Diagnostic tools and methods of servicing consumer appliances

A diagnostic tool and method of servicing a consumer appliance is provided herein. The diagnostic tool may include a casing and a controller. The casing may be spaced apart from the consumer appliance. The controller may be selectively connected to the consumer appliance. The controller may be configured to direct a service operation. Moreover, the service operation may include receiving non-functional character data from the consumer appliance at the diagnostic tool, assigning an appliance configuration manifest to the consumer appliance based on the received non-functional character data, determining a service action based on the appliance configuration manifest, and initiating the determined service action at the diagnostic tool.

FIELD OF THE INVENTION

The present subject matter relates generally to consumer appliances and, more particularly, to features and methods for servicing or diagnosing consumer appliances.

BACKGROUND OF THE INVENTION

Consumer appliances, such as refrigerator appliances, oven appliances, microwave appliances, dishwasher appliances, etc., generally include one or more components for directing operation of a given consumer appliance. For example, a consumer appliance may include a controller having a printed circuit board and memory that is connected to a control pad. Through programmed instructions and input from the control pad, the controller may work with the other components of the appliance to direct operations thereof.

In order to service multiple and varied consumer appliances, it is often important to uniquely identify each consumer appliance. Certain functions may be common to multiple different models, but different models may also have functions that are not common between them. In other words, there may be a number of variations between different consumer appliances of the same type (e.g., two or more refrigerator appliance models). Between different types of consumer appliances (e.g., a refrigerator appliance model and an oven appliance model), even more variations may exist. Over time, even identical models of a consumer appliance (e.g., appliances having the same model number) may have variations between them (e.g., different versions of software installed on the controller of each respective consumer appliance). Each of these variations may or may not influence how a service professional can interact with a given consumer appliance. In some circumstances, certain variations will change how the service professional can interact with the given appliance, while other variations will not. For instance, different interfaces or sets of service options from a diagnostic tool may be appropriate based on certain variations. A common interface or set of service options may be appropriate based on other variations.

Given the large and ever-changing pool of consumer appliances that a service professional may need to service, uniquely identifying each consumer appliance can be especially difficult. Existing systems typically rely on exhaustive databases of specific model identifiers (e.g., model numbers). Such databases can be cumbersome and difficult to maintain. Moreover, the databases may fail to account for changes to individual appliances that share a common model (e.g., updates or repairs that may be made to one consumer appliance of a certain model number, but not to another consumer appliance of the same model number).

Therefore, further improvements to methods and diagnostic tools for servicing consumer appliances are necessary. In particular, it would be advantageous to provide methods and tools that can uniquely identify an appliance, yet do not require reliance on, or determination of, a single preset model number.

BRIEF DESCRIPTION OF THE INVENTION

In one exemplary aspect of the present disclosure, a method of servicing a consumer appliance is provided. The method may include receiving non-functional character data from a control board of the consumer appliance at a diagnostic tool selectively connected to the control board. The method may also include assigning an appliance configuration manifest to the consumer appliance based on the received non-functional character data. The method may further include determining a service action based on the appliance configuration manifest. The method may still further include initiating the determined service action at the diagnostic tool.

In another exemplary aspect of the present disclosure, a diagnostic tool for a consumer appliance having a control board is provided. The diagnostic tool may include a casing and a controller. The casing may be spaced apart from the consumer appliance. The controller may be selectively connected to the control board of the consumer appliance and configured to direct a service operation. The service operation may include receiving non-functional character data from the control board of the consumer appliance at the diagnostic tool, assigning an appliance configuration manifest to the consumer appliance based on the received non-functional character data, determining a service action based on the appliance configuration manifest, and initiating the determined service action at the diagnostic tool.

DETAILED DESCRIPTION

It is noted that, for the purposes of the present disclosure, 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”). 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.

Turning now to the figures,FIGS. 1 and 2provide different schematic views of a servicing system100according to exemplary embodiments of the present disclosure. Generally, it is understood that such systems may be utilized to service (e.g., test, update, diagnose, debug, etc.) a consumer appliance102. In particular, a diagnostic tool104and a remote server106may be permitted to communicate with consumer appliance102in order to aid or facilitate one or more service operations, as will be described in detail below. Moreover, as shown, diagnostic tool104can be communicatively coupled with a network108and various nodes coupled with the network108, such as a remote server106. Additionally or alternatively, although network108is shown, diagnostic tool104may not be communicatively coupled via network108; rather, diagnostic tool104can be communicatively coupled via a suitable wired or wireless means not over network108, such as, for example, via physical wires, transceiving, transmitting, or receiving components. The communicative coupling may establish a constant or intermittent connection between diagnostic tool104and network108. For instance, if the connection is intermittent, diagnostic tool104may continue to operate “offline” such that data or information gathered during a break in the connection may be transmitted after the connection is reestablished.

It is noted that although consumer appliance102is shown as a refrigerator appliance, additional or alternative embodiments may provide a different consumer appliance (e.g., different type of appliance), such as an oven appliance, microwave appliance, dishwasher appliance, washing machine appliance, dryer appliance, or any other suitable consumer appliance.

As would be understood, consumer appliance102generally includes a cabinet120and one or more appliance components128(e.g., compressor, heating element, motor, air blower, etc.) attached thereto for performing the predetermined functions of the consumer appliance102(e.g., cooling, heating, etc.). Such appliance components128are assembled in communication with a corresponding appliance controller124that is, for example, mounted on or within cabinet120of consumer appliance102). Along with appliance components128, appliance controller124may be in communication with one or more sensors (e.g., temperature sensors, pressure sensors, accelerometers, gyroscopes, etc.) attached to or within cabinet120for detecting certain corresponding conditions (e.g., temperature, pressure, acceleration, rotation, etc.) of consumer appliance102and permitting appliance controller124to record one or more log sets of such conditions.

Appliance controller124generally includes one or more control boards [e.g., a first control board124A (Control Board A) and a second control board124B (Control Board B)]. Each control board124A and124B may include one or more processors and one or more memory devices (i.e., memory). The one or more processors can be any suitable processing device (e.g., a processor core, a microprocessor, an ASIC, a FPGA, a microcontroller, etc.) and can be one processor or a plurality of processors that are operatively connected. The memory device can include one or more non-transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and combinations thereof. The memory devices can store data and instructions that are executed by the processor to cause consumer appliance102to perform various operations. For example, instructions could be instructions for directing activation of one or more appliance components128. Instructions could further be for receiving/transmitting log data signals (e.g., signals corresponding to performance or of the consumer appliance102, such as temperature, pressure, speed, rotation, or activation/deactivation history of appliance components128), recording log data as one or more log data sets over time (e.g., within memory), etc.

In some embodiments, one or more of the control boards124A,124B include (e.g., within the memory) certain non-functional character data relating to the corresponding control board124A or124B. In particular, the non-functional character data includes information regarding attributes of the control board124A or124B that do not directly relate to (e.g., are not descriptive of) the purpose or functionality of the consumer appliance102. Moreover, in contrast to a stored model number of the consumer appliance102, the non-functional character data may pertain to the control board124A or124B itself, and not overall assembled consumer appliance102.

As an example, the non-functional character data may include component identification information of the control board124A or124B, such as a board address number (e.g., provided in hexadecimal form), hardware identifier of the control board124A or124B, or image identifier relating to software preprogrammed on control board124A or124B (e.g., the type of software, which corresponds to the type of consumer appliance102to be controlled). As an additional or alternative example, the non-functional character data may include software version information (e.g., the version or iteration number of the software programmed on control board124A or124B). As yet another additional or alternative example, the non-functional character data may include parametric version information (e.g., the version or iteration number of parametric data stored on control board124A or124B to facilitate software execution). As still another additional or alternative example, the non-functional character data may include personality configuration information (e.g., one or more programmed settings specifying which portion or package of the software is to be executed).

As will be described in greater detail below, one or more elements of non-functional data (e.g., a plurality of non-functional data elements) may be collected and used to determine an appliance configuration manifest (ACM). Advantageously, the ACM may account for variations in multiple consumer appliances that do and do not influence service operations without trying to specifically identify each unique model of consumer appliance that may be connected to or serviced by diagnostic tool104.

Appliance controller124includes one or more communications modules130such that consumer appliance102can selectively connect to and communicate with diagnostic tool104(e.g., over one or more conductive signal lines, shared communication busses, or wireless communications bands). In certain embodiments, conductive transmission lines132, such as wires, extend between consumer appliance102and diagnostic tool104in connection therewith. Communications module130can be an onboard component of appliance controller124or it can be a separate, off board component. In some embodiments, communications module130includes or is joined to an RJ45 terminal134on cabinet120. When connected to the diagnostic tool104, the RJ45 terminal134on cabinet120may thus be positioned between appliance controller124and diagnostic tool104.

As illustrated inFIG. 1, diagnostic tool104generally includes a casing140spaced apart from consumer appliance102(e.g., when connected thereto). In some embodiments, a user interface is provided on (e.g., mounted or attached to) casing140. As indicated inFIGS. 1 and 2, user interface generally includes one or more control inputs142, such as one or more of a variety of electrical, mechanical, or electro-mechanical input devices. Control inputs142may include, for example, rotary dials, knobs, push buttons, and touch pads. A controller144is in communication with user interface142and control inputs142through which a user (e.g., service professional) may select various operational features and modes for diagnostic tool104or consumer appliance102(e.g., when connected thereto). User interface may further include a display component143, such as a digital or analog display in communication with controller144and configured to provide operational feedback to a user or service professional. In particular, the display component143may be configured to present or display a graphical user interface (GUI) programmed into controller144. As will be described in greater detail below, multiple GUIs may be provided within each controller144. The GUI that is presented or displayed at any given moment may be based at least in part on the ACM of the appliance to which diagnostic tool104is connected (e.g., consumer appliance102). In certain embodiments, user interface, including control inputs142, represents or includes a general purpose I/O (“GPIO”) device or functional block.

Controller144may include one or more processors146and one or more memory devices148(i.e., memory). The one or more processors146can be any suitable processing device (e.g., a processor core, a microprocessor, an ASIC, a FPGA, a microcontroller, etc.) and can be one processor or a plurality of processors that are operatively connected. The memory device148can include one or more non-transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and combinations thereof. The memory devices148can store data148B and instructions148A that are executed by the processors146to cause diagnostic tool104to perform operations. For example, instructions148A could be instructions148A for executing or directing a service operation (e.g., presenting a suitable GUI, executing one or more parser algorithms, etc.), receiving/transmitting signals to/from consumer appliance102, receiving/transmitting signals to/from remote server106. The memory devices148may also include data148B, such as a one or more GUI files, ACMs, software installation files, etc. that can be retrieved, manipulated, created or stored by processors146.

Controller144includes a communications module150such that diagnostic tool104can selectively connect to and communicate with consumer appliance102(e.g., over one or more transmission lines132, shared communication busses, wireless communications bands, etc.). Communications module150can be an onboard component of controller144or it can be a separate, off board component. In some embodiments, communications module150includes or is joined to a communications terminal154on casing140(e.g., such that terminal154is formed directly on casing140or held in attachment on casing140by an intermediate adapter). Generally, communications terminal154may include, or be provided as, any suitable transceiving terminal (e.g., USB, RJ45, etc.). When connected to the consumer appliance102, the communications terminal154on casing140may thus be positioned between controller144and appliance controller124. In some embodiments, a conductive transmission line132may be selectively joined to and removed from the communications terminal154on casing140or the RJ45 terminal134on cabinet120(e.g., to selectively connect and disconnect controller144and appliance controller124).

In some embodiments, controller144includes a network interface156such that diagnostic tool104can connect to and communicate over one or more networks (e.g., network108) with one or more network nodes. Network interface156can be an onboard component of controller144or it can be a separate, off board component. Controller144can also include one or more transmitting, receiving, or transceiving components for transmitting/receiving communications with other devices communicatively coupled with diagnostic tool104. Additionally or alternatively, one or more transmitting, receiving, or transceiving components can be located off board for controller144.

Network108can be any suitable type of network, such as a local area network (e.g., intranet), wide area network (e.g., internet), low power wireless networks [e.g., Bluetooth Low Energy (BLE)], cellular network (e.g., GSM, CDMA, etc.), or some combination thereof and can include any number of wired or wireless links. In general, communication over network108can be carried via any type of wired or wireless connection, using a wide variety of communication protocols (e.g., TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g., HTML, XML), or protection schemes (e.g., VPN, secure HTTP, SSL).

In some embodiments, a remote server106, such as a web server, is in operable communication with diagnostic tool104. The remote server106can be used to host a service platform or cloud-based application. Additionally or alternatively, remote server106can be used to host an information database (e.g., of ACMs, GUI files, recorded log data, or other relevant service data). Remote server106can be implemented using any suitable computing device(s). Remote server106may include one or more processors166and one or more memory devices168(i.e., memory). The one or more processors166can be any suitable processing device (e.g., a processor core, a microprocessor, an ASIC, a FPGA, a microcontroller, etc.) and can be one processor or a plurality of processors that are operatively connected. The memory device168can include one or more non-transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and combinations thereof. The memory devices168can store data168B and instructions168A which are executed by the processors166to cause remote server106to perform operations. For example, instructions168A could be instructions168A for receiving/transmitting files related to one or more ACMs, GUIs, log data, etc.

The memory devices168may also include data168B, such as ACMs, GUI files, log data, etc., that can be retrieved, manipulated, created, or stored by processors166. The data168B can be stored in one or more databases. The one or more databases can be connected to remote server106by a high bandwidth LAN or WAN, or can also be connected to remote server106through network108. Optionally, the one or more databases can be split up so that they are located in multiple locales.

Remote server106includes a network interface176such that interactive remote server106can connect to and communicate over one or more networks (e.g., network108) with one or more network nodes. Network interface176can be an onboard component or it can be a separate, off board component. In turn, remote server106can exchange data with one or more nodes over the network108. In particular, remote server106can exchange data with diagnostic tool104. Although not pictured, it is understood that remote server106may further exchange data with any number of client devices over the network108. The client devices can be any suitable type of computing device, such as a general purpose computer, special purpose computer, laptop, desktop, integrated circuit, mobile device, smartphone, tablet, or another suitable computing device. Information or signals (e.g., relating to ACMs, GUIs, log data, etc.) may thus be exchanged between diagnostic tool104and various separate client devices through remote server106.

Referring now toFIG. 3, various methods (e.g., method300) may be provided for use with system100in accordance with the present disclosure. In general, the various steps of methods as disclosed herein may, in exemplary embodiments, be performed by the controller144as part of an operation that the controller144is configured to initiate (e.g., a service operation). During such methods, controller144may receive inputs and transmit outputs from various other portions of the system100. For example, controller144may send signals to and receive signals from remote server106, consumer appliance102, as well as other suitable components. The present methods may advantageously permit identification and service of multiple different consumer appliances and types of consumer appliances without the need to maintain an exhaustive list of each unique consumer appliance102. Moreover, such methods may advantageously permit the improved and reduced transfer of data (e.g., to/from consumer appliances, diagnostic tools, or remote servers).

FIG. 3depicts steps performed in a particular order for purpose of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that (except as otherwise indicated) the steps of any of the methods disclosed herein can be modified, adapted, rearranged, omitted, or expanded in various ways without deviating from the scope of the present disclosure.

At310, the method300includes receiving non-functional character data. In particular, the non-functional character data may be received at the diagnostic tool from one or more control boards of the consumer appliance. Thus, the diagnostic tool may be selectively connected to the control board of the consumer appliance, as described above (e.g., through one or more RJ45 terminals and communications modules). As also described above, the non-functional character data may include component identification information. Additionally or alternatively, the non-functional character data may include a control board address, a hardware identifier of a control board, an image identifier relating to software preprogrammed on a control board, software version information, parametric version information, or personality configuration information. In certain embodiments, a plurality of non-functional data elements is collected. Thus, diagnostic tool may direct the consumer appliance to transmit multiple unique non-functional data elements, such as several or all elements chosen from a control board address, a hardware identifier of a control board, an image identifier relating to software preprogrammed on a control board, software version information, parametric version information, or personality configuration information.

At320, the method300includes assigning an appliance configuration manifest (ACM) to the consumer appliance based on (e.g., as a direct function of) the received non-functional character data at310. Between discrete consumer appliance models, differences in the appliances may alter the ACM that is assigned. Assigning an ACM may thus provide a suitable identifier for the consumer appliance that is not programmed or stored on the appliance controller. For instance, an ACM code may be organized as a string or sequence of characters (e.g., numbers). Optionally, each position on the sequence of characters may correspond to a different non-functional character element. As an example, the first position or entry of a sequence of characters for an ACM may be reserved for a value related to the board address.

The value of a character at a specific sequence position may be tied to the non-functional character element. Thus, differences between each non-functional character element may correspond to a different value at the specific sequence position. One board address may cause one value at the specific sequence position while another board address may cause another value at the specific sequence position. As a result, different board addresses may result in different character values for a specific sequence position.

In some embodiments, the assigned ACM is matched to an ACM (e.g., stored ACM) from a plurality of predetermined ACMs. As a result, the ACM at320may be one of a plurality of predetermined appliance configuration manifests, which may identify the consumer appliance (e.g., type of consumer appliance, series of consumer appliance, specific model of consumer appliance, etc.). Optionally, the plurality of ACMs may be stored within the memory of the diagnostics tool or may be received from the memory of the remote server. If the ACM is a new ACM and cannot be matched to one of the plurality of ACMs, an alert signal may be transmitted (e.g., from the diagnostic tool to the remote server). In response to the alert signal, a remote service professional may assemble a new ACM that can be subsequently transferred from the remote server.

In some embodiments,320further includes calculating an identification key from the assigned ACM. For instance, the identification key may represent a new character string or sequence that reduces or compresses the size of the character sequence of the ACM. Optionally, the calculation may be made according to a cyclic redundancy check algorithm, a cryptographic hash function, or another suitable operation.

At330, the method300includes determining a service action based on the ACM. Therefore, the determination at330may be contingent upon (e.g., a function of) what the ACM is at320. Optionally,330may include selecting one or more service actions from a plurality of preset service actions (e.g., stored within the diagnostic tool). Each service action of the plurality of preset service actions may be correlated to one or more unique appliance configuration manifests. Thus, a certain ACM may prompt a certain correlated service action. In embodiments wherein an identification key is calculated, the service actions may be similarly correlated to different identification keys.

At340, the method300includes initiating the determined service action of330. In particular, the determined service action may be initiated at the diagnostic tool. For instance, the diagnostic tool may initiate the determined service action in direct response to the determination at330.

In some embodiments, the service action is presentation of a graphical user interface (GUI) on the display of the diagnostic tool. Multiple GUIs may be provided and may correspond to one or more different ACMs. Some discrete ACMs may cause a different discrete GUI to be presented. Other discrete ACMs may cause the same GUI to be presented. As an example, some refrigerator appliances (e.g., models) may prompt presentation of different discrete GUIs, while other refrigerator appliances (e.g., models) may prompt presentation of the same GUI. In some such embodiments, one or more suitable parsing algorithms may be executed based on the presented GUI.

In additional or alternative embodiments, the service action is collecting a recorded log data set from the control board(s) of the consumer appliance. Different consumer appliances (e.g., different models of a specific consumer appliance, different types of consumer appliances, etc.) may record different data or information during operation. Thus, it may be advantageous for the diagnostic tool to only attempt the collection of relevant information (e.g., class of information, such as temperature history, activation/deactivation history, etc.). Some discrete ACMs may cause a different discrete log data set to be collected. Other discrete ACMs may cause the same log data set to be collected. As an example, some refrigerator appliances (e.g., models) may prompt the collection of a certain log data set (e.g., temperature history), while other refrigerator appliances (e.g., models) may prompt the collection of the same log data set. As another example, some refrigerator appliances (e.g., models) may prompt the collection of a certain log data set (e.g., temperature history), while other refrigerator appliances (e.g., models) may prompt the collection of another log data set (e.g., activation/deactivation history for a compressor of the refrigerator appliance).