Note: Descriptions are shown in the official language in which they were submitted.
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Description
Title of Invention: BALANCER BALANCER HOUSING,9
WASHING MACHINE HAVING THE SAME AND CONTROL
METHOD THEREOF
Technical Field
[1] Embodiments of the present disclosure relate to a balancer having a
balancer housing
capable of supplying electric power to a balancing module to counterbalance an
un-
balanced load, a washing machine and a control method thereof to diagnose a
mal-
function of the balancer.
Background Art
[2] A washing machine is an appliance that washes laundry using electric
power. In
general, a washing machine comprises a tub to store wash water, a rotary drum
rotatably mounted in the tub, and a motor to rotate the rotary drum.
1131 The washing machine performs a series of processes such as washing,
rinsing and de-
hydration process using rotational movement of the rotary drum.
[4] When the rotary drum rotates, if laundry is not evenly distributed in
the rotary drum
but accumulates at one side of the rotary drum, vibration and noise may occur
due to
eccentric rotation of the rotary drum, and components such as the rotary drum,
the
motor or the like may be damaged.
Disclosure of Invention
Technical Problem
1151 Accordingly, the washing machine is equipped with a balancer in order
to stabilize
rotation of the rotary drum by counterbalancing an unbalanced load generated
in the
rotary drum.
[6] Recently, a balancer capable of actively moving to a position
counterbalancing an
unbalanced load and a structure capable of transmitting external electric
power to such
a movable balancer have been developed.
Solution to Problem
1171 It is an aspect of the present disclosure to provide a washing machine
equipped with
a balancer housing capable of transmitting electric power from an external
power
source to a balancing module.
1181 It is another aspect of the present disclosure to provide a washing
machine and a
control method thereof to diagnose a malfunction of a balancer.
1191 Additional aspects of the disclosure will be set forth in part in the
description which
follows and, in part, will be apparent from the description, or may be learned
by
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practice of the disclosure.
[10] In accordance with an aspect of the present disclosure, a washing
machine includes a
rotary drum, and at least one balancer configured to counterbalance an
unbalanced load
generated in the rotary drum. The at least one balancer includes at least one
balancer
housing mounted to the rotary drum, and at least one balancing module having a
moving unit to move inside the balancer housing. The balancer housing includes
at
least one electrode provided at an inner surface of the balancer housing in a
circum-
ferential direction of the balancer housing in order to transmit electric
power to the
moving unit of the balancing module, at least one electric wire electrically
connected
to the electrode in order to apply electric power from an external power
source to the
electrode, and a connector provided at an outer surface of the balancer
housing in order
to electrically connect the electric wire and the electrode.
[11] The connector may include a socket protrudingly provided at the outer
surface of the
balancer housing, the socket being located at a position corresponding to a
position of
the electrode, and a plug unit configured to be coupled to the socket unit.
[12] The plug unit may include a wire terminal to fix an end portion of the
electric wire in
the plug unit.
[13] The socket unit may include a socket hole formed at a center portion
thereof, into
which the plug unit is inserted.
[14] The socket unit may further include an electrode terminal to
electrically connect the
wire terminal and the electrode.
[15] The connector may further include a protruding part provided at the
socket unit
provided outer surface of the balancer housing, the protruding part having a
shape cor-
responding to a shape of the plug unit.
[16] The protruding part and the plug unit may be coupled to each other by
ultrasonic
welding.
[17] The plug unit may include a waterproof recess which is depressed
inwardly at a
portion thereof.
[18] The waterproof recess may be filled with an epoxy resin to prevent
water from
passing through the plug unit.
[19] The electrode may be formed by coating a conductive film on the inner
surface of the
balancer housing.
[20] The washing machine may further include at least one lifter
protrudingly provided at
an inner circumferential surface of the rotary drum.
[21] The lifter may have an end portion which is in contact with the
balancer.
[22] The connector may pass through the end portion of the lifter.
[23] The electric wire may have an end portion connected to the connector,
and may pass
through the lifter.
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[24] In accordance with another aspect of the present disclosure, a washing
machine
includes a rotary drum in which laundry is placed, the rotary drum being
capable of
rotating by a driving source, at least one balancer housing mounted to the
rotary drum,
and at least one lifter mounted to an inner circumferential surface of the
rotary drum.
The balancer housing includes at least one electric wire electrically
connected to the
balancer housing, and a connector provided at an outer surface of the balancer
housing
in order to electrically connect the electric wire and the balancer housing.
The electric
wire passes through the lifter.
[25] The connector may pass through an end portion of the lifter, and may
be insertedly
disposed in the lifter.
[26] The washing machine may further include a flange disposed at the rear
portion of the
rotary drum and coupled to a driving shaft which enables the rotary drum to
rotate.
[27] The electric wire passing through the lifter may extend along the
flange.
[28] In accordance with a further aspect of the present disclosure, a
washing machine
includes a rotary drum in which laundry is placed, the rotary drum being
capable of
rotating by a driving source, a flange mounted to a rear surface of the rotary
drum and
coupled to a driving shaft which enables the rotary drum to rotate, and a
balancer
housing disposed at the rear portion of the flange. The balancer housing
includes at
least one electric wire electrically connected to the balancer housing, and a
connector
provided at an outer surface of the balancer housing in order to electrically
connect the
electric wire and the balancer housing. The electric wire may include one end
portion
connected to the connector, and the other end portion extending along the
flange and
passing through the driving shaft.
[29] The driving shaft may be formed in a hollow cylindrical shape, through
which the
electric wire passes.
[30] In accordance with a further aspect of the present disclosure, a
balancer mounted to a
rotary drum to counterbalance an unbalanced load generated in rotation of the
rotary
drum, includes at least one balancing module configured to move to a position
capable
of counterbalancing the unbalanced load of the rotary drum, and a balancer
housing
formed with a ring-shaped channel therein along which the balancing module
moves.
The balancer housing includes at least one electrode provided at an inner
surface of the
balancer housing in a circumferential direction of the balancer housing, and a
connector provided at an outer surface of the balancer housing in order to
electrically
connect an external power source and the electrode.
[31] The connector may include a socket unit protrudingly provided at the
outer surface of
the balancer housing, the socket unit being located corresponding to a
position of the
electrode, and a plug unit configured to be coupled to the socket unit.
11321 In accordance with a further aspect of the present disclosure, a
balancer housing of a
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balancer configured to counterbalance an unbalanced load generated in rotation
of a
rotary drum, includes at least one electrode provided at an inner surface of
the balancer
housing in a circumferential direction of the balancer housing in order to
supply
electric power to the balancer, a socket unit protrudingly provided at an
outer surface
of the balancer housing, and a plug unit configured to be coupled to the
socket unit in
order to apply external electric power to the electrode.
[33] The socket unit may include a socket hole formed at a center portion
thereof, into
which the plug unit is inserted.
[34] The plug unit may be inserted into the socket hole, and may be
electrically connected
to the electrode.
[35] In accordance with a further aspect of the present disclosure, a
washing machine
includes a rotary drum, a balancer to counterbalance an unbalanced load
generated in
the rotary drum, the balancer including at least one balancer housing mounted
to the
rotary drum, and a balancing module having a movement motor which enables the
balancing module to move inside the balancer housing, a power supply unit to
supply
electric power to the balancer, a detection unit to detect at least one signal
of electric
current and voltage of the electric power applied from the power supply unit
to the
balancer, and a control unit to determine whether the intensity of the
detected signal is
within a normal range and determine that the balancer malfunctions upon
determining
that the intensity of the detected signal is outside the normal range.
[36] The washing machine may further include a driving unit to drive the
movement
motor of the balancing module, and the control unit may stop driving of the
movement
motor upon determining that the balancer malfunctions.
[37] The balancer may further include a connector connected to an external
power source
to receive electric power from the external power source, at least two
electrodes
provided at the balancer housing to receive electric power from the connector,
the
electrodes having different polarities from each other, and at least two
brushes
provided at the balancing module and configured to be respectively in contact
with the
at least two electrodes to receive the electric power.
[38] The control unit may determine whether the detected voltage is within
a normal
range, and may determine whether there is poor contact between the connector
and the
electrodes or poor contact of at least one contact point between the
electrodes and the
brushes.
[39] The control unit may determine whether the detected electric current
is within a
normal range, and may determine whether there is poor contact between the
connector
and the electrodes or poor contact of at least one contact point between the
electrodes
and the brushes.
11401 The washing machine may further include a wash motor to apply
rotational force to
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the rotary drum, and an unbalance detection unit to detect the amount of
unbalance in
rotation of the wash motor. The control unit may control a position and a
speed of the
movement motor based on the detected amount of unbalance.
[41] The detection unit may include a speed detection unit to detect the
speed of the
movement motor, and the control unit may adjust the speed of the movement
motor
based on the detected speed.
[42] The power supply unit may include a slip ring in which electric
current generated by
rotation of the wash motor is induced.
[43] In accordance with a further aspect of the present disclosure, a
control method of a
washing machine includes if electric power is supplied to a balancer mounted
to a
rotary drum, detecting an electric signal of the electric power supplied to
the balancer,
determining whether the balancer malfunctions based on the detected electric
signal,
outputting a malfunction signal of the balancer upon determining that the
balancer mal-
functions, and stopping driving of a balancing module provided at the
balancer.
[44] The supplying the electric power to the balancer may include receiving
the electric
power from an external power source using a connector mounted to a balancer
housing, transmitting the electric power supplied to the connector to two
electrodes
having different polarities provided at the balancer housing, and receiving
the electric
power transmitted to the two electrodes through two brushes provided at the
balancing
module.
[45] The determining whether the balancer malfunctions based on the
detected electric
signal may include detecting voltage of a power supply unit, and determining
whether
there is poor contact between the connector and the electrodes or poor contact
of at
least one contact point between the electrodes and the brushes by comparing
the
detected voltage with reference voltage within a normal range.
[46] The determining whether the balancer malfunctions based on the
detected electric
signal may include detecting electric current of a power supply unit, and
determining
whether there is poor contact between the connector and the electrodes or poor
contact
of at least one contact point between the electrodes and the brushes by
comparing the
detected electric current with first reference electric current within a
normal range.
[47] The determining whether the balancer malfunctions based on the
detected electric
signal may further include determining whether there is a short between the
two
brushes by comparing the detected electric current with second reference
electric
current.
[48] The determining whether the balancer malfunctions based on the
detected electric
signal may further include determining whether a movement motor to move the
balancing module malfunctions by comparing the detected electric current with
third
reference electric current.
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Advantageous Effects of Invention
[49] As described above, electric power from an external power source may
be
transmitted to the balancing module by a simple method through the electrodes
of the
balancer housing.
[50] The balancer housing may have a structure capable of easily connecting
the electric
wires thereto and preventing wash water from passing through the balancer
housing.
[51] In addition, because a malfunction of the balancing module moving
inside an
enclosed space defined by the balancer housing and a malfunction of the power
supply
system of the balancer housing are diagnosed, a user may easily know
occurrence of a
malfunction of the balancer. Accordingly, a user may quickly address a
malfunction of
the balancer, thereby preventing other components from being negatively
influenced
and increasing product lifespan.
Brief Description of Drawings
[52] These and/or other aspects of the disclosure will become apparent and
more readily
appreciated from the following description of embodiments, taken in
conjunction with
the accompanying drawings of which:
[53] FIG. 1 is a view illustrating constitution of a washing machine
according to an em-
bodiment of the present disclosure;
[54] FIG. 2 is an exploded perspective view of a rotary drum of the washing
machine
depicted in FIG. 1;
[55] FIG. 3 is a perspective view of a flange of the washing machine
depicted in FIG. 1;
[56] FIG. 4 is a sectional view of the rotary drum to which electric wires
are mounted;
[57] FIG. 5 is an exploded perspective view of a balancer according to an
embodiment of
the present disclosure;
[58] FIG. 6 is a sectional view of a balancer housing of the balancer
according to an em-
bodiment of the present disclosure;
[59] FIGS. 7 and 8 are views illustrating the balancer housing and a
connector;
[60] FIG. 9 is a sectional view taken along line I-I in FIG. 8;
[61] FIG. 10 is a view illustrating the balancer housing and electrodes;
[62] FIG. 11 is a view illustrating a balancing module according to an
embodiment of the
present disclosure;
[63] FIG. 12 is a view illustrating the balancer housing and the balancing
module
according to an embodiment of the present disclosure;
[64] FIG. 13 is a view illustrating a moving unit depicted in FIG. 11;
[65] FIG. 14 is a view illustrating a bearing and the balancer housing
according to an em-
bodiment of the present disclosure;
11661 FIGS. 15 and 16 are views illustrating operation of the balancing
module in the
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balancer housing;
[67] FIG. 17 is a view illustrating a balancing module according to another
embodiment
of the present disclosure;
[68] FIG. 18 is a control block diagram of the washing machine according to
an em-
bodiment of the present disclosure; and
[69] FIGS. 19 through 21 are control flowcharts of the washing machine
according to an
embodiment of the present disclosure.
Best Mode for Carrying out the Invention
[70] Reference will now be made in detail to embodiments of the present
disclosure,
examples of which are illustrated in the accompanying drawings, wherein like
reference numerals refer to like elements throughout.
[71] FIG. 1 is a view illustrating constitution of a washing machine
according to an em-
bodiment of the present disclosure.
[72] As shown in FIG. 1, a washing machine 1 comprises a cabinet 10
defining an ap-
pearance of the washing machine, a tub 20 disposed in the cabinet 10, a rotary
drum 30
rotatably disposed in the tub 20, and a wash motor 40 to rotate the rotary
drum 30.
[73] In accordance with embodiments, the tub 20 may be formed integrally
with the
cabinet 10.
[74] The cabinet 10 is formed with a laundry entrance hole 11 at a front
portion thereof,
through which a user places laundry into the rotary drum 30. A door 12 is
provided at
the front portion of the cabinet 10 in order to open and close the laundry
entrance hole
11.
[75] A water supply pipe 50, through which wash water is supplied to the
tub 20, is
mounted above the tub 20. One end portion of the water supply pipe 50 is
connected to
an external water supply source (not shown), and the other end portion of the
water
supply pipe 50 is connected to a detergent supply device 52.
[76] The detergent supply device 52 is connected to the tub 20 by a
connection pipe 54.
The water supplied through the water supply pipe 50 flows into the tub 20
together
with a detergent via the detergent supply device 52.
[77] A drain pump 60 and a drain pipe 62 are mounted below the tub 20, in
order to
discharge the water in the tub 20 from the cabinet 10.
[78] The rotary drum 30 includes a cylindrical body 31, a front plate 32
provided at a
front portion of the cylindrical body 31, and a rear plate 33 provided at a
rear portion
of the cylindrical body 31. The front plate 32 is formed with an opening 32a
through
which laundry is placed or removed into/from the rotary drum 30.
[79] The rotary drum 30 is formed with a plurality of through-holes 34 for
wash water cir-
culation on a peripheral surface thereof. The rotary drum 30 is also provided
with a
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plurality of lifters 35 on an inner circumferential surface thereof, in order
to lift
laundry when the rotary drum 30 rotates.
[80] A driving shaft 42 is mounted between the rotary drum 30 and the wash
motor 40.
One end portion of the driving shaft 42 is connected to the rear plate 33 of
the rotary
drum 30, and the other end portion of the driving shaft 42 extends outside a
rear wall
of the tub 20. If the wash motor 40 drives the driving shaft 42, the rotary
drum 30
connected to the driving shaft 42 rotates about the driving shaft 42.
[81] A bearing housing 70 is mounted to the rear wall of the tub 20, in
order to rotatably
support the driving shaft 42. The bearing housing 70 may be made of aluminum
alloy,
and may be inserted into the rear wall of the tub 20 in an injection molding
process of
the tub 20. Bearings 72 are disposed between the bearing housing 70 and the
driving
shaft 42 so that the driving shaft 42 may smoothly rotate.
[82] In a washing process, the wash motor 40 rotates the rotary drum 30 at
a relatively
low speed in an alternating forward and reverse direction. Laundry in the
rotary drum
30 repeatedly may move up and down, thereby removing contaminants from the
laundry.
[83] In a dehydration process, the wash motor 40 rotates the rotary drum 30
at a relatively
high speed in one direction. Accordingly, water is separated from the laundry
by cen-
trifugal force exerted thereon.
[84] When the rotary drum 30 rotates during the dehydration process, if the
laundry is not
evenly distributed in the rotary drum 30 but accumulates at one side of the
rotary drum
30, rotation of the rotary drum 30 may become unstable and vibration and noise
may
occur.
[85] In order to accomplish stable rotation of the rotary drum 30, the
washing machine 1
includes at least one balancer 100 (100a and 100b) and a power supply unit to
supply
driving power to the balancer. The power supply unit may be configured as a
slip ring,
an electric generator or a switched mode power supply (SMPS), for example.
[86] Hereinafter, an exemplary embodiment of using a slip ring as the power
supply unit
will be explained.
[87] The wash motor 40 includes a ring-shaped stator, a rotor 40a rotatably
disposed
around the stator, a driving shaft, one end portion of which is connected to
the rotor
40a to rotate together with the rotor 40a, and a slip ring 80 disposed at the
rear portion
of the rotor 40a. The rotor 40a is configured to rotate by electromagnetic
interaction
with the stator. The driving shaft is formed in a cylindrical shape with a
hollow
portion, through which an electric wire may pass. The slip ring 80 receives
electric
current generated by rotation of the rotor 40a.
[88] The slip ring 80, which is coupled to a rear surface of the rotor 40a
of the wash motor
40, includes a body 81 fixed to the rotor 40a, and a rotating member 82
rotatably
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disposed in the body 81. The rotating member 82 is connected with an electric
wire
122 extending through the driving shaft 42.
[89] The slip ring 80 receives electricity generated by rotation of the
rotor 40a, and
supplies the same to the balancer 100 through the electric wire 122.
[90] An exemplary embodiment of using an electric generator as the power
supply unit
will now be briefly explained.
[91] The washing machine may include an electric generator mounted to the
rotor of the
wash motor.
[92] If electric current flows through a stator coil of the wash motor, a
magnetic field is
generated. The rotor may rotate by the magnetic field generated from the
stator coil
and a magnetic field of a rotor magnet.
[93] In relative relation between the magnet of the generator and the coil
of the generator,
if the rotor rotates, the magnetic flux applied to the coil from the magnet
changes, and
electric current flows through the coil of the generator.
[94] According to such an operational principle, the rotor rotates, and
electricity is
generated from the coil of the electric generator.
[95] That is, rotation of the driving shaft drives the electric generator
coupled to the rotor
of the wash motor, thereby generating electricity through the electric
generator.
[96] FIG. 2 is an exploded perspective view of the rotary drum of the
washing machine
depicted in FIG. 1, FIG. 3 is a perspective view of a flange, and FIG. 4 is a
sectional
view of the rotary drum.
[97] As shown in FIG. 2, the rotary drum 30 includes a cylindrical body 31,
a front plate
32 provided at a front portion of the cylindrical body 31, and a rear plate 33
provided
at a rear portion of the cylindrical body 31. The front plate 32 is formed
with an
opening 32a through which laundry is placed in or removed from the rotary drum
30.
[98] The front plate 32 has a forwardly protruding stepped portion. A
balancer is mounted
to the stepped portion of the front plate 32.
[99] The rear plate 33 is coupled to the rear portion of the cylindrical
body 31 to cover the
same. A flange 36 is mounted to a rear surface of the rear plate 33.
[100] The cylindrical body 31 of the rotary drum 30 is formed with plural
through-holes
34, through which the inside and the outside of the rotary drum 30 communicate
with
each other. A plurality of lifters 35 are mounted to an inner circumferential
surface of
the cylindrical body 31 of the rotary drum 30.
[101] The driving shaft 42 is coupled to a center portion of the flange 36.
A balancer is
mounted to a rear surface of the flange 36.
[102] The balancer mounted to the front plate 32 is called a front balancer
100a, and the
balancer mounted to the rear surface of the flange 36 is called a rear
balancer 100b.
Although as a non-limiting example, two balancers are shown in FIG. 2A, the
present
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disclosure is not limited thereto. The washing machine may include at least
one
balancer.
[103] The flange 36 is provided with a guide part 37 through which the
electric wire 122
passes.
[104] As shown in FIG. 3, the guide part 37 defines a receiving space in
the flange 36, and
the receiving space of the guide part 37 communicates with the hollow portion
of the
driving shaft 42. Accordingly, the electric wire 122 received in the hollow
portion of
the driving shaft 42 may pass through the receiving space of the guide part
37.
[105] That is, the guide part 37 extends from the driving shaft 42, and
guides the electric
wire 122 from the outside of the tub 20 to the inside of the tub 20 through
the driving
shaft 42.
[106] The guide part 37 is sealed from the outside. Alternatively, the
guide part with an
enclosed structure may be provided outside the flange.
[107] The electric wire 122 passes through the hollow portion of the
driving shaft 42 and
the receiving space of the guide part 37 of the flange 36, and serves to
transmit
external electric power to the front balancer 100a and the rear balancer 100b.
[108] In detail, as shown in FIG. 4, a part of the electric wire 122
passing through the
receiving space of the guide part 37 extends to a connector 120 of the rear
balancer
100b, and is electrically and mechanically connected to the same. The other
part of the
electric wire 122 extends to a connector 120 of the front balancer 100a
through the
lifter 35, and is electrically and mechanically connected to the same.
[109] An insertion part 35a is formed inside the lifter 35, into which the
electric wire 122 is
inserted. The electric wire 122 inserted into the insertion part 35a extends
to the front
balancer 100a positioned in front of the rotary drum from the rear portion of
the rotary
drum.
[110] The flange, the front balancer and the rear balancer are fixed to the
cylindrical body
of the rotary drum. Because the cylindrical body of the rotary drum, the
flange, the
front balancer, the rear balancer and the electric wire rotate integrally by
rotation of the
wash motor 40, the electric wire is prevented from being twisted.
[111] FIG. 5 is an exploded perspective view of the balancer according to
an embodiment
of the present disclosure, and FIG. 6 is a sectional view of a balancer
housing of the
balancer according to an embodiment of the present disclosure. The front
balancer
100a and the rear balancer 100b have the same structure.
[112] As shown in FIG. 5, the balancer 100 (100a and 100b) includes a
balancer housing
110 and balancing modules 200a and 200b provided inside the balancer housing
110.
[113] In this embodiment, as a non-limiting example, two balancing modules
200a and
200b are provided at each balancer 100. However, the number of balancing
modules
may be less or greater than two.
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[114] The balancer housing 110 includes a first housing 115 formed in a
ring shape with an
opening, and a second housing 116 covering the opening of the first housing
115. The
first housing 115 and the second housing 116 may be welded to each other, and
define
an enclosed internal space 119 therebetween. However, the present disclosure
is not
limited thereto. For example, other methods of securing the first housing 115
to the
second housing 116 may be used such as mounting with fastening members. The
structure of the balancer housing will now be explained with reference to FIG.
6.
[115] The first housing 115 includes a first wall 115a, a second wall 115b
opposing the
first wall 115a, and a third wall 115c connecting end portions of the first
and second
walls 115a and 115b, thereby having a about 90'rotated U-shaped section. The
second
housing 116 has inner and outer rims which are bent toward the first housing
115. The
inner and outer rims of the second housing 116 are thermally welded to inner
and outer
rims 115d of the first housing 115. However, the present disclosure is not
limited
thereto. For example, other methods of securing the inner and outer rims of
the first
and second housing may be used such as mounting with fastening members.
[116] For thermal welding, the inner and outer rims 115d of the first
housing 115 protrude
outwardly from the first and second walls 115a and 115b of the first housing
115, and
the second housing 116 has a size to cover the rims 115d of the first housing
115.
[117] Electrodes 111 and 112 are provided at an inner surface of the second
housing 116 in
order to transmit electric power from an external power source to the
balancing
modules 200a and 200b. The electrodes 111 and 112 may be formed by coating a
conductive film on the inner surface of the balancer housing. The electrodes
111 and
112 have different polarities. That is, one of the electrodes 111 and 112 is a
positive
electrode and the other is a negative electrode.
[118] The electrodes 111 and 112 are provided along the circumference of
the ring-shaped
second housing 116. Therefore, although the balancing modules 200a and 200b
move
and the positions thereof are changed in the balancer housing 110, the
electrodes 111
and 112 may continuously transmit electric power to the balancing modules 200a
and
200b.
[119] In an embodiment, the electrodes 111 and 112 are positioned at the
second housing
116. However, the electrodes may be positioned at any other portion of the
balancer
housing 110.
[120] In the case that both the front balancer 100a and the rear balancer
100b are coupled
to the cylindrical body 31 interposed therebetween, the second housing of the
front
balancer 100a and the second housing of the rear balancer 100b oppose each
other
while interposing the cylindrical body 31 therebetween, and the first housing
of the
front balancer 100a and the first housing of the rear balancer 100b are
directed
outward.
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[121] A connector 120 is provided at an outer surface of the second housing
116 of the
balancer housing 110, in order to electrically connect the electrodes 111 and
112 to an
external power source (not shown).
[122] The connector 120 of the front balancer 100a is directed toward the
lifter 35 of the
cylindrical body 31 and the flange 36, and the connector 120 of the rear
balancer 100b
is directed toward the flange 36.
[123] That is, the connector of the front balancer 100a is disposed
adjacent to the lifter 35
accommodating the electric wire 122 therein, and the connector of the rear
balancer
100b is disposed adjacent to the guide part 37 of the flange 36.
[124] Because the connectors of the front and rear balancers 100a and 100b
are directed
toward the flange 36, connection with the electric wire 122 passing through
the guide
part 37 of the flange 36 may be facilitated.
[125] FIGS. 7 and 8 are views illustrating the balancer housing and the
connector, and FIG.
9 is a sectional view taken along line I-I in FIG. 8.
[126] As shown in FIGS. 7 through 9, the connector 120 is disposed at the
outer surface of
the second housing 116 of the balancer housing 110. The connector 120 includes
a
plug unit 120a and a socket unit 120b.
[127] The plug unit 120a includes a plug body 121 and electric wires 122
(122a and 122b)
provided in the plug body 121.
[128] The plug unit 120a serves to support the electric wires 122a and 122b
electrically
connecting an external power source (not shown) and the balancer housing 110,
so as
to easily connect the electric wires 122a and 122b to the balancer housing
110.
[129] The socket unit 120b is coupled to the balancer housing 110 and
engaged with the
plug unit 120a, thereby connecting the balancer housing 110 and the plug unit
120a.
[130] The plug unit 120a is provided with wire terminals 123 (123a and
123b) inserted
therein, to which the electric wires 122a and 122b are connected. The wire
terminals
123a and 123b serve to support the flexible electric wires 122a and 122b to be
easily
inserted into the socket unit 120b.
[131] The wire terminals 123a and 123b may protrude from the plug unit
120a. As
described above, because the electrodes 111 and 112 have two different
polarities, i.e.,
positive polarity and negative polarity, and the number of electric wires 122a
and 122b
connected to the electrodes 111 and 112 is two, the number of wire terminals
123a and
123b is also two.
[132] The socket unit 120b may protrude from the outer surface of the
second housing 116
of the balancer housing 110. The socket unit 120b may be positioned at any
other
portion of the balancer housing 110.
[133] The socket unit 120b includes a socket body 126. Socket holes 127
(127a and 127b)
are formed in the socket body 126, into which the wire terminals 123a and 123b
are
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inserted. That is, the socket unit 120b may have a hollow shape as a whole.
The
number of socket holes 127a and 127b is also two. One of the socket holes 127a
and
127b has positive polarity and the other has negative polarity.
[134] Electrode terminals 124 (124a and 124b) are provided in the socket
holes 127a and
127b. The electrode terminals 124a and 124b electrically connect the
electrodes 111
and 112 and the wire terminals 123a and 123b. The electric wires 122a and 122b
may
be connected to the electrodes 111 and 112 corresponding to the respective
polarities
by the electrode terminals 124a and 124b.
[135] The socket unit 120b further includes a protruding part 128
surrounding the socket
body 126. The protruding part 128 protrudes from the outer surface of the
second
housing 116 of the balancer housing 110. The protruding part 128 may have the
same
size as the peripheral surface of the plug unit 120a. Accordingly, when the
plug unit
120a is engaged with the socket unit 120b, the peripheral surface of the
protruding part
128 and the peripheral surface of the plug unit 120a may be smoothly
connected.
[136] An assembly method of the connector 120 includes the processes of
connecting the
wire terminals 123a and 123b to end portions of the electric wires 122a and
122b,
mounting the electric wires 122a and 122b with the wire terminals 123a and
123b to
the plug unit 120a, and engaging the plug unit 120a with the socket unit 120b.
As a
result, the electric wires 122a and 122b and the electrodes 111 and 112 may be
elec-
trically connected.
[137] Because the balancer housing 110 is accommodated in the tub 20, the
outer surface
of the balancer housing 110 may constantly contact wash water. Therefore, the
connector 120 with the electrical structure is required to have a waterproof
structure.
[138] The plug unit 120a is formed with a waterproof recess 125 which is
depressed
inwardly at a portion thereof. The waterproof recess 125 is positioned at a
portion of
the plug unit 120a opposite to the portion engaged with the socket unit 120b.
[139] The electric wires 122a and 122b with the wire terminals 123a and
123b are inserted
and fixed into the waterproof recess 125. The waterproof recess 125 is filled
with an
epoxy resin so as to achieve waterproof effects of the plug unit 120a.
[140] The engaged portion between the protruding part 128 of the socket
unit 120b and the
plug unit 120a is also required to have a waterproof structure. Any suitable
en-
gagement method achieving waterproof effects may be adopted to engage the
protruding part 128 of the socket unit 120b and the plug unit 120a. In an
embodiment,
as a non-limiting example, the protruding part 128 of the socket unit 120b and
the plug
unit 120a are not only engaged but also achieve waterproof effects through
ultrasonic
welding.
[141] Any suitable waterproof structure and method other than the epoxy
resin-filling
method and the ultrasonic welding method may be included in the principles and
spirit
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of the present disclosure.
[142] FIG. 10 is a view illustrating the balancer housing and the
electrodes.
[143] As shown in FIG. 10, when a width of the electrodes 111 and 112 may
be different
from a width of the connector, a portion of the electrodes 111 and 112 may
protrude so
as to contact the electrode terminals 124a and 124b.
[144] FIG. 11 is a view illustrating the balancing module according to an
embodiment of
the present disclosure, and FIG. 12 is a view illustrating the balancer
housing and the
balancing module according to an embodiment of the present disclosure.
[145] Hereinafter, the balancing module disposed in a ring-shaped channel
119 (refer to
FIG. 9) formed in the balancer housing 110 (refer to FIG. 3) will be
explained.
[146] As shown in FIGS. 11 and 12, the balancing module 200 includes a main
plate 210
defining a basic shape of the balancing module 200.
[147] The main plate 210 includes a middle plate 211 and side plates 212
and 213 disposed
at both sides of the middle plate 211. The side plates 212 and 213 incline
with respect
to the middle plate 211 at a certain angle. Accordingly, the balancing module
200 may
easily move along the ring-shaped channel 119.
[148] The side plates 212 and 213 are respectively provided with
counterweights 270. The
counterweights 270 serve to counterbalance the unbalanced load occurring when
laundry accumulates at one side of the rotary drum 30, thereby balancing
rotation of
the rotary drum 30.
[149] One of the counterweights 270 is mounted with a control module 230 at
a front
surface thereof. The control module 230 includes components to enable a moving
unit
220 to operate.
[150] The other of the counterweights 270 is mounted with a position
detecting part 260.
The position detecting part 260 may be configured as a magnetic body including
a
permanent magnet, a light emitting element or a reflective plate to reflect
light radiated
thereto.
[151] A position sensor 23 may be mounted to the tub 20 at a position
corresponding to the
balancer housing 110. The position sensor 23 detects the position of the
balancing
module 200. The position sensor 23 may be configured as a hall sensor, an
infrared
sensor or an optical fiber sensor, for example.
[152] When the position sensor is a hall sensor, the position detecting
part may be a
magnetic body. When the position sensor is an infrared sensor, the position
detecting
part may be a light emitting element. When the position sensor is an optical
fiber
sensor, the position detecting part may be a reflective plate.
[153] Bearings 250 are respectively coupled to end portions of the side
plates 212 and 213.
The Bearings 250 serve to prevent the balancing module 200 from colliding with
the
inner surface of the balancer housing 110. In addition, the bearings 250 serve
to restrict
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free movement of the balancing module 200 to a certain extent, so that the
balancing
module 200 may be fixed at the accurate position capable of counterbalancing
the un-
balanced load. This will be explained later with reference to FIG. 14.
[154] A moving unit 220 is mounted to the middle plate 211. The moving unit
220 includes
at least one wheel 222 which enables the balancing module 200 to move, and a
movement motor 221 to rotate the wheel 222. This will be explained later with
reference to FIG. 13.
[155] Brushes 240 (241 and 242) may be provided at the rear portion of the
moving unit
220. The brushes 241 and 242 are in contact with the electrodes 111 and 112 of
the
balancer housing 110 and are electrically connected to the electrodes 111 and
112.
Even when the balancing module 200 moves, the brushes 241 and 242 keep contact
with the electrodes 111 and 112, thereby constantly supplying electric power
to the
balancing module 200, especially, to the moving unit 220.
[156] Corresponding to two positive and negative electrodes 111 and 112,
the number of
brushes 241 and 242 may also be two. Two brushes 241 and 242 may be arranged
so
as to respectively contact the electrodes 111 and 112.
[157] Because the brushes 241 and 242 are in contact with the electrodes
111 and 112 in
the rotary drum 30 which vibrates while rotating, the brushes 241 and 242 may
be
damaged. In order to prevent such damage, internal end portions of the brushes
241
and 242 may be supported by elastic members.
[158] FIG. 13 is a view illustrating the moving unit depicted in FIG. 11.
[159] As shown in FIG. 13, the moving unit 220 includes at least one wheel
222 which
enables the balancing module 200 to move, and a movement motor 221 to rotate
the
wheel 222.
[160] Gears 224 and 226 are provided between the movement motor 221 and the
wheel
222, in order to transmit driving force from the movement motor 221 to the
wheel 222.
[161] In this embodiment, because a driving shaft 223 of the movement motor
221 and a
rotation shaft 225 of the wheel 222 are perpendicular to each other, the gears
include a
first gear 224 and a second gear 226 which are configured as a worm gear.
[162] The first gear 224 is formed at the driving shaft 223 of the movement
motor 221, and
the second gear 226 is engaged with the first gear 224 to rotate with the
same. The
rotation shaft 225 is coupled through a center portion of the second gear 226,
and a
plurality of wheels 222 are mounted to both end portions of the rotation shaft
225. A
wheel cap 227 secures each wheel 222 to the rotation shaft 225.
[163] The first and second gears 224 and 226 may be configured as a helical
gear which is
a cylindrical shaped gear with helicoid teeth.
[164] The first and second gears 224 and 226, which are configured as a
worm gear or a
helical gear, may restrict rotation of the wheels 222 when the movement motor
221 is
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inactivated. Accordingly, when electric power is not supplied from an external
power
source (not shown), the balancing module 200 may not move, but may be fixed at
a
final position.
[165] FIG. 14 is a view illustrating the bearing and the balancer housing
according to an
embodiment of the present disclosure.
[166] As shown in FIG. 14, the bearing 250 is formed to contact the inner
surface of the
balancer housing 110. The bearing 250 in an embodiment is configured as a
friction
bearing. While contacting the inner surface of the balancer housing 110, the
bearing
250 serves to restrict movement of the balancing module 200 to a certain
extent and
also prevent the balancing module 200 from colliding with the inner surface of
the
balancer housing 110.
[167] The bearing 250 includes convex portions 251 which come into contact
with the
inner surface of the balancer housing 110, and concave portions 252 which are
depressed from the convex portions 251. That is, the bearing 250 has a wavy
surface.
[168] Foreign materials present in the balancer housing 110 may pass
through the concave
portions 252, thereby preventing the foreign materials from gathering at the
concave
portions 252 and blocking movement of the balancing module 200.
[169] In addition, by adjusting a size of the convex portions 251, the
balancing module 200
may be prevented from colliding with the inner surface of the balancer housing
110,
and the brushes 241 and 242 may contact the electrodes 111 and 112 while an
adequate
distance is maintained between the balancing module 200 and the inner surface
of the
balancer housing 110.
[170] FIGS. 15 and 16 are views illustrating operation of the balancing
module in the
balancer housing.
[171] FIG. 15 illustrates an operational state of the balancing module 200
when the rotary
drum 30 rotates at a relatively low speed or is in a stationary state.
[172] As shown in FIG. 15, the main plate 210 of the balancing module 200
maintains an
initial state thereof. Therefore, the middle plate 211 and the side plates 212
and 213
maintain a certain intial angle 01 therebetween.
[173] The bearings 250 mounted to the end portions of the side plates 212
and 213 contact
a first inner surface 113 of the balancer housing 110, which is positioned
inwardly in a
radial direction of the balancer housing 110. The wheels 222 contact a second
inner
surface 114 of the balancer housing 110, which is positioned outwardly in the
radial
direction of the balancer housing 110. That is, the contact regions between
the
balancing module 200 and the balancer housing 110 include the contact regions
between the bearings 250 and the first inner surface 113 and the contact
regions
between the wheels 222 and the second inner surface 114. The wheels 222 are
pressurized toward the second inner surface 114 of the balancer housing 110.
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[174] FIG. 16 illustrates an operational state of the balancing module 200
when the rotary
drum 30 rotates at a relatively high speed.
[175] As shown in FIG. 16, by centrifugal force, an angle 02 between the
middle plate 211
and the side plates 212 and 213 becomes larger than the angle Olin the
stationary state
of the rotary drum 30. That is, the side plates 212 and 213 further spread
outwardly in
the radial direction of the balancer housing 110.
[176] As the side plates 212 and 213 spread out, both the bearings 250 and
the wheels 222
come into contact with the second inner surface 114 of the balancer housing
110.
[177] Accordingly, the pressure applied to the wheels 222 decreases, and
the wheels 222
may rotate more freely, which enables the balancing module 200 to easily move
to a
desired position. That is, because the balancing module 200 moves more freely
in the
high speed rotating state of the rotary drum 30, the balancing module 200 may
move to
a position capable of more rapidly counterbalancing the unbalanced load of the
rotary
drum 30.
[178] FIG. 17 is a view illustrating a balancing module according to
another embodiment
of the present disclosure.
[179] As shown in FIG. 17, a balancing module 300 according to another
embodiment of
the present disclosure includes a main plate 310 defining a basic shape of the
balancing
module 300.
[180] The main plate 310 is provided with counterweights (not shown) and a
moving unit
320.
[181] The moving unit 320 includes at least one wheel 322 which enables the
balancing
module 300 to move, and a movement motor 321 to rotate the wheel 322.
[182] Bearings 350 are mounted to both end portions of the main plate 310.
In an em-
bodiment, the bearings 350 are configured as a ball bearing. Accordingly, the
balancing module 300 may easily move inside the balancer housing 110 by the
bearings 350.
[183] FIG. 18 is a control block diagram of the washing machine having the
balancer. The
washing machine includes a control module 230 to diagnose a malfunction of the
balancer 100.
[184] A main control module 90 controls the processes of supplying water,
draining,
washing, rinsing, dehydrating and the like, based on an operation command
input by a
user.
[185] In the dehydration process, the main control module 90 controls
rotation of the wash
motor 40 and simultaneously checks the amount of unbalance. The main control
module 90 controls rotation of the wash motor 40 based on the checked amount
of
unbalance, or transmits the checked amount of unbalance to the control module
230 of
the balancer.
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[186] The main control module 90 includes an unbalance detection unit 91, a
control unit
92, a driving unit 93, a communication unit 94 and a display unit 95.
[187] The unbalance detection unit 91 detects the amount of unbalance
occurring by
laundry unevenly distributed in the rotary drum. Here, the amount of unbalance
includes unbalanced force exerted on the rotary drum.
[188] The control unit 92 compares the amount of unbalance detected by the
unbalance
detection unit 91 with the reference amount of unbalance. If the detected
amount of
unbalance is less than or equal to the reference amount of unbalance, the
control unit
92 controls the wash motor 40 to accelerate. If the detected amount of
unbalance
exceeds the reference amount of unbalance, the control unit 92 transmits the
checked
amount of unbalance to the control module 230 of the balancer in order to
control the
balance of the rotary drum.
[189] If a balancer malfunction signal from the control module 230 of the
balancer is
transmitted to the control unit 92, the control unit 92 controls the display
unit 95 to
display the malfunction signal.
[190] The driving unit 93 rotates the wash motor 40 in forward and reverse
directions
based on the command of the control unit 92.
[191] The communication unit 94 transmits the detected amount of unbalance
to the control
module 230 of the balancer based on the command of the control unit 92. In
addition,
if a balancer malfunction signal from the control module 230 of the balancer
is
transmitted, the communication unit 94 transmits the balancer malfunction
signal to the
control unit 92.
[192] The display unit 95 displays a malfunction of the balancer 100 using
error codes cor-
responding to the balancer malfunction signals. The error codes respectively
rep-
resenting the balancer malfunction signals are previously set and stored.
[193] The control module 230 of the balancer receives the detected amount
of unbalance
from the main control module 90 for operation control of the washing machine,
and
controls rotation of the movement motor 221 based on the detected amount of
unbalance.
[194] The control module 230 diagnoses a malfunction of the balancer 100
based on an
electric signal of electric power supplied from a power supply unit 80. If it
is de-
termined that the balancer malfunctions based on diagnosis results, the
control module
230 transmits the balancer malfunction signal to the main control module 90.
[195] The power supply unit 80 may be configured as a slip ring, an
electric generator, a
wireless power transfer device, a battery or a switched mode power supply
(SMPS),
for example.
[196] The control module 230 includes a detection unit 231, a control unit
232, a storage
unit 233, a driving unit 234 and a communication unit 235.
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[197] The detection unit 231 detects an electric signal of power supplied
from the power
supply unit 80, and transmits the detected electric signal to the control unit
232. The
detection unit 231 includes at least one of a voltage detection unit 231a,
which detects
voltage between the electric wires 122a and 122b used as power supply lines,
and an
electric current detection unit 23 lb, which detects electric current flowing
through the
electric wires 122a and 122b used as the power supply lines.
[198] The voltage detection unit 231a and the electric current detection
unit 23 lb are elec-
trically connected to the power supply unit 80 through the wires 122a and
122b, and
accordingly receive electric power from the power supply unit 80.
[199] The detection unit 231 further includes a speed detection unit 231c
to detect a ro-
tational speed of the movement motor 221.
[200] The control unit 232 controls the position of the balancing module
based on the
detected amount of unbalance.
[201] In detail, the control unit 232 determines a target position of the
balancing module, at
which force capable of compensating for unbalanced force corresponding to the
detected amount of unbalance is generated, and controls rotation of the
movement
motor 221 so that the balancing module may move to the determined target
position.
[202] In the case that two balancing modules are provided, the control unit
232 calculates
resultant force of two balancing modules capable of compensating for the
unbalanced
force, determines target positions of two balancing modules, at which the
calculated
resultant force is generated, and respectively controls rotation of two
movement motors
221 of two balancing modules so that two balancing modules may respectively
move
to the determined target positions.
[203] That is, the control unit 232 controls the respective positions of
two balancing
modules so that the resultant force generated by two balancing modules may
compensate for the unbalanced force generated by laundry.
[204] The rotational speed of the movement motor 221 detected by the speed
detection unit
231c is fed back to the control unit 232, and the control unit 232 performs
speed ad-
justment of the movement motor 221 so that the balancing module may move to
the
target position.
[205] As described above, when unbalance of the rotary drum occurs, the
unbalanced load
generated in the rotary drum may be counterbalanced by moving the balancing
module
along the internal space of the balancer housing. As a result, vibration and
noise may
be reduced.
[206] The control unit 232 diagnoses a malfunction of the balancer 100
based on an electric
signal transmitted through the electric wires. If it is determined that the
balancer mal-
functions based on diagnosis results, the control unit 232 controls to stop
movement of
the balancer, and transmits the balancer malfunction signal to the main
control module
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90 through the communication unit 235.
[207] The control unit 232 compares the voltage detected by the detection
unit 231 with
reference voltage within a normal range, and diagnoses poor contact in the
power
supply lines.
[208] The control unit 232 compares electric current detected by the
detection unit 231
with first reference electric current within a normal range, and diagnoses
poor contact
in the power supply lines. The control unit 232 compares the electric current
detected
by the detection unit 231 with second reference electric current, and
diagnoses an
electric short between the brushes. The control unit 232 compares the electric
current
detected by the detection unit 231 with third reference electric current, and
diagnoses a
malfunction of the movement motor 221.
[209] The storage unit 233 stores the reference voltage within a normal
range to diagnose a
malfunction of the balancer.
[210] In addition, the storage unit 233 stores the first reference electric
current, the second
reference electric current and the third reference electric current to
diagnose a mal-
function of the balancer.
[211] Here, the first reference electric current is electric current within
a normal range to
determine poor contact in the power supply lines, the second reference
electric current
is electric current to determine an electric short between the brushes, and
the third
reference electric current is electric current to determine a malfunction of
the
movement motor 221. The intensity of the first reference electric current is
the lowest,
and the intensity of the third reference electric current is the highest.
[212] The storage unit 233 also stores the error codes respectively
representing the balancer
malfunction signals.
[213] The driving unit 234 rotates the movement motor 221 in forward and
reverse di-
rections or stops rotation of the movement motor 221 based on the command of
the
control unit 232.
[214] The communication unit 235 transmits the balancer malfunction signal
to the main
control module 90 or transmits the detected amount of unbalance from the main
control module 90 to the control unit 232 based on the command of the control
unit
232.
[215] FIGS. 19 through 21 are control flowcharts of the washing machine
having the
balancer.
[216] Based on an operation command input by a user through an input unit
(not shown),
the washing machine performs the processes of supplying water, detecting
laundry,
soaking laundry, draining, washing, rinsing, dehydrating and the like, and
simul-
taneously enables the display unit 95 to display the current operation state
and the
following operation state.
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[217] While performing the processes of detecting laundry, soaking laundry,
washing,
rinsing, dehydrating and the like, the washing machine rotates the wash motor
40 in
forward and reverse directions at a certain speed preset in accordance with
each
operation algorithm.
[218] Through rotation of the wash motor 40, electric power is generated
inside the
washing machine, which is different from the commercial power. The generated
electric power is supplied to at least one balancer 100 (100a and 100b)
through electric
wires 122 (122a and 122b).
[219] The washing machine includes a slip ring 80 as the power supply unit,
which induces
electric power according to rotor rotation of the wash motor 40.
[220] That is, when the wash motor 40 rotates, electric power is induced in
the slip ring 80.
The electric power induced in the slip ring 80 is transmitted to the rear
balancer 100b
through the electric wires 122 inserted into the hollow portion of the driving
shaft 42
and the guide part 37 of the flange. The electric power induced in the slip
ring 80 is
also transmitted to the front balancer 100a through the electric wires 122
inserted into
the hollow portion of the driving shaft 42, the guide part 37 of the flange
and the
insertion part 35a of the lifter. The electric wires 122 are connected to the
connector
120 mounted to the balancer housing 110, and the electric power induced in the
slip
ring 80 is transmitted to the connector 120 through the electric wires 122.
[221] The electric power transmitted to the connector 120 is transmitted to
the electrodes
111 and 112 which are electrically connected to the connector 120 and provided
in the
balancer housing 110. The electric power transmitted to the electrodes 111 and
112 is
transmitted to two brushes of the balancing module which are respectively in
contact
with the electrodes 111 and 112. The electric power transmitted to two brushes
is
transmitted to the control module 230 of the balancing module and the movement
motor 221.
[222] Through the above-described transmission path, the electric power
generated from
the slip ring disposed outside the tub may be supplied to the balancers 100
disposed
inside the tub.
[223] If the electric power is applied to each balancer 100 through the
connector 120
mounted to the balancer housing at operation 401, the control module 230 of
each
balancer 100 detects an electric signal of the power applied to the balancer
100 through
the detection unit 231 at operation 402, compares the detected electric signal
with the
reference electric signal within a normal range at operation 403, diagnoses a
mal-
function of the balancer 100 at operation 404, and outputs the malfunction
signal to
enable a user to be aware of the malfunction upon determining that the
balancer 100
malfunctions at operation 405.
112241 During the dehydration process in a normal state of the balancer
100, the unbalance
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of the rotary drum is controlled by controlling movement of the balancing
module
based on the amount of unbalance of the rotary drum.
[225] In detail, based on the unbalanced force of the rotary drum detected
by the unbalance
detection unit 91 in the dehydration process, the control module 230
calculates
resultant force of two balancing modules capable of compensating for the
detected un-
balanced force, determines target positions of two balancing modules, at which
the
calculated resultant force is generated, and respectively drives two movement
motors
221 of two balancing modules so that two balancing modules may respectively
move
to the determined target positions.
[226] When the movement motor 221 is driven, the control module 230 detects
a rotational
speed of the movement motor 221 through the speed detection unit 231c, and
adjusts
the rotational speed of the movement motor 221 using the detected speed.
[227] If the unbalanced load of the rotary drum is counterbalanced,
rotation of the wash
motor 40 is accelerated to a preset rotational speed for normal dehydration.
[228] The method of diagnosing a malfunction of the balancer 100 will be
explained in
more detail with reference to FIGS. 20 and 21.
[229] FIG. 20 is a flowchart of the balancer malfunction diagnosis method
based on
voltage applied to the balancer.
[230] As shown in FIG. 20, the control module 230 of the balancer detects
voltage applied
to the balancer through the voltage detection unit 231a at operation 411, and
compares
the detected voltage with reference voltage within a normal range to determine
whether
the detected voltage is less than the reference voltage at operation 412. If
the detected
voltage is equal to the reference voltage within a normal range, it is
determined that the
balancer is in a normal state.
[231] However, if the detected voltage is less than the reference voltage,
the control
module 230 of the balancer determines that there is poor contact in the power
supply
lines, stops driving of the balancer, and transmits a malfunction signal
having an error
code for poor contact in the power supply lines to the main control module 90.
[232] The poor contact in the power supply lines may include poor contact
between the
connector and the electrodes due to moisture, carbon dust of the brushes,
spring
tension, broken wires or the like, or poor contact of at least one contact
point between
the electrodes and the brushes.
[233] Because poor contact in the power supply lines causes a voltage drop,
whether there
is poor contact in the power supply lines may be determined by comparing the
detected
voltage with the reference voltage. Here, the reference voltage is defined as
voltage
necessary to drive the balancer.
[234] Upon receiving the malfunction signal from the control module 230 of
the balancer,
the main control module 90 outputs the poor contact in the power supply lines
by
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displaying the malfunction signal through the display unit 95 at operation
413.
[235] That is, the display unit 95 displays an error code corresponding to
the malfunction
signal of the balancer, thereby enabling a user to be aware of a malfunction
of the
balancer.
[236] FIG. 21 is a flowchart of the balancer malfunction diagnosis method
based on
electric current applied to the balancer.
[237] As shown in FIG. 21, the control module 230 of the balancer detects
electric current
applied to the balancer through the electric current detection unit 23 lb at
operation
421, and compares the detected electric current with the first reference
electric current
within a normal range to determine whether the detected electric current is
less than the
first reference electric current at operation 422.
[238] If the detected electric current is less than the first reference
electric current, the
control module 230 determines that there is poor contact in the power supply
lines, and
outputs the poor contact in the power supply lines at operation 423.
[239] That is, the control module 230 stops driving of the balancer, and
transmits a mal-
function signal having an error code for poor contact in the power supply
lines to the
main control module 90 in order to inform a user of the malfunction of the
balancer.
[240] Based on a control command of the main control module 90, the display
unit 95
displays a malfunction information related to poor contact in the power supply
lines,
thereby enabling a user to be aware of the same.
[241] The poor contact in the power supply lines may include poor contact
between the
connector and the electrodes due to moisture, carbon dust of the brushes,
spring
tension, broken wires or the like, or poor contact of at least one contact
point between
the electrodes and the brushes.
[242] If the detected electric current is greater than or equal to the
first reference electric
current, the control module 230 of the balancer compares the detected electric
current
with the second reference electric current, and the detected electric current
with the
third reference electric current at operation 424.
[243] If the detected electric current is less than the second reference
electric current, the
control module 230 determines that the balancer is in a normal state. However,
if the
detected electric current is greater than or equal to the second reference
electric current
and less than the third reference electric current, the control module 230
determines
that there is a short between two brushes, stops driving of the balancer, and
outputs the
malfunction of the balancer at operation 425. That is, the control module 230
transmits
a malfunction signal having an error code for a short between the brushes to
the main
control module 90 in order to inform a user of the malfunction of the
balancer.
[244] Based on a control command of the main control module 90, the display
unit 95
displays a malfunction information related to a short between the brushes,
thereby
CA 02875648 2016-07-14
24
enabling a user to be aware of the same.
[245] The control module 230 determines whether the detected electric
current is greater
than the third reference electric current at operation 426. If the detected
electric current
is greater than the third reference electric current, the control module 230
determines
that the movement motor malfunctions, stops driving of the balancer, and
outputs the
malfunction of the movement motor at operation 427. That is, the control
module 230
transmits a malfunction signal having an error code for malfunction of the
movement
motor to the main control module 90. Based on a control command of the main
control
module 90, the display unit 95 displays a malfunction information related to a
mal-
function of the movement motor, thereby enabling a user to be aware of the
same.
1246! Here, the malfunction of the movement motor may include restriction
in rotation,
failure to start the movement motor or the like.
[247] If poor contact between the connector and the electrodes or poor
contact between the
electrodes and the brushes occurs, a voltage drop is caused, and electric
current
decreases due to increase in contact resistance. Thus, the reference electric
current
necessary to drive the balancer becomes low.
[248] Accordingly, in order to determine whether there is poor contact in
the power supply
lines, the detected electric current is compared with the first reference
electric current.
[249] If a short between two brushes of the balancing module occurs, the
electric current
increases above the first reference electric current necessary to drive the
balancer. If
driving of the movement motor is not normally performed, abnormal current
greater
than the first reference electric current flows through the control module
230.
[250] Accordingly, in order to determine whether there is a short between
the brushes and
whether the movement motor malfunctions, the detected electric current is
compared
with the second reference electric current generated by occurrence of a short
between
the brushes and the third reference electric current generated by a
malfunction of the
movement motor.
[251] As such, a short between two brushes or a malfunctino of the movement
motor may
be diagnosed through the electric current applied to the balancer.
[252] Although the balancer malfunction diagnosis method based on either
voltage or
electric current has been described above with reference to FIGS. 17 and 18, a
balancer
malfunction diagnosis method based on both voltage and electric current
applied to the
balancer may also be accomplished.
[253] Although a few embodiments of the present disclosure have been shown
and
described, it would be appreciated by those skilled in the art that changes
may be made
in these embodiments without departing from the principles of the
disclosure, the scope of which is defined in the claims and their equivalents.
