the transverse direction T), as this exemplary appliance is a front load appliance. A motor 122, such as a pancake motor, is in mechanical communication with laundry basket 120 to selectively rotate laundry basket 120 (e.g., during an agitation or a rinse phase of laundry appliance 100). Motor 122 may be mechanically coupled to laundry basket 120 directly or indirectly (e.g., via a pulley and a belt—not pictured). Laundry basket 120 is received within a tub 124 that defines a (e.g., laundry or drying) chamber 126 that is configured for receipt of articles for washing or drying.

As used herein, the terms “clothing” or “articles” includes but need not be limited to fabrics, textiles, garments, linens, papers, or other items from which the extraction of moisture is desirable. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together or dried together in laundry appliance 100 (e.g., the combination washer and dryer) and may include a mixture of different or similar articles of clothing of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process.

The tub 124 holds wash and rinse fluids for agitation in laundry basket 120 within tub 124. As used herein, “wash fluid” may refer to water, detergent, fabric softener, bleach, or any other suitable wash additive or combination thereof. Indeed, for simplicity of discussion, these terms may all be used interchangeably herein without limiting the present subject matter to any particular “wash fluid.”

Laundry basket 120 may define one or more agitator features that extend into chamber 126 to assist in agitation, cleaning, and drying of articles disposed within chamber 126 during operation of laundry appliance 100. For example, as illustrated in FIG. 2, a plurality of baffles or ribs 128 extend from basket 120 into chamber 126. In this manner, for example, ribs 128 may lift articles disposed in laundry basket 120 and then allow such articles to tumble back to a bottom of drum laundry basket 120 as it rotates. Ribs 128 may be mounted to laundry basket 120 such that ribs 128 rotate with laundry basket 120 during operation of laundry appliance 100.

Referring generally to FIGS. 1 and 2, cabinet 102 may include a front panel 130 which defines an opening 132 that permits user access to laundry basket 120 and tub 124. More specifically, laundry appliance 100 includes a door 134 that is positioned over opening 132 and is rotatably mounted to front panel 130. In this manner, door 134 permits selective access to opening 132 by being movable between an open position (not shown) facilitating access to a tub 124 and a closed position (FIG. 1) prohibiting access to tub 124. Laundry appliance 100 may further a latch assembly 136 (see FIG. 1) that is mounted to cabinet 102 or door 134 for selectively locking door 134 in the closed position or detecting the door 134 in the closed position. Latch assembly 136 may be desirable, for example, to ensure only secured access to chamber 126 or to otherwise ensure and verify that door 134 is closed during certain operating cycles or events.

In some embodiments, a window 138 in door 134 permits viewing of laundry basket 120 when door 134 is in the closed position (e.g., during operation of laundry appliance 100). Door 134 may include a handle (not shown) that, for example, a user may pull when opening and closing door 134. Further, although door 134 is illustrated as mounted to front panel 130, it should be appreciated that door 134 may be mounted to another side of cabinet 102 or any other suitable support according to alternative embodiments.

Referring again to FIG. 2, laundry basket 120 may also define a plurality of perforations 140 in order to facilitate fluid communication between an interior of basket 120 and tub 124. A sump 142 is defined by tub 124 at a bottom of tub 124 along the vertical direction V. Thus, sump 142 is configured for receipt of and generally collects wash fluid during operation of laundry appliance 100. For example, during operation of laundry appliance 100, wash fluid may be urged by gravity from basket 120 to sump 142 through plurality of perforations 140.

In some embodiments, a drain pump assembly 144 is located beneath tub 124 and is in fluid communication with sump 142 for periodically discharging soiled wash fluid from laundry appliance 100. Drain pump assembly 144 may generally include a drain pump 146 which is in fluid communication with sump 142 and with an external drain 148 through a drain hose 150. During a drain cycle or phase (e.g., as a portion of a wash cycle), drain pump 146 urges a flow of wash fluid from sump 142, through drain hose 150, and to external drain 148. More specifically, drain pump 146 includes a motor (not shown) which is energized during a drain cycle such that drain pump 146 draws wash fluid from sump 142 and urges it through drain hose 150 to external drain 148.

A spout 154 is configured for directing a flow of fluid into tub 124. For example, spout 154 may be in fluid communication with a water supply 155 (FIG. 2) in order to direct fluid (e.g., clean water or wash fluid) into tub 124. Spout 154 may also be in fluid communication with the sump 142. For example, pump assembly 144 may direct wash fluid disposed in sump 142 to spout 154 in order to circulate wash fluid in tub 124.

As illustrated in FIG. 2, a detergent drawer 156 may be slidably mounted within front panel 130. Detergent drawer 156 receives a wash additive (e.g., detergent, fabric softener, bleach, or any other suitable liquid or powder) and directs the fluid additive to wash chamber 126 during operation of laundry appliance 100. According to the illustrated embodiment, detergent drawer 156 may also be fluidly coupled to spout 154 to facilitate the complete and accurate dispensing of wash additive.

In optional embodiments, a bulk reservoir 157 is disposed within cabinet 102 and is configured for receipt of fluid additive or detergent for use during operation of laundry appliance 100. Moreover, bulk reservoir 157 may be sized such that a volume of fluid additive sufficient for a plurality or multitude of wash cycles of laundry appliance 100 (e.g., five, ten, twenty, fifty, or any other suitable number of wash cycles) may fill bulk reservoir 157. Thus, for example, a user can fill bulk reservoir 157 with fluid additive and operate laundry appliance 100 for a plurality of wash cycles without refilling bulk reservoir 157 with fluid additive. A reservoir pump (not shown) may be configured for selective delivery of the fluid additive from bulk reservoir 157 to tub 124.

A water supply valve or control valve 158 may provide a flow of water from a water supply source (such as a municipal water supply 155) into detergent dispenser 156 or into tub 124. In this manner, control valve 158 may generally be operable to supply water into detergent dispenser 156 to generate a wash fluid (e.g., for use in a wash cycle) or a flow of fresh water (e.g., for a rinse phase). It should be appreciated that control valve 158 may be positioned at any other suitable location within cabinet 102.

A control panel 160 including a plurality of input selectors 162 (e.g., buttons, knobs, toggles, touch screens, etc.) is coupled to front panel 130. Control panel 160 and input selectors 162 collectively form a user interface input for operator selection of machine cycles and features. For example, in one embodiment, a display 164 indicates selected features, a countdown timer, or other items of interest to machine users.

Operation of laundry appliance 100 is controlled by a controller or processing device 166 (FIG. 1) that is operatively coupled to control panel 160 for user manipulation to select laundry cycles and features. In response to user manipulation of control panel 160, controller 166 operates the various components of laundry appliance 100 to execute selected machine cycles and features.

Controller 166 may include a memory and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with a cleaning cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 166 may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry-such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Control panel 160 and other components of laundry appliance 100 may be in communication with controller 166 via one or more signal lines or shared communication busses.

In some embodiments, controller 166 can store or include one or more machine-learned models 510 (FIG. 5). As examples, the machine-learned model(s) 510 (FIG. 5) can be or can otherwise include various machine-learned models such as, for example, neural networks (e.g., deep neural networks, etc.), support vector machines, decision trees, ensemble models, k-nearest neighbors models, Bayesian networks, or other types of models including linear models or non-linear models. Example neural networks include feed-forward neural networks (e.g., convolutional neural networks, etc.), recurrent neural networks (e.g., long short-term memory recurrent neural networks, etc.), or other forms of neural networks.

During operation of laundry appliance 100, laundry items are loaded into laundry basket 120 through opening 132, and a washing or wash/dry operation (e.g., having discrete wash and dry cycles) is initiated through operator manipulation of input selectors 162. Tub 124 is filled with water, detergent, or other fluid additives (e.g., via spout 154 and or detergent drawer 156). One or more valves (e.g., control valve 158) can be controlled by laundry appliance 100 to provide for filling laundry basket 120 to the appropriate level for the amount of articles being washed or rinsed. By way of example for a wash cycle, once laundry basket 120 is properly filled with fluid, the contents of laundry basket 120 can be agitated (e.g., with ribs 128) for washing of articles in laundry basket 120.

After an agitation phase of the wash cycle is completed, tub 124 can be drained. Laundry articles can then be rinsed by again adding fluid to tub 124, depending on the particulars of the cleaning cycle selected by a user. Ribs 128 may again provide agitation within laundry basket 120. One or more spin cycles or phases may also be used. In particular, a spin phase may be applied after the wash cycle or after the rinse phase in order to wring wash fluid from the articles being washed. During a final spin cycle, basket 120 is rotated at relatively high speeds and drain pump assembly 144 may discharge wash fluid from sump 142. Following the wash cycle, a dry cycle may be executed, as will be described in greater detail below.

While described in the context of a specific embodiment of horizontal axis laundry appliance 100, using the teachings disclosed herein it will be understood that horizontal axis laundry appliance 100 is provided by way of example only. Other laundry appliances having different configurations, different appearances, or different features may also be utilized with the present subject matter as well (e.g., vertical axis laundry appliances). For instance, aspects of the present subject matter may be applicable to dedicated dryers or drying appliances, as would be understood. Indeed, it should be appreciated that aspects of the present subject matter may further apply to other laundry appliances. In this regard, the same methods as systems and methods as described herein may be used to implement dry cycles for other appliances, as described in more detail below.

Referring still to FIG. 1, a schematic diagram of an external communication system 170 will be described according to an exemplary embodiment of the present subject matter. In general, external communication system 170 is configured for permitting interaction, data transfer, and other communications with laundry appliance 100. For example, this communication may be used to provide and receive operating parameters, user instructions or notifications, performance characteristics, user preferences, one or more models of operation, or any other suitable information for improved performance of laundry appliance 100.

External communication system 170 permits controller 166 of laundry appliance 100 to communicate with external devices either directly or through a network 172. For example, a consumer may use a consumer device 174 to communicate directly with laundry appliance 100. For example, consumer devices 174 may be in direct or indirect communication with laundry appliance 100, such directly through a local area network (LAN), Wi-Fi, Bluetooth, Zigbee, etc. or indirectly through network 172. In general, consumer device 174 may include its own user interface and be any suitable device for providing or receiving communications or commands from a user. In this regard, consumer device 174 may include, for example, a personal phone, a tablet, a laptop computer, or another mobile device.

In addition, a remote server 176 may be in communication with laundry appliance 100 or consumer device 174 through network 172. In this regard, for example, remote server 176 may be a cloud-based server 176, and is thus located at a distant location, such as in a separate state, country, etc. In general, communication between the remote server 176 and the client devices may be carried via a network interface using any type of wireless connection, using a variety of communication protocols (e.g. TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g. HTML, XML), or protection schemes (e.g. VPN, secure HTTP, SSL).

In some embodiments, the remote server 176 (e.g., a controller thereof) can store or include one or more machine-learned models 510 (FIG. 5) (e.g., separate from or in addition to machine-learned models stored with controller 166). As examples, the machine-learned model(s) 510 (FIG. 5) can be or can otherwise include various machine-learned models such as, for example, neural networks (e.g., deep neural networks, etc.), support vector machines, decision trees, ensemble models, k-nearest neighbors models, Bayesian networks, or other types of models including linear models or non-linear models. Example neural networks include feed-forward neural networks (e.g., convolutional neural networks, etc.), recurrent neural networks (e.g., long short-term memory recurrent neural networks, etc.), or other forms of neural networks. The machine-learned models of the remote server 176 may be used by the appliance 100 (e.g., by transmitting such models directly to the appliance 100 or by exchanging data signals according to a client-server relationship). Additionally or alternatively, remote server 176 can train the machine-learned models through use of a model trainer (e.g., training algorithm), as would be understood. Optionally, such a model trainer may train machine-learned models based on a set of training data compiled from a plurality of different appliances or appliance models.

In general, network 172 can be any type of communication network. For example, network 172 can include one or more of a wireless network, a wired network, a personal area network, a local area network, a wide area network, the internet, a cellular network, etc. According to an exemplary embodiment, consumer device 174 may communicate with a remote server 176 over network 172, such as the internet, to provide user inputs, receive user notifications or instructions, etc. In addition, consumer device 174 and remote server 176 may communicate with laundry appliance 100 to communicate similar information.

External communication system 170 is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system 170 provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more laundry appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.

Referring again to FIG. 2, conditioning system 200 may include a return duct 220 that is mounted to tub 124 for circulating air within chamber 126 to facilitate a dry cycle. For example, according to the illustrated exemplary embodiments, return duct 220 is fluid coupled to tub 124 proximate a top of tub 124. Return duct 220 receives heated air that has been heated or dehumidified by a conditioning system 200 and provides the heated air to laundry basket 120 via one or more holes defined by rear wall 206 or cylindrical wall 208 of laundry basket 120 (e.g., such as perforations 140).

During a dry cycle, moisture laden, heated air is drawn from laundry basket 120 by an air handler, such as a blower fan 222, which may generate a negative air pressure within laundry basket 120. As the air passes from blower fan 222, it enters an intake duct 224 and then is passed into conditioning system 200. In some embodiments, the conditioning system 200 may have a heater 202 that includes or is provided as an electric heating element (e.g., a resistive heating element) or a gas-powered heating element (e.g., a gas burner), as would be understood. According to the illustrated exemplary embodiment, laundry appliance 100 is a heat pump dryer appliance and thus conditioning system 200 may be or include a heater including a heat pump having a sealed refrigerant circuit, as described in more detail below with reference to FIG. 3. Heated air (with a lower moisture content than was received from laundry basket 120), exits conditioning system 200 and returns to laundry basket 120 by a return duct 220. As air is heated and circulated through the chamber 126, the basket 120 may be rotated (e.g., as motivated by the motor 122), such as at a set tumble speed, to permit agitation (e.g., at non-plastering or sub-plaster speeds), as is understood. After the clothing articles have been dried (e.g., following completion of the dry cycle), the articles may be removed from the laundry basket 120 via opening 132.

As shown, laundry appliance 100 may further include one or more lint filters 230 (FIG. 3) to collect lint during drying operations. The moisture laden heated air passes through intake duct 224 enclosing screen filter 230, which traps lint particles. More specifically, filter 230 may be placed into an air flow path 232 defined by laundry basket 120, conditioning system 200, intake duct 224, and return duct 220. Filter 230 may be positioned in the process air flow path 232 and may include a screen, mesh, other material to capture lint in the air flow 232. The location of lint filters in laundry appliance 100 as shown in FIG. 3 is provided by way of example only, and other locations may be used as well. According to exemplary embodiments, lint filter 230 is readily accessible by a user of the appliance. As such, lint filter 230 should be manually cleaned by removal of the filter, pulling or wiping away accumulated lint, and then replacing the filter 230 for subsequent drying or dry cycles.

According to optional embodiments, laundry appliance 100 may facilitate a steam dry process. In this regard, laundry appliance 100 may offer a steam dry cycle, during which steam is injected into chamber 126 (e.g., to function similar to a traditional garment steamer to help remove wrinkles, static, etc.). Accordingly, as shown for example in FIG. 3, laundry appliance 100 may include a misting nozzle 234 that is in fluid communication with a water supply 236 (e.g., such as water supply 155) in order to direct mist into chamber 126. Laundry appliance 100 may further include a water supply valve or control valve 238 for selecting discharging the flow of mist into chamber 126. It should be appreciated that control valve 238 may be positioned at any other suitable location within cabinet 102.

FIG. 3 provides a schematic view of laundry appliance 100 and depicts conditioning system 200 in more detail. In the illustrated embodiments, laundry appliance 100 is a heat pump dryer appliance and thus conditioning system 200 includes a sealed system 250. Sealed system 250 includes various operational components, which can be encased or located within a machinery compartment of laundry appliance 100. In some embodiments, the operational components are operable to execute a vapor compression cycle for heating process air passing through conditioning system 200. The operational components of sealed system 250 include an evaporator 252, a compressor 254, a condenser 256, and one or more expansion devices 258 connected in series along a refrigerant circuit or line 260. Refrigerant line 260 is charged with a working fluid, which in this example is a refrigerant. Sealed system 250 depicted in FIG. 3 is provided by way of example only. Thus, it is within the scope of the present subject matter for other configurations of the sealed system to be used as well. As will be understood by those skilled in the art, sealed system 250 may include additional components (e.g., at least one additional evaporator, compressor, expansion device, or condenser). For instance, sealed system 250 may include two evaporators.

In performing a dry cycle, one or more laundry articles LA may be placed within the chamber 126 of laundry basket 120. For instance, following a wash cycle, articles may remain within the chamber 126. Hot dry air HDA may be supplied to chamber 126 via return duct 220. The hot dry air HDA enters chamber 126 of laundry basket 120 via a tub inlet 264 defined by laundry basket 120 (e.g., the plurality of holes defined in rear wall 206 or cylindrical wall 208 of laundry basket 120 as shown in FIG. 2). The hot dry air HDA provided to chamber 126 causes moisture within laundry articles LA to evaporate. Accordingly, the air within chamber 126 increases in water content and exits chamber 126 as warm moisture laden air MLA. The warm moisture laden air MLA exits chamber 126, such as through a tub outlet 266 defined by laundry basket 120 and flows into intake duct 224.

After exiting chamber 126 of laundry basket 120, the warm moisture laden air MLA may flow downstream to conditioning system 200. Blower fan 222 moves the warm moisture laden air MLA, as well as the air more generally, through a process air flow path 232 defined by laundry basket 120, conditioning system 200, intake duct 224, and return duct 220. Thus, generally, blower fan 222 is operable to move air through or along the process air flow path 232. The duct system includes all ducts that provide fluid communication (e.g., airflow communication) between tub outlet 266 and conditioning system 200 and between conditioning system 200 and tub inlet 264. Although blower fan 222 is shown positioned between laundry basket 120 and conditioning system 200 along intake duct 224, it will be appreciated that blower fan 222 can be positioned in other suitable positions or locations along the duct system.

As further depicted in FIG. 3, the warm moisture laden air MLA flows into or across evaporator 252 of the conditioning system 200. As the moisture-laden air MLA passes across evaporator 252, the temperature of the air is reduced through heat exchange with refrigerant that is vaporized within, for example, coils or tubing of evaporator 252. This vaporization process absorbs both the sensible and the latent heat from the moisture-laden air MLA-thereby reducing its temperature. As a result, moisture in the air is condensed and such condensate water may be drained from conditioning system 200 (e.g., using a drain line 262, which is also depicted in FIG. 3).

In optional embodiments, a condenser tank or a condensate collection tank 270 is in fluid communication with conditioning system 200 (e.g., via drain line 262). Collection tank 270 is operable to receive condensate water from the process air flowing through conditioning system 200, and more particularly, condensate water from evaporator 252. A sensor 272 may be operable to detect when water within collection tank 270 has reached a predetermined level. Sensor 272 can be any suitable type of sensor, such as a float switch as shown in FIG. 3. Sensor 272 can be communicatively coupled with controller 166 (e.g., via a suitable wired or wireless communication link). A drain pump 274 is in fluid communication with collection tank 270. Drain pump 274 is operable to remove a volume of water from collection tank 270 and, for example, discharge the collected condensate to an external drain. In some embodiments, drain pump 274 can remove a known or predetermined volume of water from collection tank 270. Drain pump 274 can remove the condensate water from collection tank 270 and can move or drain the condensate water downstream (e.g., to a gray water collection system). Particularly, in some embodiments, controller 166 is configured to receive, from sensor 272, an input indicating that water within the collection tank has reached the predetermined level. In response to the input indicating that water within collection tank 270 has reached the predetermined level, controller 166 can cause drain pump 274 to remove the predetermined volume of water from collection tank 270.

Air passing over evaporator 252 becomes cooler than when it exited laundry basket 120 at tub outlet 266. As shown in FIG. 3, cool air CA (cool relative to hot dry air HDA and moisture laden air MLA) flowing downstream of evaporator 252 is subsequently caused to flow across condenser 256 (e.g., across coils or tubing thereof), which condenses refrigerant therein. The refrigerant enters condenser 256 in a gaseous state at a relatively high temperature compared to the cool air CA from evaporator 252. As a result, heat energy is transferred to the cool air CA at the condenser 256, thereby elevating its temperature and providing warm dry air HDA for resupply to laundry basket 120 of laundry appliance 100. The warm dry air HDA passes over and around laundry articles LA within the chamber 126 of the laundry basket 120, such that warm moisture laden air MLA is generated, as mentioned above.

With respect to sealed system 250, compressor 254 pressurizes refrigerant (i.e., increases the pressure of the refrigerant) passing therethrough and generally motivates refrigerant through the sealed refrigerant circuit or refrigerant line 260 of conditioning system 200. Compressor 254 may be communicatively coupled with controller 166 (communication lines not shown in FIG. 3). Refrigerant is supplied from the evaporator 252 to compressor 254 in a low pressure gas phase. The pressurization of the refrigerant within compressor 254 increases the temperature of the refrigerant. The compressed refrigerant is fed from compressor 254 to condenser 256 through refrigerant line 260. As the relatively cool air CA from evaporator 252 flows across condenser 256, the refrigerant is cooled and its temperature is lowered as heat is transferred to the air for supply to chamber 126 of laundry basket 120.

Upon exiting condenser 256, the refrigerant is fed through refrigerant line 260 to expansion device 258. Although only one expansion device 258 is shown, such is by way of example only. It is understood that multiple such devices may be used. In the illustrated example, expansion device 258 is an electronic expansion valve, although a thermal expansion valve or any other suitable expansion device can be used. In additional embodiments, any other suitable expansion device, such as a capillary tube, may be used as well. Expansion device 258 lowers the pressure of the refrigerant and controls the amount of refrigerant that is allowed to enter the evaporator 252. Importantly, the flow of liquid refrigerant into evaporator 252 is limited by expansion device 258 in order to keep the pressure low and allow expansion of the refrigerant back into the gas phase in evaporator 252. The evaporation of the refrigerant in evaporator 252 converts the refrigerant from its liquid-dominated phase to a gas phase while cooling and drying the moisture laden air MLA received from chamber 126 of laundry basket 120. The process is repeated as air is circulated along process air flow path 232 while the refrigerant is cycled through sealed system 250, as described above.

In the case of a tumble dry cycle, the heater (e.g., sealed system 250) remains inactive such that heat is not actively generated or, alternatively, the heater may be directed to a relatively low heat setting (i.e., a first heat setting that is lower in power, voltage, duty cycle, or temperature than a second heat setting of the dry cycle). For instance, the compressor 254 may be directed to a reduced state. Optionally, compressor 254 may be held inactive to restrict the flow of refrigerant through sealed system 250. Nonetheless, air may be cycled through chamber 126 along the same path as air circulated during a dry cycle (e.g., as described above).

As shown in FIGS. 2 and 3 one or more measurement devices 180 may be provided in the washing machine appliance 100 for measuring movement of the tub 124, in particular during rotation of the basket 120, such as during a dry cycle of a drying operation. Measurement devices 180 may measure a variety of suitable variables that can be correlated to movement of the tub 124. The movement measured by such devices 180 can be utilized to monitor the relative moisture content or dry state of articles within the tub 124 and to permit dry-article detection (e.g., without using or requiring a separate humidity sensor).

A measurement device 180 in accordance with the present disclosure may include an accelerometer which measures translational motion, such as acceleration along one or more directions. Additionally or alternatively, a measurement device 180 may include a gyroscope, which measures rotational motion, such as rotational velocity about an axis. A measurement device 180 in accordance with the present disclosure is mounted to the tub 124 (e.g., on a sidewall of tub 124) to sense movement of the tub 124 relative to the cabinet 102 by measuring uniform periodic motion, non-uniform periodic motion, or excursions of the tub 124 during appliance 100 operation. For instance, movement may be measured as discrete identifiable components (e.g., in a predetermined direction, such as a radial direction perpendicular to the rotation axis A).

In exemplary embodiments, a measurement device 180 may include at least one gyroscope or at least one accelerometer. The measurement device 180, for example, may be a printed circuit board that includes the gyroscope and accelerometer thereon. The measurement device 180 may be mounted to the tub 124 (e.g., via a suitable mechanical fastener, adhesive, etc.) and may be oriented such that the various sub-components (e.g., the gyroscope and accelerometer) are oriented to measure movement along or about particular directions as discussed herein. Notably, the gyroscope and accelerometer in exemplary embodiments are advantageously mounted to the tub 124 at a single location (e.g., the location of the printed circuit board or other component of the measurement device 180 on which the gyroscope and accelerometer are grouped). Such positioning at a single location advantageously reduces the costs and complexity (e.g., due to additional wiring, etc.) of out-of-balance detection, while still providing relatively accurate out-of-balance detection as discussed herein. Alternatively, however, the gyroscope and accelerometer need not be mounted at a single location. For example, a gyroscope located at one location on tub 124 can measure the rotation of an accelerometer located at a different location on tub 124, because rotation about a given axis is the same everywhere on a solid object such as tub 124.

Additionally or alternatively, the measurement device 180 may include another suitable sensor or device for measuring movement of the tub 124. For instance, the measurement device 180 may be provided as or include an optical sensor, an inductive sensor, an ultrasonic sensor, etc.

Turning briefly to FIG. 4, recorded measurements 400 (e.g., detected at the measurement device 180-FIG. 2) taken over time (e.g., during a dry cycle) are illustrated. As shown, a filtered moving average (indicated at line 410) of the recorded measurements 400 may be tracked. Using an adaptive evaluation, such as by employing a predetermined model, such as a machine-learned model 510-FIG. 5), an inflection point or region 420 of the measurements may be identified. Notably, the inflection point or region 420 of the measurements may correspond to a dry state of articles within the chamber 126 of the laundry appliance 100 (FIG. 2). In other words, it may be determined when articles have transitioned from a moisture-laden or wet state 430 to a dry state 440 (and, thus, have been dried) based on the movements of the tub 124 (e.g., without using a humidity or moisture sensor).

As shown in FIG. 5, the detected or recorded measurements 400 (FIG. 4) may be analyzed by one of the machine-learned models 510 (e.g., a single model). For instance, a machine vision or visual detection model at 510 may receive the measurements 400 for a dry cycle and evaluate the same. The machine-learned model 510 may evaluate measurements 400 for determination of a dry cycle (e.g., to ascertain the inflection point or region at which articles are dry).

Now that the construction of laundry appliance 100 and the configuration of controller 166 according to exemplary embodiments have been presented, an exemplary method 600 of operating a laundry appliance will be described. Although the discussion below refers to the exemplary method 600 of operating laundry appliance 100, one skilled in the art will appreciate that the exemplary method 600 is applicable to the operation of a variety of other laundry appliances. In exemplary embodiments, the various method steps as disclosed herein may be performed by controller 166 (e.g., as a dry operation) or a separate, dedicated controller.

Advantageously, embodiments described herein may provide a laundry appliance or method facilitating a robust, durable, cost-efficient, or accurate assembly for detecting if or when articles within the appliance are dry. Additionally or alternatively, the described embodiments may notably permit dry detection without requiring a dedicated humidity sensor.

Referring now to FIG. 6, at 610, the method 600 includes receiving a cycle selection. For instance, a user may engage (e.g., press, turn, toggle, touch, etc.) the user interface of the laundry appliance to select a particular cycle or operation (e.g., including attributes thereof) or otherwise register an intent for a laundry operation to begin. Additionally or alternatively, a user may engage (e.g., press, turn, toggle, touch, etc.) a consumer device from a remote location relative to the laundry appliance to select a particular cycle or operation (or attributes thereof) or otherwise register

At 620, the method 600 includes initiating or directing a dry cycle (e.g., solely or as part of a more extensive laundry operation having multiple discrete cycles). Generally, the dry cycle is for the articles within the laundry chamber and is based on the cycle selection of 610. Thus, 620 may follow or be in response to 610.

The dry cycle may be one of a plurality of selectable dry cycles, each of which may correspond to one or more corresponding criteria. Such criteria may include a specific cycle (e.g., according to a material, color, or characteristic of the load of articles) or load size (e.g., number, mass, or relative volume of the load of articles. Moreover, the criteria may be specified explicitly by the user or automatically detected by one or more features of the appliance, as is generally understood.

In some embodiments, the dry cycle includes instructions or steps for elements of the laundry appliance to perform during or as part of the dry cycle. For instance, 620 may include activating the heater according to the dry cycle. Thus, one or more portions of the heater (e.g., heating element or conditioning system) may generate heat conveyed to the articles or the laundry chamber, as described above and as would further be understood. Additionally or alternatively, 620 may include activating the basket motor or otherwise directing rotation of the laundry basket (e.g., at a predetermined or constant rotation speed), as described above and as would further be understood.

In optional embodiments, the dry cycle is executed or directed as part of a larger or more extensive operation, such as a wash/dry operation within a combination washer and dryer appliance. In turn, 620 may include initiating a wash/dry operation for articles within the laundry basket. Generally, the wash/dry operation includes a discrete wash cycle and dry cycle. In other words, the wash/dry operation may include a first cycle in which the articles are wetted and washed (e.g., as described above) and a separate second cycle that follows the first cycle and in which the wetted/washed articles are actively heated or dried (e.g., as described above). Thus, 620 may include initiating the wash cycle (e.g., as prompted by 610) and cause it to be executed before directing the dry cycle.

At 630, the method 600 includes receiving a plurality of motion signals during the dry cycle. For example, 630 may occur during 620, during a predetermined time period, during a predefined portion of a dry cycle (e.g., at a predetermined rotation speed), or at another suitable period. Moreover, the motion signals may be received while the basket is being rotated (e.g., at the predetermined rotation speed).

As described above, the motion signals may be received from an accelerometer. In turn, 630 may include measuring movement, such as by detecting movement of the tub as one or more amplitudes (e.g., in a radial direction perpendicular to the rotation axis of the basket). In some such embodiments, movement is measured as a plurality of amplitudes (e.g. horizontal amplitudes using a measurement device, described above). A plurality of motion signals may be received sequentially at discrete time points. Thus, the motion signals may be sequential signals collected at discrete time points, such as to detect movement over time.

At 640, the method 600 includes evaluating the plurality of received motion signals. For instance, using the plurality of amplitudes of 630, 640 may include evaluating a change in amplitude (e.g., change over time). In other words, the change in amplitude may be evaluated from, and based on, the plurality of detected amplitudes.

In some embodiments, the evaluation at 640 is performed according to a predetermined model. Optionally, the predetermined model may correspond to a specific cycle or load size (e.g., specified 610 or otherwise previously determined, as would be understood). Additionally or alternatively, 640 may include using a machine-learned model. Exemplary machine-learned models will be described below according to exemplary embodiments. However, it should be appreciated that any suitable model may be used to analyze the data received at step 630, and the present subject matter is not intended to be limited to the specific models described herein unless indicated otherwise. In addition, it should be appreciated that the machine-learned models may include supervised and/or unsupervised models and methods. In this regard, for example, supervised machine learning methods (e.g., such as targeted machine learning) may help identify problems, anomalies, or other occurrences which have been identified and trained into the model. By contrast, unsupervised machine learning methods may be used to detect clusters of potential failures, similarities among data, event patterns, abnormal concentrations of a phenomenon, etc.

As explained briefly above, a remote server can be used to host a service platform, a cloud-based application, and/or an information database (e.g., a machine-learned model, a series of machine-learned models, received data, or other relevant service data-optionally including intermediate processing data products). The remote server and other portions of overall system can be regulated or implemented using any suitable computing device(s). In this regard, each server generally includes a controller (e.g., similar to controller) having one or more processors and one or more memory devices (i.e., memory). The one or more processors can be any suitable processing device (e.g., a processor core, a microprocessor, a CPU, an ASIC, a FPGA, a microcontroller, etc.) and can be one processor or a plurality of processors that are operatively connected. The memory device can include one or more non-transitory computer-readable storage mediums, such as RAM, DRAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., or combinations thereof. The memory devices can store data and instructions (e.g., on-transitory programming instructions) that are executed by the processors to cause the remote server to perform operations. For example, instructions could be instructions for receiving/transmitting component signals (e.g., including data or information), appliance data or performance metrics, fault codes or conditions, analyzation results, machine-learned models, etc.

In some embodiments, the remote server or appliance can store or include one or more machine-learned models such as, for example, neural networks (e.g., deep neural networks, etc.), support vector machines, decision trees, ensemble models, k-nearest neighbors models, Bayesian networks, logistics models, gradient boost models, XGBoost models, or other types of models including linear models or non-linear models. Example neural networks include feed-forward neural networks (e.g., convolutional neural networks, etc.), recurrent neural networks (e.g., long short-term memory recurrent neural networks, etc.), or other forms of neural networks.

The machine-learned models of the remote server or appliance may be used to analyze the appliance data transmitted from the laundry appliance. Additionally or alternatively, the remote server can train the machine-learned models through use of a model trainer (e.g., training algorithm), as would be understood. For example, as explained above, these models may include supervised models (e.g., trained or targeted toward certain problems or occurrences) and/or unsupervised models and methods (e.g., used to detect clusters of data similarities). Optionally, such a model trainer may train machine-learned models based on a set of training data compiled from a plurality of different appliances, appliance models, etc.

At 650, the method 600 includes determining a dry state of the articles (e.g., based on 640). The dry state may, for instance, be set as a threshold condition or state for moisture content (e.g., whether the articles have been dried to a desired level). Thus, it may be determined when articles have transitioned from a moisture-laden or wet state to a dry state (and, thus, have been dried), as described above. In turn, 650 may include detecting the dry state at a particular point in time. Optionally, the dry state may be required to be detected multiple times. For instance, 650 may include detecting the dry state at three or more sequential time points of the discrete time points for the sequential signals. In some such embodiments, the three or more sequential time points are required to be consecutive (e.g., consecutive intervals at which motion is detected).

If no such detection is made (or the dry state is unable to be immediately determined), it is understood that the dry cycle may be permitted to continue (e.g., uninterrupted) as various steps (e.g., 630 or 640) are repeated.

At 660, the method 600 includes modifying direction of the dry cycle based on the determined dry state. For instance, activation or use one or more portion of the appliance may be changed from its state prior to 660 (e.g., state held at or according to 620). In some embodiments, 660 includes modifying rotation of the laundry appliance. As an example, the rotation speed of the basket may be reduced or halted (i.e., stopped) in response to 650. In additional or alternative embodiments, 660 includes modifying activation of the heater. As an example, the heat generated at the heating element or conditioning system may be reduced or halted (i.e., stopped) following (e.g., subsequently or in response to) determining the dry state of the articles. As an additional or alternative example, the air speed or rotational speed of the blower may be reduced or halted (i.e., stopped) following (e.g., subsequently or in response to) determining the dry state of the articles.

Following 660, the dry cycle may be ended, as would be understood in light of the present disclosure.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.