RT /db/80014/9-02

### Agenda Agenda

RTIdb/80014/9-02 1

### DOE Clothes Washer Test Cloth Meeting 

### 9124102 Background 

## In June, 1999, Alliance Laundry Systems notified 

## DOE of significant inconsistencies in 

## RMC test results using the new Appendix Jl procedure. An intensivetest programwas begun.



# + Samples of cloth were tested at three independenttextile labsfor differences in characteristics 

# +Arthur 

## D. Littletested multipletest cloth batchesto assess the impact of variations in spin conditions on RMC results 71

## A commercial extractor was used in place of a washing machineto negate any effects of drum design 71 

## Conditions were varied to assess impact on RMC


## - Soak Temperature


## - SoakTime


## - Load Size 

# - Spin Speed 

# - Spin Time DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 Background 

## In June, 1999, Alliance Laundry Systems notified DOE of significant inconsistencies in RMC test results using the new Appendix J1 procedure. An intensive test program was begun

.

• Samples of cloth were tested at three independent textile labs for differences in characteristics • Arthur D. Little tested multiple test cloth batches to assess the impact of variations in spin conditions on RMC results 71 

## A commercial extractor was used in place of a washing machine to negate any effects of drum design 71 

## Conditions were varied to assess impact on RMC

- Soak Temperature

- Soak Time

- Load Size

- Spin Speed

- Spin Time

RT/db/80014/9-02 2

### DOE ClothesWasher Test Cloth Meeting 

### 9124102 Background (Cont.) 

## Initial extractor-based tests showed a significant difference in cloth performance. Ultimately, a decision wasmade to use cloth from Riegal MillsITextileInnovators exclusively. 

# \

Cotton Goods 55.0% - a:.., 50.0% Textile Innovators-."'.::

g factor . . . . . . 0 1 45.0% - x. a! '. '. '. '. '. 40.0% - '. '. '. 35.0% - "Alliance" '. '. 30.0% -
25.0% - -. . x... -.-.-_ -.---__. DOE Clothes Washer Test Cloth Meeting 9/24/02 Background (Cant.) 

## Initial extractor-based tests showed a significant difference in cloth performance. Ultimately, a decision was made to use cloth from Riegal Mills/Textile Innovators exclusively.

70.0%
65.0%
60.0%
55.0%
50.0%
o :& 45.0% 0:: 40.0%
35.0%
30.0%
25.0% Cotton Goods

Textile Innovators



### --- "-



### - ----;( 20.0% +-------,--------,--------,--------,-------,------ o 100 200 300 400 500 9 factor RT/db/8001419.o2 3

### DOE Clothes Washer Test Cloth Meeting 9/24/02 

### Background (Cont.) 

## Lots 1,2

## and 3 

## showed remarkable similarity, encouraging the premisethat a single, tightly controlled textile manufacturing process would resolvethe issue. This assumption changed with Lot 4, 

## requiring development of a correction curve.

Soak Time: 20 minutes Soak Temp: Warm Spin Time: 15 min DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 Background (Cont.) 

## Lots 1, 2 and 3 showed remarkable similarity, encouraging the premise that a single, tightly controlled textile manufacturing process would resolve the issue. This assumption changed with Lot 4, requiring development of a correction curve.

55 50 45**~** o u 40 :E 0:: 35 30 25 Lot 4

Lots 1,2,3 Soak Time: 20 minutes Soak Temp: Warm Spin Time: 15 min Lot 1 -li-Lot 2 ---a-Lot 3**~Lot4 20+------~----~--~----~----~----~----~----~--~**  

## o 100 200 300 400 500 600 700 800 900 9 RT /db/80014/9-02 4

### DOE ClothesWasher Test Cloth Meeting 

### 9124102 Background (Cont.) 

## RMC Correction Curve



# + Linear least squares fit relating corrected RMC (to Lot 3 Baseline)to values measured in another lot at 509,2009 and 350g:
where A 

## (slope) and B (intercept) are coefficients of the linear least squares fit 

# + Check accuracy using a Root mean square relation such that:

where 12 is the number of test conditions DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 Background (Cant.) 

### RMC Correction Curve

• Linear least squares fit relating corrected RMC (to Lot 3 Baseline) to values measured in another lot at 50g, 200g and 350g: RMCcorrected 

# =A. RMCMeasured 

## + B where A (slope) and B (intercept) are coefficients ofthe linear least squares fit

• Check accuracy using a Root mean square relation such that: 1/2 12 (RMCSTANDARD 

# i - RMCLot 

## x 

# i? L

- - <2% i=1 

## 10 where 12 is the number of test conditions

RT/db/80014/9-02 5

### DOE 

### ClothesWasher Test Cloth Meeting 

### 9124102 The Lot 

### 7 Problem 

## The Lot

## #7 correction curve satisfied the goodness-of-fit test criterion (i.e., RMS<2%) 

## but Lot 7 

## was found to have inconsistencies during manufacturers' testing.

20% 20% 40% 60% 80% Measured Lot #7 RMC 

### % DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 The Lot 7 Problem 

## The Lot #7 correction curve satisfied the goodness-of-fit test criterion (i.e., RMS<2%) but Lot 7 was found to have inconsistencies during manufacturers' testing.

700/0**~** 0 0 

### 600/0 :E**~** 

### 500/0 RMS 

### = 1.2% "C CI> 

# .... 400/0 0 CI> '- '- 0 

### 30% 0 

### y

## =0.6564x + 0.0948**~** 

## =0.987 

### 200/020% 600/0 800/0 Measured Lot 

### #7 RMC 

### 0/0

RTIdb/80014/9-02 6

### DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 

### The Lot 7 

### Problem (Cont.) 

## Testing multiple batches taken from Lot #7 

## revealedfairly large at low (50g) 

## spin levels. differences

+-ADL Lot 7 Lot 7 Retest +Alliance 7 -0- Whirlpool 7 DOE Clothes Washer Test Cloth Meeting 9/24/02 The Lot 7 Problem (Cont.) 

## Testing multiple batches taken from Lot #7 revealed fairly large differences at low (50g) spin levels.

80.0% 78.0% 76.0% 74.0% 72.0% 70.0% 68.0% 66.0% 64.0% 62.0% 60.0%

o 58.0% 0::: () 56.0%**~** 54.0% 52.0% 50.0% 48.0% 46.0% 44.0% 42.0% 40.0% 38.0% 36.0% 34.0% 32.0% 30.0%**~** '\'\

\\ -k '\\..**~ ~<** 

### r~-""'-'**~ ~**  

### \"'- 

# ""'\":,**~** 

## "**"'~"'"** 

# - ......... 

# "'**""'~ ~~** **~, ~~**  ------_." ._------**~,,----** ----"._"----""----

### ~"**~**

--

# ~ ..

# -**~~""**

# ~**~** ---.ADL Lot 7 l-l-lLot 7 Retest**~Alliance7** ---Whirlpool 7 "--!--GE 7

RT/db/80014/9-02 7

### DOE 

### Clothes Washer Test Cloth Meeting 9/24/02 The Lot 7 Problem (Cont.) 

## The data spread at 50g for Lot 7 produces different correction curves depending on the batch used.
Lot#7 Original CorrectionCurve (ADL Batch)

20% 1 I , I 1 I 20% 30% 40% 50% 60% 70% 80% Measured RMC % Lot#7 Additional Correction Curve (Whirlpool Batch)

20% 1 , 20% 30% 40% 50% 60% 70% 80% Measured RMC % 

### Corrected RMC%estimates based on two different batches of Lot

### #7 are given below. Measured Corrected RMC Difference RMC % Original Curve Additional Curve ( +I-Error) 40 36 37 50 42 44 60 49 52 70 55 60 4.2 75 59 63 4.8 

### Lot#7 

### batch differences could result in under (or over) estimating baseline RMC% by as much as 

## 1:5%. 

## ((TMN RT/db/80014/9-02 8 

### DOE Clothes Washer Test Cloth Meeting 9/24/02 The Lot 7 Problem (Cant.) 

## The data spread at 50g for Lot 7 produces different correction curves depending on the batch used.**~** 

# .. 0 ::!: 0:: 

## " (\) 

# - () 

## e

... 0 0 70% 60% 50% 40% 30% 20% Lot #7 Original Correction Curve (ADL Batch)

RMS = 1.2%

-
y =0.6564x + 0.0948**~** =0.987 20% 30% 40% 50% 60% 70% 80% Measured RMC %**~** 

## .. 0 ::!: 0:: 

## " (\) 

# - () (\) 

### ... ... 0 0 Lot #7 Additional Correction Curve (Whirlpool Batch)
70% 60% 50% 40% 30% 20% 20% RMS 

### =1.2%

y= O.77x + 0.0574**~** = 0.988 30% 40% 50% 60% 70% 80% Measured RMC % 

### Corrected RMC% estimates based on two different batches of Lot #7 are given below. Measured Corrected RMC Difference RMC% Original Curve Additional Curve ( +/. Error) 40 36 37 0.8 50 42 44 1.9 60 49 52 3.1 70 55 60 4.2 75 59 63 4.8 

### Lot #7 batch differences could result in under (or over) estimating baseline RMCOfc) by as much as 

### :!:. 50/0.**«TIIII~** RT/db/80014/9-02 8

### DOE ClothesWasher Test Cloth Meeting 9124102 The Lot 

### 7 Problem (Cont.) DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 The Lot 7 Problem (Cont.)

RT/db/80014/9-02 9

### DOE ClothesWasher Test Cloth Meeting 9/24/02 

### The Lot 7 Problem 

### (Cont.) 

## Correction curves were then developed usingfour spin speeds (50-1 00-200-3506).

Lot#7 Correction Curve

## - Original Batch [Including lOOgTests]

20% 30% 40% 50% 60% 70% 80% Measured RMC % Lot#7 Correction Curve

## - Whirlpool Batch [ including 100gTests]

3 20% 30% 40% 50% 60% 70% 80% Measured RMC %

Lot#7 Revised RMC Corrections [ based on 50-100-200350g ] Measured Corrected RMC % Difference RMC % 40 50 60 70 75 Original Batch Whirlpool Batch { +I- Error) 36 37 

# 10.61
Adding the 100g data does not reducethe variation significantly. 

# c(T~x RT/db/80014/9-02

DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 The Lot 7 Problem (Cont.) 

## Correction curves were then developed using four spin speeds (50-100-200-350g).
Lot #7 Correction Curve
- Original Batch [Including 100g Tests]

o**60%·+----------~~------------~~** :i! 0::: RMS = 1.8% 't:J**50%·+------"----"~----~~~---------1**

### ~ 

## e**40%·+---------~~--------------1** 

### ... o o 30%·+------6'-""" y 

### =0.6779x + 0.0916 R2 = 0.965**20%+---~--~----~--~--~--~** 20% 30% 40% 50% 60% 70% 80% Measured RMC % ";!. Lot #7 Correction Curve
- Whirlpool Batch [ including 100g Tests]

o**60%·+--------~--------------~----~** :i! RMS = 1.4%**~ 50%·+-------------~~~~------~**  S CJ 

## e**40%·+-------------;;II""'-----------------~** 

### ... o o**30%·+--~--~---~pL""----------~~--------~ 20%·+---~--~----~--~----~--~**  20% 30% 40% 50% 60% 70% 80% Measured RMC %

Lot #7 Revised RMC Corrections [ based on 50-100-200-350g ] Measured Corrected RMC % Difference RMC% Original Batch Whirlpool Batch ( +/- Error} 40 36 37 0.6 50 43 45 1.7 60 50 53 2.8 70 57 61 4.0 75 60 65 4.5 

## Adding the 100g data does not reduce the variation significantly. ((TIIII]l RTIdb/80014/9-02 10

### DOE ClothesWasher Test Cloth Meeting 9/24/02 

### The Lot 7 Problem (Cont.) 

## A composite correction curve based on RMC data from all Lot #7

## test batches and four spin speeds tends to reducethe error.
Lot #7 Correction Curve [Composite]

20x4 20% 30% 40% 50% 60% 70% 80% Measured RMC % (All Batches) ADL Batch#7 Measured Corrected RMC % Difference RMC % 40

Whirlpool Batch#7 ADL Curve Composite Curve 36 37

Measured Corrected RMC % RMC % Whirlpool Curve Composite Curve 40 37 37 50 45 44 60 53 51 70 61 59 75 65 62 Difference +I- Error

I.9 2.2 

## Baseline RMC% estimates can be expected to vary by less than - 

## + 2.5% DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 The Lot 7 Problem (Cant.) 

## A composite correction curve based on RMC data from all Lot #7 test batches and four spin speeds tends to reduce the error.

';!. Lot #7 Correction Curve [Composite]

o**60%,+----·---------~--1** :l!: RMS 

### =1.4% 0:::**~ 50%,+--------~~~-----1** 

### ~ f**40%·+-----~~~-------~** 

### ... o y =0.7325x + 0.0737 o**30%,+----·~~-----~~R~2-=O~.9=78~---~ 20%,+---~--~-~--~----~~**  20% 30% 40% 50% 60% 70% 80% Measured RMC % (All Batches) ADL Batch #7 Measured RMC% 40 50 60 70 75 Corrected RMC % ADL Curve Composite Curve 36 37 43 44 50 51 57 59 60 62 Whirlpool Batch #7 Measured RMC% 40 50 60 70 75 Corrected RMC % Whirlpool Curve Composite Curve 37 37 45 44 53 51 61 59 65 62 Difference ( +/- Error -0.4 -0.9 -1.5 -2.0 -2.3

Difference ( +/- Error 0.2 0.8 1.4 1.9 2.2 

## Baseline RMC% estimates can be expected to vary by less than:!:. 

## 2.50/0

RT/db/80014/9-02 11

### DOE ClothesWasher Test Cloth Meeting

### 9/24/02 The Lot 7 Problem (Cont.) 

## Testing of Lot#8 

## also yielded significant differences at the 50g spin level.

Roll Averages @ 509 [95%Confidence Intervals]

Lot

### #8

# - Roll IW @ 

### Upper 

### rn Expected 

### Low

### er 

# ·.

DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 The Lot 7 Problem (Cant.) 

## Testing of Lot #8 also yielded significant differences at the 50g spin level.**~** 

### 74 CI 0 

### 72

## ~ 70 <I> 

### en 

### 68 C'O '- 

### 66 <I> 

### > <C 

### 64**I~** 

### 1 Roll Averages 

### @ 50g [950/0 Confidenee Intervals]**~~** 

# .. III ,j 

### ;; 2

Lot

### #8 - Roll 10# 

### upperl III 

### Expected 

## I Lower ,

RT/db/80014!9-02 12

### DOE ClothesWasher Test Cloth Meeting 9/24/02 The Lot 7 Problem (Cont.) 

## A 

## composite correction curve based on all Lot#8 

## test batches and four spin speeds was then derived to assess the accuracy of correction to baseline 

## RMC%. Lot #8 Composite Correction Curve Batch #I Measured Corrected RMC % Difference RMC % Batch #I Curve Composite Curve I 40 36 35 50 43 43 60 51 50 70 59 57 75 62 61 

### Batch

### #4 Measured Corrected RMC %] Difference RMC % Batch#4 Curve CompositeCurve 40 35 35 50 42 43 60 49 50 70 56 57 75 59 61 +I- Error



### Baseline RMC% estimates varied by 

### lessthan

## 2 2% over the range of test conditions. 

# TI^$ RT/db/80014/9-02 13



### DOE Clothes Washer Test Cloth Meeting 9/24/02 The Lot 7 Problem (Cont.) 

## A composite correction curve based on all Lot #8 test batches and four spin speeds was then derived to assess the accuracy of correction to baseline RMC%. Lot #8 Composite Correction Curve Batch #1 Measured RMC% 40 50 60 70 75 

### Batch #4 Measured RMC% 40 50 60 70 75 Corrected RMC % Batch #1 Curve Composite Curve 36 35 43 43 51 50 59 57 62 61

Corrected RMC %] Batch #4 Curve Composite Curve 35 35 42 43 49 50 56 57 59 61 Difference +/- Error -0.4 -0.7 -0.9 -1.2 -1.3

Difference

+/- Error 0.5 0.9 1.3 1.7 1.9


### Baseline RMC% estimates varied by 

### less than 

## ±20/0 overthe range oftest conditions.

RT/db/8001419-02 13

### DOE Clothes Washer Test Cloth Meeting 9/24/02 

### The 

### Lot 7 

### Problem (Cont.) 

## If the composite curve approach (using multiple batches and four spin speeds) is adopted, measures of accuracy are needed to address differences between each new lot and the baseline (Lot 3). Comparison of All Test Lots

0 100 200 300 400 Spin Speed [g] Lot#8(Roll 1) Lot#7ADL Lot#6 Lot#5 

### + Lot#4 + Lot#3

Correction Curves

# --- Summary Statistics Lot# 4 Lot # 5 Lot# 6 Lot# 7ADL Lot# 7(All) Lot# 8 (All) Slope = Intercept = RMS = '" 

# . , 

# .

DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 The Lot 7 Problem (Cont.) 

## Ifthe composite curve approach (using multiple batches and four spin speeds) is adopted, measures of accuracy are needed to address differences between each new lot and the baseline (Lot 3).

80**~** 0 (j 70 :E 

### rx:: 60 Cl) en 50 C'tS a... Cl) 40

### ~ 30 0 

### Comparison ofAll Test Lots

100 200 300

Spin Speed [g] 400 -+- Lot#8(Roll 1) --.-Lot#7ADL Lot#6 Lot#5**~Lot#4** -e-Lot#3

Correction Curves
- - - Summary Statistics Lot#4 Lot # 5 Lot # 6 Lot # 7ADL Lot # 7(AII) Lot # 8 (All) Slope 

## = 0.96 1.00 0.78 0.68 0.73 0.73 Intercept

## = -0.037 -0.033 0.070 0.092 0.074 0.061 RMS 

## = 0.51 0.45 1.43 1.82 1.44 2.03
RTIdb/80014/9-02 14

### DOE Clothes Washer Test Cloth Meeting9124102 Discussionof Options 

# ·.

DOE Clothes Washer Test Cloth Meeting 

### 9/24/02 Discussion of Options



## Test Procedure

Modifications "Look Up" Table for RMC at Low G's Other

RTIdb/80014/9-02 15