Other Top & Front Loading Washing Machine Results

The XYO mechanical balancer reduces vibration by compensating for variable mass imbalance during the spin cycle of washing machines. Test results with a prototype XYO balancer demonstrate a significant impact on the performance of front and top loading washing machines. Additional benefits include:

• Higher spin speeds
• Reduced energy consumption
• Lower noise emissions
• Less mechanical wear

Without XYO

With XYO

Note:

• The results in this report are based on separate tests from the GE washing machine report; however, the improvements with XYO are significant in both reports.
• These results are based on prototype XYO balancer designs. While the results shown are significantly positive, it is possible to exceed them with further optimization.
• Tests were conducted with mass imbalance loads ranging from 0.1 kg to 1.5 kg; however, the XYO balancer can be designed to compensate for greater loads if desired.
• Perpetual Industries is looking for a capable partner that needs the competitive advantage that XYO can provide.

Without XYO

With XYO

ADDITIONAL BENEFITS INCLUDE:

• Lower shipping costs by eliminating the use of heavy counterweights used to the stabilize the tub during operation.
• Reduced manufacturing costs because mechanical items such as hydraulic dampers and springs can be removed, or replaced with smaller, lighter and cheaper components.
• Fewer warranty claims will result from the increased product life of the washing machine; excessive vibration will be avoided using the XYO balancer to reduce mechanical wear
• Longer warranty periods can be offered to customers for a competitive advantage.

TEST OVERVIEW

During the spin cycle of all washing machines and extractors the mass imbalance caused by wet clothes can lead to violent vibration. Since excessive vibration can have negative impacts (e.g., increased energy consumption, noise emissions and mechanical wear) manufacturers have tried several techniques to reduce or eliminate vibration. Some examples of these techniques include: adding counterweights to reduce movement, implementing fuzzy logic systems to redistribute the load, using elaborate suspension systems. None of these techniques solve the vibration problem at its source. In fact, they increase the manufacturing and shipping costs of the product.

TEST OBJECTIVE

To determine the impact and benefits of implementing XYO technology in household washing machines, comparative testing was performed. The testing consisted of quantifying the performance of a stock machine to that of a system equipped with XYO. A sample XYO system for a top loading washing machine appears in Figure 7.

TEST OVERVIEW

The main vibration concern in washing machines is the motion of the spin basket. Reducing the displacement of the spin basket leads to many advantages. The measurements presented here concentrate on quantifying the vibration of the spin basket and real world concerns such as noise and energy consumption. Values such as orbits, acceleration, energy consumption and noise were quantified on a stock machine and compared to a machine with the XYO balancer installed.

Mass Imbalance was applied to both types of machines by securing rubber weights of varying mass.

Orbits for the top loading washer presented were generated using a Bentley Nevada ADRE 3 measurement analysis system. The orbits were obtained by integrating the signal from a set of velocity transducers. The orbits for the front loading washer were obtained by mechanical trace.

Acceleration of the spin basket for both machines were recorded using a 50g (100mV/g) accelerometer.

Noise emissions were measured using a type 2 BEHA 93-20 Sound level meter inside a sound chamber.

Current was measured with a digital clamp multi-meter.

Rotational speed was measured by placing a piece of reflective tape on the rotor and rotation was detected by an optical pickup.

TOP-LOADING WASHING MACHINE

Vibration displacement is shown in Figure 9 using orbit plots and the results are further summarized in Figure 10. Vibration was significantly reduced (96%) when a prototype XYO balancer was fitted to the machine.

Without XYO

With XYO

TOP-LOADING WASHING MACHINE (CONTINUED)

Without XYO

With XYO

TOP-LOADING WASHING MACHINE (CONTINUED)

Without XYO

With XYO

TOP-LOADING WASHING MACHINE (CONTINUED)

Using XYO on a top-loading washing machine resulted in significant vibration reduction. The additional benefits are highlighted in Figures 12 to 15 and Tables 1 to 2 below. It should be noted that the 5kg counterweight was removed while testing with the prototype XYO balancer; it was no longer necessary for stabilizing the washing machine because of the capabilities of XYO. The weight reduction of the washing machine is an additional benefit of XYO that can lower manufacturing and shipping costs.

Without XYO

With XYO

Table 1. Summary of results for top-loading washing machine

TOP-LOADING WASHING MACHINE (CONTINUED)

Without XYO

With XYO

Table 2. Summary of results for top-loading washing machine

Note:
Noise transmission through a wooden floor was reduced by 90% with the XYO balancer; this significantly impacts noise emissions in residential living spaces.

FRONT-LOADING WASHING MACHINE

Vibration displacement was recorded with orbit plots (Figure 16). Vibration was significantly reduced (93%) when the XYO balancer was fitted to the machine.

Without XYO

With XYO

FRONT-LOADING WASHING MACHINE (CONTINUED)

The acceleration test results for the spin basket with 0.5 kg of mass imbalance is presented in Figure 17. Two 50g accelerometers were placed on the front and rear of the spin basket. XYO reduced the vibration by 81% at the front of the spin basket.

Without XYO

With XYO

FRONT-LOADING WASHING MACHINE (CONTINUED)

Using XYO on a front-loading washing machine resulted in significant vibration reduction.The additional benefits are highlighted in Figures 18 to 21 and Tables 3 to 4 below. It should be noted that the 16kg counterweight was removed while testing with the XYO balancer; it was no longer necessary for stabilizing the washing machine because of the capabilities of the XYO balancer. The weight reduction of the washing machine is an additional benefit of XYO that can lower manufacturing and shipping costs.

Without XYO

With XYO

Table 3. Summary of results for front-loading washing machine

FRONT-LOADING WASHING MACHINE (CONTINUED)

Without XYO

With XYO

Table 4. Summary of results for top-loading washing machine

Implementing the XYO technology in washing machines can provide manufacturers a significant competitive advantage. Some of the benefits of XYO include:

• Washing machine manufacturers can offer longer warranty periods due to lower mechanical wear with XYO
• Since vibration is reduced there will be less wear and tear on mechanical components and therefore less warranty claims should be experienced
• By using XYO the manufacturer solves the vibration problem at the source. Thus, the manufacturer should be able to use cheaper components and avoid costly methods that were previously used to deal with problems arising from vibration caused by imbalanced loads.
• The washer will spin faster because of reduced vibration and will result in greater water extraction and reduced spin cycle times. This will also result in further energy savings due to shorter drying times.
• The reduction in spin cycle time and direct reduction of energy consumed by the motor will translate into a substantial improvement in energy rating of the washing machine.
• The reduced noise emission of a washing machines equipped with XYO will provide a competitive advantage in the marketplace.
• The manufacturing and shipping costs of the machine can be reduced by removing the large heavy counterweights.
• Complicated and expensive electronic imbalance detection systems are no longer required. By implementing XYO, expensive sensors and programming can be eliminated.

The XYO technology has been implemented very successfully in top-loading and front-loading washing machines, as well as industrial washer extractors. The results presented here are based on a prototype XYO balancer design and they can be improved further.

Perpetual Industries wants to work with a capable and innovative washing machine manufacturer to optimize and implement the XYO technology and provide a strong competitive advantage in the market.