EE-RM-TP-03-100 COMMENT 01D

RT /db/800 14/9-02 
Agenda 

EE-RM-TP-03-100 COMMENT 01D

Agenda 

RT Idb/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 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 

- SoakTime 

- Load Size 

- Spin Speed 

- Spin Time 

EE-RM-TP-03-100 COMMENT 01D

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 Clothes Washer 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 

MillsITextile Innovators exclusively. 

\ Cotton Goods 

55.0% - 

a:.., 

50.0% 

Textile Innovators-."'.:: 

g factor 

. . . . . . 0 1 45.0% - 

a! x. '. '. '. '. 

40.0% - '. '. '. '. 

35.0% - 

"Alliance" '. 30.0% '. - 

25.0% - 

-. . x. .. -. -.-_ -.---__. 

EE-RM-TP-03-100 COMMENT 01D

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 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. 

Soak Time: 20 minutes 

Soak Temp: Warm 

Spin Time: 15 min 

EE-RM-TP-03-100 COMMENT 01D

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 Clothes Washer 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 

EE-RM-TP-03-100 COMMENT 01D

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 of the 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 Clothes Washer 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 % 

EE-RM-TP-03-100 COMMENT 01D

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> .... 

0 400/0 CI> 

'-'-

0 30% 0 

y = 0.6564x + 0.0948 

~ = 0.987 

200/0 

20% 600/0 800/0 

Measured Lot #7 RMC 0/0 

RT Idb/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 revealed fairly large 

at low (50g) spin levels. 

differences 

+-ADL Lot 7 

Lot 7 Retest 

+Alliance 7 

-0- Whirlpool 7 

EE-RM-TP-03-100 COMMENT 01D

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-l Lot 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 Correction Curve 

(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 

EE-RM-TP-03-100 COMMENT 01D

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 Clothes Washer Test Cloth Meeting 9124102 The Lot 7 Problem (Cont.) 

EE-RM-TP-03-100 COMMENT 01D

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

RT/db/80014/9-02 9 
DOE Clothes Washer Test Cloth Meeting 9/24/02 The Lot 7 Problem (Cont.) 

Correction curves were then developed using four spin speeds 

(50-1 00-200-3506). 

Lot #7 Correction Curve - Original Batch 

[Including lOOg Tests] 

20% 30% 40% 50% 60% 70% 80% 

Measured RMC % 

Lot #7 Correction Curve - Whirlpool Batch 

[ including 100g Tests] 

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 reduce the variation significantly. 

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

EE-RM-TP-03-100 COMMENT 01D

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 

e CJ 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 RT Idb/80014/9-02 10 
DOE Clothes Washer 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 reduce the 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% 

EE-RM-TP-03-100 COMMENT 01D

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 Clothes Washer 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 

· . EE-RM-TP-03-100 COMMENT 01D

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 

'-

<I> 66 

> <C 64 

I~ 1 

Roll Averages @ 50g 

[950/0 Confide nee Inte rvals] 

~~ .. 

III ,j 

;; 2 

Lot #8 - Roll 10# 

upperl 

III Expected 

I Lower , 

RT/db/80014!9-02 12 
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 #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 Composite Curve 

40 35 35 

50 42 43 

60 49 50 

70 56 57 

75 59 61 

+I- Error 

Baseline RMC% estimates varied by less than 2 2% over the range of test conditions. 

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

EE-RM-TP-03-100 COMMENT 01D

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 over the range of test 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 = 

'" . , . EE-RM-TP-03-100 COMMENT 01D

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). 

80 

0 ~ 

(j 70 

:E 

rx:: 60 

Cl) 

en 50 C'tS 

a... 

Cl) 40 

~ 30 

0 

Comparison of All 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 # 7 ADL 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 

RT Idb/80014/9-02 14 
DOE Clothes Washer Test Cloth Meeting 9124102 Discussion of Options 

EE-RM-TP-03-100 COMMENT 01D

· . 

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 

RT Idb/80014/9-02 15