Abstract:
A control system for a laundry machine provides a system for engaging a laundry machine in a drop-off mode, allowing an operator to use the machine as necessary to process customer garments without being required to activate the machine via a payment interface. In an embodiment of the invention, the system provides a lock-out function for allowing a machine to be reserved for a specific user holding a predetermined password or code. In a further embodiment of the invention, the laundry machine is configured with a low power and/or shut down facility, whereby the power consumption of the machine may be greatly reduce during idle periods.

Description:
FIELD OF THE INVENTION 
     The invention generally relates to laundry machines, and more particularly to a control system for a laundry machine for improving the efficient utilization of the machine. 
     BACKGROUND OF THE INVENTION 
     Many commercial laundry machines are designed to allow users, e.g., members of the public, to activate the machines and use them for washing garments. Typically users will pay for the service provided by the machine via the insertion of coins, cash, cards, etc. However, it is often desirable for a machine to be available on a more limited basis, i.e., for use by a facility operator without paying, or for use by members of the public on a reservation basis. However, present systems for allowing these types of actions are not satisfactory, requiring excess operator involvement or oversight. In addition, such machines may be very expensive to operate with respect to their use of electrical energy, however, it is difficult to manage the power consumption of such machines, especially when the machines are not in active use. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, it is an object of the invention to provide a system and method for engaging a laundry machine, e.g., a washer, dryer, tumbler, etc., in a drop-off mode, allowing an operator to use the machine as necessary to process customer garments without being required to activate the machine via a payment interface. 
     To that end, it is a related object to provide a control system for a washer with a lock-out function for allowing a machine to be reserved for a specific user holding a predetermined password or code. 
     It is a further related object of the invention to provide a laundry machine with a low power and/or shut down facility, whereby the power consumption of the machine may be greatly reduced during idle periods. 
     These objects and other related objects are achieved in various embodiments of the present invention. The features and advantages of the invention can be understood from the description of embodiments of the invention set forth below with reference to the drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partially schematic front view of a washer/extractor-type laundry machine with a wash drum therein that rotates about a generally horizontal axis; 
         FIG. 2  is a schematic view showing the functional modules of the laundry machine; 
         FIG. 3  is a flowchart showing a process of initiating and functioning within a drop-off mode according to an embodiment of the invention; 
         FIG. 4  is a flowchart showing a process of initiating and functioning within a lock-out mode according to an embodiment of the invention; 
         FIG. 5  is a flowchart showing a process of initiating and functioning within an idle mode according to an embodiment of the invention; and 
         FIG. 6  is a flowchart illustrating a process for setting an installation date in a delayed manner according to an embodiment of the invention to account for time when machine may not be fully operational. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a laundry machine  20  that incorporates an embodiment of the control system for controlling the operation of the machine  20  in accordance with described embodiments of the invention. In the embodiment shown in  FIG. 1 , the laundry machine  20  is of the front-loading washer-extractor type, with a front door  22  that can be opened for loading clothing to be cleaned into the machine. The laundry machine has a wash drum  24  into which the clothing is loaded. The drum  24  is supported in the washer-extractor for rotation about a generally horizontal central axis. During the washing and rinsing phases of the cleaning operation, the drum  24  is partially filled with water (or other solvent used for cleaning) and is rotated at relatively low speeds to tumble the clothing to enhance the cleaning effects. After the washing and rinsing phases are completed, the drum  24  with the wet clothing therein is rotated at a relatively high angular velocity to remove (or “extract”) residual water from the wet clothing by means of centrifugal force. To effectively extract water from the clothing, the rotational velocity of the drum  24  is often relatively high, generating centrifugal forces as great as 300 times the earth&#39;s gravitational field force. 
     As shown in  FIG. 2 , the drum  24  is driven by a motor  28 , which is coupled to the drum  24  via suitable means such as belt/pulley arrangement  30  or gears. The motor  28  may be, for example, an AC motor that provides a torque sufficient for driving the drum  24  with wet clothing therein to desired rotational speeds. The motor  28  is powered by a drive controller  36 , which provides the needed voltage and current for energizing the motor  28 . In one embodiment, the drive controller  36  includes a microprocessor  38  that is suitably programmed for controlling the powering of the motor  28 , and a non-volatile memory  42  for storing programs and control data for the microprocessor  38 . The non-volatile memory  42  may be read-only, and the programs stored in such a non-volatile memory  42  are commonly referred to as “firmware.” The drive controller  36  further includes a power circuit  44  that provides the current and voltage for the motor  28  under the control of the microprocessor  38 . As described in greater detail below, the power circuit includes a detection circuit  46  for sensing a phase angle difference between the voltage and current applied to the motor  28 . 
     To control its general operations, the laundry machine  20  includes a machine controller  50 . The machine controller  50  sends control signals to various components of the laundry machine  20 , including the drive controller  36 , for carrying out a selected washing operation, which may include multiple washing, rinsing, and extraction phases. The machine controller  50  includes a control panel  56  that can be used by a user to enter operation instructions and parameters. The machine controller  50  includes a microprocessor  52  and a non-volatile memory  54  for storing program software and operation data. In a preferred embodiment, the memory  54  for storing the software programs for the microprocessor  38  is read-only. 
     To control the operations of the laundry machine  20  and to receive operational information, the machine controller  50  is interfaced with active components of the laundry machine  20  by means of appropriate communication and power connections. As shown in  FIG. 2 , the machine controller  50  is connected to drive controller  36  for the motor  28  driving the wash drum  24  by means a communication line  60 , which may be used by the machine controller  50  to send control signals or instructions to the drive controller  36 . The machine controller  50  is further connected to the drive controller  36  by a signal line  64  for receiving data from the drive controller  36 . The signal line  64  connects the machine controller  50  to a signaling device in the drive controller  36  circuit. In one embodiment, the signaling device is a relay  66 , which may be a mechanical relay or a transistor-based solid-state device. As described in greater detail below, the relay  66  is operated by the drive controller  36  to provide a digital signal that indicates the magnitude of a detected imbalance of the laundry load in the drum. 
     Turning now to  FIG. 3 , to initiate and function within a drop-off mode, the controller functions according to computer-executable instructions on a computer-readable medium, in conjunction with data and information stored on the same or different medium. The process stages of  FIG. 3  illustrate the manner in which the aforementioned instructions are executed, although it will be appreciated that other instructions and sequences may be used without departing from the spirit of the invention. 
     For entering the drop-off mode, the controller  50  detects a drop-off mode activation sequence or code at stage  301 . The activation code may be presented to the controller  50  via user-manipulation of the user interface  56  or may be sent to the controller  50  via a network or other communication link. For example, in a commercial laundry facility open to the public, an operator of the facility may desire to program machines from a central location, and may program one or more machines to enter the drop-off mode. 
     In accordance with a feature of the invention, once the drop-off activation code is received, the machine controller  50  determines at stage  302  whether the machine is configured to accept such a code. For example, a machine may be programmed via a configuration file or setting to enable or disable activation of the drop-off mode. If it is determined at stage  302  that the machine is not configured so as to enable activation of the drop-off code, then the process  300  exits after stage  302 . Otherwise, the process moves forward to stage  303 , wherein the machine switches to a drop-off mode. Pursuant to entering the drop-off mode, the controller causes an appropriate message to be displayed via the user display panel in stage  304 . For example, the display may be changed to read “busy” or other appropriate message to alert potential users that the machine is not available for use at the moment. 
     In addition, at stage  305  the controller disables certain control inputs of the machine. For example, in an embodiment of the invention, the controller  50  may disable or cause to be ignored any coin deposit, card insertion, start button depression and/or other control inputs usable to use the machine in modes other than the drop-off mode. However, the keypad preferably remains enabled so that a user code may be entered as will be discussed below. In addition, the connection of the machine to the network or other communications link may be maintained such that instructions or user codes for the machine  20  may be provided from the central control location if needed. 
     In an embodiment of the invention, if the machine  20  is executing a wash cycle when the drop-off activation code is received, the machine  20  continues to the completion of the cycle. In a further embodiment of the invention, an override code may be provided via the user interface  56  or the network connection to halt the operation of the machine  20  mid-cycle after the drop-off activation code is received and cause the machine  20  to enter the drop-off mode immediately. The override code may be a sequence or combination of input button key strokes. For example, one possible key combination usable as an override code is the simultaneous depression of both the #5 and #6 keys. Other combinatorial and/or sequential codes may be used as desired. 
     At stage  306 , the controller  50  causes the machine to enter a wait state. In the wait state, the machine  20  is not usable other than by entry of a user code. At stage  307 , the controller  50  determines whether a valid user code has been entered. Typically, a user code may be entered by entering the digits of the code via the user interface keypad  56 , followed by pushing a “start” button or similar button. If entry of a valid user code is not detected in stage  307 , the process loops back through stage  307  until entry of a valid user code is detected. At this point, the process flows to stage  308 . It will be appreciated that the wait state may be exited other than by entry of a separate and distinct valid user code if desired by the manufacturer or facility operator. For example, reentry of the drop-off mode activation sequence or code may be received to exit the drop-off mode. 
     At stage  308  of process  300 , the controller  50  re-enables any input elements that were disabled at stage  305 . For example, in an embodiment of the invention, the controller  50  re-enables the coin deposit, card insertion, start button and/or other control inputs usable to use the machine  20  in modes other than the drop-off mode. In an embodiment of the invention, although the coin deposit and/or card insertion devices may be enabled, the machine  20  is configured to operate free of charge once the valid user code is input to the machine. 
     At stage  309 , the machine  20  receives via the user interface  56  a set of user instructions defining or selecting a wash cycle to be executed, and the indicated cycle is executed in stage  310 . After the cycle has finished, the process flows to stage  311 , wherein the drop-off mode is reactivated and the process returns to stage  306 . 
     The drop-off process  300  described above is useful when an operator of a laundry facility desires to use the laundry machines to process clothes received or “dropped-off” by customers to be washed for the customer. In addition, the drop-off function may be used to allow a machine  20  to be used by a customer as part of a promotion or to fulfill refund obligations, or to otherwise provide service without requiring payment. 
     A similar machine mode that is useful in the same or different circumstances is referred to herein as a lock-out mode. This mode makes the machine  20  available for use only to members of the public that are able to enter a predetermined unlock code. This is useful, for example, in enabling users to reserve machines locally or remotely so that they may know that a machine will be available for them to use at a reserved time. The process  400  illustrated in the flow chart of  FIG. 4  illustrates an exemplary process for locking and unlocking a machine  20 , but it will be appreciated that other similar processes may be used without departing from the scope of the invention. 
     At stage  401 , the machine  20  (i.e., via the processor therein) detects a lock-out activation sequence or code as well as a sequence of lock-out parameters. In a preferred embodiment of the invention, the lockout code is received from a remote source, e.g., a remote user in communication with the machine via one or more servers to reserve the machine for a certain time. The sequence of lock-out parameters preferably identifies the time period during which the machine should be reserved. Typically, for example, the sequence of lock-out parameters will include a start time (e.g., hour and minute) and duration (e.g., a specified number of hours and/or minutes). 
     In accordance with a feature of the invention, once the lock-out activation code and lock-out parameters are received, the machine controller  50  determines at stage  402  whether the machine  20  is configured to accept a lock-out request, e.g., via a configuration file, setting or otherwise. If it is determined at stage  402  that the machine  20  is not configured so as to accept a lock-out request, then the process  400  exits after stage  402 . Otherwise, the process  400  moves forward to stage  403 , wherein the machine  20  determines whether the designated start time has been reached. If it is determined at stage  403  that the designated start time has not been reached, then the process  400  loops through stage  403  until such time as the designated start time has been reached. 
     When the designated start time has been reached, the process  400  proceeds to stage  404 , wherein the machine  20  enters the lock-out mode. Pursuant to entering the lock-out mode, the controller  50  causes an appropriate message to be displayed via the user display  56  panel in stage  405 . For example, the display may be changed to read “res,” “reserved,” or other appropriate message to alert potential users that the machine  20  has been reserved by another user. In addition, the controller  50  disables or ignores any coin deposit, card insertion, start button depression and/or other control inputs other than those needed to enter a reservation code. In addition, when the machine  20  enters the lock-out mode it also starts a timer in stage  406 . The machine  20  will exit the lock-out mode either when the appropriate reservation code is entered during the duration of the lock-out period or when the lockout period expires. 
     Thus, at stage  407 , the machine  20  determines whether a valid reservation code has been entered, e.g., by comparing any entered reservation code with a known valid reservation code. If it is determined at stage  407  that a valid reservation code has been entered, the process  400  flows to stage  409 . Otherwise the process flows to stage  408 , wherein the machine  20  determines whether the lock-out duration has expired, e.g., whether the timer matches the specified duration. If it is determined at stage  408  that the lock-out duration has expired, the process flows to stage  410 , wherein the machine  20  exits the lock-out mode, and the process exits. Otherwise, if it is determined at stage  408  that the lock-out duration has not expired, the process returns to stage  407 . 
     Referring still to  FIG. 4 , if it was determined at stage  407  that a valid reservation code had been entered and the process  400  continued to stage  409 , the machine  20  unlocks the user interface  56  elements that were locked at stage  405  and exits. At this point, the user is able to pay or otherwise activate the machine  20  for use and enter the appropriate instructions to cause the machine  20  to execute a desired wash cycle. 
     In order to save electrical power during idle periods or periods of traditionally low usage, the machine  20  may also be configured to accept a request to enter a low power or shut down mode (also referred to generally herein as idle modes). These modes enable a facility to conserve electrical power, but they render the machine  20  less readily usable in that the machine  20  must be caused to exit the low power/shut down mode prior to use. The flow chart of  FIG. 5  illustrates a process  500  for machine entry to, and behavior during, such a mode. 
     At stage  501 , the machine  20  receives at its controller  50  via a network connection, or by comparing a current date, day and/or time with a preprogrammed date, day, and/or time, or other operator interface  56  a request to enter shut down/low power mode, as well as a set of shut down/low power parameters. The shut down/low power parameters preferably include a start and end time, or a start time and duration. In accordance with a feature of the invention, once the shut down/low power mode request and parameters are received, the machine controller  50  determines at stage  502  whether the machine  20  is configured to accept a shut down/low power request, e.g., via a configuration file, setting or otherwise. Typically, the configuration information will specify which of the idle modes is enabled, as different modes will exhibit different behaviors. 
     If the machine  20  is not configured to accept an idle request, then the process  500  exits. Otherwise, the process  500  moves forward to stage  503 , wherein the machine  20  determines whether the designated start date and time has been reached. If it is determined at stage  503  that the designated start date and time has not been reached, then the process  500  loops through stage  503  until the designated start date and time is reached. 
     At the designated start date and time, the process proceeds to stage  504 , wherein the machine  20  enters the configured idle mode. As noted above, the machine  20  supports two idle modes, namely a shut-down mode and a low-power mode. In the shut-down mode, the machine  20  is using less electrical energy than it would when active, but there is still power supplied to and derived from a transformer associated with the power circuit of the machine  20 . Is this mode, the machine  20  will not be usable by customers, but the display will be active, and may display a message such as “off.” 
     In the low power mode, the screen may be blank. However, in both modes, the communications facilities of the machine  20  remain active to allow remote awakening of the machine if desired. 
     When the machine  20  enters the idle mode, the controller  50  sets an idle timer at stage  505  so that the end of the desired idle period can be ascertained. At stage  506 , the controller continually checks the idle timer to determine whether the idle period has expired. When it is determined that the idle period has expired, the controller  50  exits the idle mode and the process  500  exits. 
     Timing is also significant for purposes of warranty expiration and service expectations. In particular, it is useful to know generally when a machine was installed, but starting a warranty expiration count down at the moment a machine is installed would disadvantage customers. In particular, during the first several runs of the machine, it is typical to perform adjustments and service and to otherwise use the machine for set up rather than commercial or other profitable purposes. 
     Thus, in a further embodiment of the invention, the installation date is fixed after a predetermined number of cycles of the machine. In the described embodiment of the invention, the predetermined number is ten, but any other number, larger or smaller, may be used instead. 
     In the exampled of  FIG. 6 , a process for recording the machine installation date is illustrated. At stage  601  of process  600 , the controller awaits the end of a laundry cycle. Once the end of a cycle is detected, the process  600  flows to stage  602 . At stage  602 , the controller determines whether the number of cycles completed is ten. If it is determined at stage  602  that the number of cycles completed is not yet ten, the process returns to stage  601 . Otherwise, the process flows to stage  603 , wherein the current date (e.g., month/date/year) is read and recorded as the installation date. The process then exits. 
     In view of the many possible embodiments to which the principles of this invention may be applied, it should be recognized that the embodiment described herein with respect to the drawing Figures is meant to be illustrative only and should not be taken as limiting the scope of invention. Those of skill in the art will recognize that the elements of the illustrated embodiments can be modified in arrangement and detail without departing from the spirit of the invention. Therefore, the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and equivalents thereof.