System and Method for Operating a Washer Appliance

The present subject matter relates generally to laundry appliances.

Appliances, such as residential and commercial laundry appliances, may occasionally have fault conditions that partially or fully inhibit operation of the appliance. Users may encounter a situation in which a dryer appliance may have a fault condition, such as rendering the dryer appliance inoperable. Laundry articles at the washer appliance can reside for an extended period at the washer appliance, which can result in mildew or other undesired conditions, or require re-washing the laundry articles.

Systems and methods for overcoming such issues are desired and would be advantageous.

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.

An aspect of the present disclosure is directed to a system for appliance communication. The system includes a washer appliance having a first controller including a first communications device. A dryer appliance includes a second controller having a second communications device configured to communicatively couple to the first communications device to form an interconnected pair of washer and dryer appliances. One or both of the first and second controllers is configured to execute instructions that cause the washer appliance and the dryer appliance to perform operations. The operations include determining a fault condition at the dryer appliance; transmitting, to the washer appliance, a communications signal corresponding to the fault condition to at the dryer appliance; and adjusting, at the washer appliance, a washer mode based on the communications signal.

An aspect of the present disclosure is directed to a computer-implemented method for operating a washer appliance. The method includes determining, at a dryer appliance, a fault condition at the dryer appliance; transmitting, from the dryer appliance to the washer appliance, a communications signal corresponding to the fault condition at the dryer appliance; and adjusting, at the washer appliance, a washer mode based on the communications signal.

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.

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

As used herein, the terms “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).

Referring now to the drawings,depicts a schematic exemplary embodiment of an interconnected system of appliances (hereinafter, “system”). Embodiments of the systemform a system for appliance communication and a system for determining an operational state of an appliance. Embodiments of the systemmay be configured to perform operations or steps of a method for operating a washer appliance (hereinafter, “method”).

Embodiments of the systemincludes two or more appliances,positioned within communicative range of one another relative to a short range radio communications device, such as depicted inat short range radio communications devices,at respective appliances,. The short range radio communications devices,are configured to allow direct wireless communication between one another. Devices,are configured to use a radio frequency to share data over a short distance (e.g., up to approximately 3 meters, or up to approximately 30 meters). Embodiments of the systemare configured to communicatively couple together the devices,at respective appliances,. Embodiments of the devices,may be configured in accordance with Bluetooth® wireless communications standards, such as Bluetooth® Low Energy (BLE), or other appropriate short range, low-power, wireless protocols, such as, but not limited to, Unison, Xender, Xigbee®, and the like.

Devices,may be configured for direct wireless communication in contrast to internet communications devices,at respective appliances,configured to communicatively couple to a remote or cloud-based serveror computing network. Networkmay include one or more of a local area network (LAN), a wide area network (WAN), a personal area network (PAN), the Internet, a cellular network, or any other suitable wireless network. Internet communications devices,are configured to transmit and receive signals, data packets, information, datasets, and the like, over the networkand between the appliance,and the server. The servermay be configured to store and transmit data in a database, or providing computational processing, relating to controls, control signals, software patches or updates, or other Over-the-Air (OTA) processes as may be appropriate for appliances,. In addition, such communication may use a variety of communication protocols (e.g., TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g., HTML, XML), and/or protection schemes (e.g., VPN, secure HTTP, SSL).

It should be appreciated that devices,may form radio communications devices configured to allow for direct communication or pairing of one another (e.g., depicted schematically via linein), such as may contrast with devices,forming relatively long-range radio communications devices as may be configured to communicate through a wired or wireless network(e.g., Internet, Intranet, LAN, WAN, PAN, etc.). Accordingly, communicative coupling via devices,may allow for receipt and transmission of data and signals, such as described herein, without requiring operation or communication through devices,or computing network. When applied to various steps of method, advantages and benefits may be provided, such as local transmission, receipt, or adjustment of signals, parameters, and operations such as further described herein.

In some embodiments, appliances,form a washer-dryer appliance pair. For example, appliances,may form a washing machine appliance positioned adjacent to a dryer appliance. Accordingly, appliances,may be positioned in relatively short range (e.g., within up to approximately 3 meters or up to 10 meters of one another).

In various embodiments, appliances,may generally form an interconnected pair of appliances positioned in relatively short range of one another such as described herein, such as positioned within the same household or commercial facility as one another. Appliances,may be configured as generally understood in the art as any household or commercial laundry appliance such as generally provided herein. For instance, the laundry appliance may be configured as, but not limited to, front opening or top opening, with or without agitator, in top-bottom configuration, or other configurations of washer and dryer appliance.

For instance, appliancemay form a laundry washing appliance including a wash chamberat which clothing articles are positioned for washing during a wash cycle, such as generally understood in the art. Appliancemay form a laundry dryer appliance including a drying chamberat which clothing articles from the washer appliance are positioned at the dryer appliance for drying during a drying cycle, such as generally understood in the art. It should be appreciated that a user may generally utilize the dryer appliance by inserting into the drying chambera laundry load of washed clothes removed from the washing chamberat the washer appliance. For instance, insertion of a laundry load for drying at the dryer appliance may generally follow completion of a wash cycle at the washer appliance.

Appliances,generally include respective sensors,configured to determine a laundry load size, a washer load type or base cycle type, a dry load size at the washer appliance and dryer appliance, a wet load size at the washer appliance and the dryer appliance, or combinations thereof. For instance, sensors,may form load sensors or pressure sensors configured to determine weight of laundry articles at the chamber,. For instance, sensors,may form delta weight or delta pressure sensors configured to determine a difference between an empty chamber weight and a laundry-loaded weight, or between a dry laundry load weight and a wet laundry load weight, or between a dry laundry load weight and an empty chamber weight, or between a wet laundry load weight and an empty chamber weight. However, sensors,may include any appropriate configuration for determining weight of laundry load at the respective chamber,.

Appliances,each include a respective controller,configured to regulate, allow, inhibit, articulate, or otherwise operate appliances,. In various embodiments, sensors,are operably coupled to respective controllers,at respective appliances,. Controller,may be positioned in a variety of locations throughout appliance,(e.g., a control panel area, at a door, etc.). In some embodiments, input/output (“I/O”) signals are routed between controller,and various operational components of appliance,along wiring harnesses that may be routed. Controller,may include a user interface panel through which a user may select various operational features and operating modes and monitor progress of the appliance,. The user interface may represent a general purpose I/O (“GPIO”) device or functional block. Additionally, the user interface may include input components, such as one or more of a variety of electrical, mechanical, or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface may also include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface may be in communication with the controller,via one or more signal lines or shared communication busses.

Controllers,include one or more processing devices,and memory devices,. As used herein, the terms “processing device,” “computing device,” “controller,” or the like may generally refer to any suitable processing device, such as a general or special purpose microprocessor, a microcontroller, an integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing units (GPUs), processing units performing other specialized calculations, semiconductor devices, etc. In addition, these “controllers” are not necessarily restricted to a single element but may include any suitable number, type, and configuration of processing devices integrated in any suitable manner to facilitate appliance operation. Alternatively, controller,may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND/OR gates, and the like) to perform control functionality instead of relying upon software.

Memory devices,may include non-transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, or other suitable memory devices (including combinations thereof). These memory devices may be a separate component from the processing device,or may be included onboard within the processor. In addition, these memory devices,can store information and/or data accessible by the one or more processors,, including instructions,that can be executed by the one or more processors, such as one or more steps of method. It should be appreciated that instructions,can be software written in any suitable programming language or can be implemented in hardware. Additionally, or alternatively, instructions,can be executed logically and/or virtually using separate threads on one or more processors,. Executed instructions,cause the system, the appliances,, or serverto perform operations, such as one or more steps of methodprovided further herein.

For example, controller,may be operable to execute programming instructions,or micro-control code associated with an operating cycle or operating mode of appliance,, or a controls update. In this regard, the instructions,may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations, such as running one or more software applications, displaying a user interface, receiving user input signals, processing user input signals, pr permitting or disabling operation of the appliance,.

Moreover, it should be noted that controller,as disclosed herein is additionally, or alternatively, configured to transmit signals, store, execute, or otherwise operate or perform any one or more methods, method steps, or portions of methods as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory device at one or more of controller,or server. The memory devices may also store data that can be retrieved, manipulated, created, or stored by the one or more processors or portions of controller,.

Referring still to, one or more of the appliances includes the controller communicatively coupled to an internet communications device (e.g., device,) and a short range radio communications device (e.g., device,). In some embodiments, the short range communications device is coupled in parallel to the controller relative to the internet communications device. For instance, the short range communications device is coupled to the controller such as to allow for communication between the controller and the short range communications device without requiring operation or operability of the internet communications device at the appliance.

In various embodiments, such as schematically depicted in, the appliance includes a communications busbetween the controller and short range radio communications device (e.g., between controllerand device, between controllerand device), such as a direct communications bus. In still various embodiments, the appliance includes a communications busbetween the internet communications device and the short range radio communications device (e.g., between deviceand, between deviceand), such as a direct communications bus. In some embodiments, the internet communications device may be configured to direct communicative coupling with the controller (e.g., deviceto controller, deviceto controller).

Respective controllers,are operably and communicatively coupled to respective operational components,at appliances,. Operational components,include any component, system, or sub-system that can be modulated, articulated, or actuated, such as, but not limited to, a motor or a heat exchanger. Operational components,can articulate a speed, agitation, or duration of operation of a tub or basket. Controller,selectively controls and operates the operational components based on a washer mode or dryer mode. As further described herein, methodcommands, permits, inhibits, or adjusts speeds, frequencies, oscillations, temperatures, or periods of time of operation of the operational component,based on steps of method.

Referring now to, a flowchart outlining exemplary steps of the methodare provided. It should be appreciated that steps provided herein may be rearranged, iterated, performed in series or parallel, or omitted. As provided above, embodiments of the method, or portions thereof, may form steps or instructions executable via a controller (e.g., controller,), that, when executed, causes an interconnected system of appliances (e.g., appliances,), to perform operations.

Methodmay include atcommunicatively coupling the dryer appliance (e.g., second appliance) to the washer appliance (e.g., first appliance). Methodatmay include communicatively coupling the washer and dryer appliances together to form an interconnected pair of washer and dryer appliance via a first short-range communications device (e.g., device) to a second short-range communications device (e.g., device).

Methodincludes atdetermining a fault condition at the dryer appliance. The fault condition can include any operational state or condition that may be diagnosed or determined by a controller at the dryer (e.g., controller). Fault conditions may include a delta temperature fault indicative of an inoperable heater system or insufficient heat generation. For instance, a fault condition may include ignition failure after commanding heat generation at the heater system, or an electrical failure inhibiting generation of heat, or a communications failure preventing transmission of signals to command heat generation, or a timer or sensor failure, or other failure mode relative to operation of the dryer appliance.

In various embodiments, determining the fault condition at the dryer appliance includes determining an operational state at a heater system (e.g., operational component). Determining the operational state at the heater system may include determining a temperature (e.g., a downstream temperature, an ignition or light-off temperature, a delta temperature over a period of time or between an ambient and light-off condition, etc.) after commanding heat generation at the heater system. Determining the operational state at the heater system may include determining an ignition status after commanding heat generation at the heater system.

Methodincludes attransmitting a communications signal corresponding to the fault condition to the washer appliance. For instance, dryer appliance, in interconnected communicative coupling with the washer appliance, can transmit the communications signal from the second controllerto the first controller. As such, the fault condition at the dryer appliance is communicated to the washer appliance.

Methodincludes atadjusting, at the washer appliance, a washer mode based on the communications signal. The washer mode can include any one or more wash cycles or settings, including, but not limited to, agitation speed, spin cycle speed, water level (e.g., height or pressure or other quantity of water), a detergent amount, or combinations thereof. Adjusting the washer mode can include adjusting a period of time or duration of any one or more of wash cycles or settings. In various embodiments, adjusting the washer mode based on the communications signal may include adjusting an operational component (e.g., operational component), such as a period of time of a spin cycle, limiting a load size at the washer appliance, or limiting a wash cycle type at the washer appliance.

Adjusting the washer mode after receiving the communications signal corresponding to the fault condition at the dryer can limit operations, modes, or cycles at the washer appliance to commensurate to the capability of the dryer appliance with the fault condition. For instance, adjusting the washer mode can limit operation of the washer, or user-selectable options, to a delicate cycle, a small-load or medium-load cycle, etc. The limited load size or washer mode may correspond to an available capability of dryer appliance with the fault condition. In another instance, adjusting the washer mode may increase a spin cycle duration to facilitate a decreased moisture extraction capability of the dryer appliance with the fault condition.

In various embodiments, methodincludes atadjusting, at the dryer appliance, a dryer mode based on transmitting the communications signal to the washer appliance. Adjusting the dryer mode may include adjusting a period of time of a tumble cycle at the dryer appliance. For instance, methodmay send the communications signal to the washer appliance indicating a fault condition at the dryer appliance. The washer mode is adjusted commensurate with the limited operating state at the dryer appliance. Additionally, methodatmay adjust the dryer mode to facilitate operation based on the fault condition and the adjusted washer mode. For instance, methodmay decrease the load size at the washer appliance or increase the spin cycle, and the decreased load or increased moisture extraction at the washer appliance may be sufficient for the dryer mode (e.g., in the decreased operating condition commensurate with the fault condition) to dry the laundry articles.

In still various embodiments, the adjusted washer mode may include disabling one or more washer modes, such as to inhibit a user from using the washer appliance while the dryer appliance is unable to dry the load. Such inhibiting may mitigate having clothes that may reside too long in the washer appliance (e.g., resulting in mildew or other undesired condition) due to the unavailability of the dryer appliance.

Embodiments of the appliances,and methodmay include a obtaining and transmitting a user override signal or obtaining and transmitting a fault-clear signal permitting full operation of the washer appliance or dryer appliance.

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.