DESIGN CONSIDERATIONS

 Today's state-of-the-art high-end appliances

are more energy efficient, consume less
water, and are smarter than the machines
developed in years past. Texas Instruments
has developed products to meet the
challenges and requirements for these new
sophisticated systems.
ENERGY EFFICIENCY
 Home appliance (a.k.a. white goods) motors
are often oversized to account for the load
torque changes and transients. Scalar
techniques for control can result in
inefficient systems and noisy operation. This,
in turn, leads to a mediocre energy
efficiency that hovers in the 40% to 50%
range.
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 By implementing the control system with TI's
digital signal controllers, designers are able
to implement smaller, quieter motors with
energy efficiency as high as 85% - 90%. A high
efficiency is necessary to receive a stamp of
approval from a governing body such as the
US Environmental Protection Agency and
Department of Energy's STAR rating.
POWER FACTOR CORRECTION
 PFC is a technique of counteracting the
undesirable effects of electric loads that
create a power factor that is less than 1. In
washing machines, PFC is needed because of
the continuous transients and surge currents
exhibited by the electric motor during the
wash cycle, for example.
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 It is also used to boost the rectified mains
voltage up to 300 V to 450 V, which is then
used to power the 3-phase inverters which
ultimately operate the electric motor. With
TI products, PFC can be performed externally
with a separate integrated circuit or it can
be done in the digital signal controller
eliminating the need for a separate external
PFC controller.
IEC 60730 COMPLIANCE
 Home appliance manufacturers continually
introduce new design enhancements to their
automatic electronic controls that ensure
safe, reliable and efficient operation of the
equipment. Among other things, the IEC
60730 specification discusses mechanical,
electrical, electronic, EMC, and abnormal
operation of AC appliances.
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 For microcontrollers, the specification
details new test and diagnostic methods for
the real-time embedded software to ensure
the safe operation of embedded control
hardware and software. All TI TMSxx24xxxx
and TMSxx28xxxx digital signal controllers
support IEC 60730 compliance.
HIGH VOLTAGE ISOLATION
 For larger, higher-performance products
where reliability and motor-control accuracy
are key concerns, TI offers isolation products
that block high voltage, isolate grounds, and
prevent noise currents from entering the
local ground and interfering with or
damaging sensitive circuitry.
INTEGRATION
 Texas Instruments provides fully-integrated
solutions such as the digital signal controllers
(for digital motor control, PFC, and other
system functions), and relay drivers that
provide up to 8 channels, zero-volt
detection, and 5 V linear regulation for 5 V
logic that may reside on the board.
PROGRAMMABLE LOGIC CONTROLLER
BASED WASHING MACHINE MODEL
 This is based around modelling a common
clothes washing machine using
 Programmable Logic Controller technology.
 This involved choosing the parts, designing
the tub, assembling all the parts, wiring the
entire system, creating the program and
troubleshooting the final product. The
project uses the Allen Bradley SLC 500 as the
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 Programmable Logic Controller and the
RSLogix 500 software to create the program
in combination with the RSLinx
communication software package. This
project will be used at real, working model,
to compliment the LogixPro programmable
logic controller modelling software already
being used
WASHING MACHINE CONTROL
CARD
EXPLANATION
 The washer normally has Fuzzy and Manual
control.
 The washer controller supports various
modes of selection and also various cycle and
process selections given by the user. There
are different inputs given from the user and
the washer controller processes the data and
gives outputs into various forms like (Audio /
Display) alarms.
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 The important feature of this washer
controller is “Inlet Valve Safety” and “Delay”
operation which helps to increase the life of
the components and the motor. The child
lock and favorite program features add more
comforts for the end users. This controller is
capable to handle various types of motors in
the washing machines which allows the OEM
manufacturer to select different motors for
cost reduction.
BLOCK DIAGRAM
WASHING MACHINE THREE-PHASE
AC-INDUCTION DIRECT VECTOR CONTROL
 The latest trend in washing machine design is
the Table of Contentsreplacement of
traditional drive systems with modern,
electronically controlled, brushless drives. In
the past,
 washing machine designs employed two
widely used drive systems. The older designs
use electromechanically controlled, two-
speed, single-phase AC-induction motors.
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 This kind of drive system is no longer used
for new machines and is found in the least
expensive washer models only. Most washers
have universal brushed motors with Triode
Alternating Current switch (TRIAC) control.
However, with the advent of new electronic
devices, these drives are becoming out-of-
date.
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 A new generation of washing machines is
designed with brushless three-phase motors.
The best candidates for this design are
three-phase AC-induction motors and
permanent magnet sinusoidal motors. Both
motors require sophisticated algorithms to
perform control functions, and this requires
microcontroller-based solutions. DSP-based
devices are preferred because of the real-
time signal processing demands from AC
motor control applications
APPLICATION CONCEPT
APPLICATION FEATURES
 The three-phase AC-induction washing machine
drive responds to new market demands for
higher performance appliances. It provides a
maximum drive performance at a competitive
price, served well by Freescale Semiconductor's
56F801x/56F802x family of digital signal
embedded controllers. An example drive design
based on the MC56F8013/MC56F8023 offers the
product designer plenty of computing power,
with advanced peripherals at a very good
price/performance ratio. The most important
features of the drive include:
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• Three-phase AC-induction motor
• Cost-efficient tachogenerator on motor shaft for
speed sensing
• Direct vector control algorithm
• Speed range 0–18000 rpm (motor speed), 0–1800 rpm
(drum speed)
• Reconstruction of three-phase currents from DC-bus
shunt resistor
• Non-recuperative braking and deceleration control
• Loss-minimizing control
• Over-current, over-voltage and under-voltage
protection
• Out-of-balance detection for spin dry
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 • Washer algorithms implementation:
 — Tumble (wash)
 — Unbalance detection
 — Spin (dry)
 • Serial RS232 control interface
 The drive was developed to the considerable
number of unique requirements of the washing
machine application. The drive is designed to run a
very wide range of speeds, from 0–18000 RPM. It is
optimized to accept a wide range of loads. This
feature reflects the condition of a real washer,
required to run reliably with an empty drum or a
drum with wet and heavy clothes.
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 Another specific feature of the washer
application is the ability to develop a high start-
up torque for the motor to force the full drum to
move. As the efficiency of washing depends on
precise speed control of the washer drum, the
presented drive comes with a PID speed control
closed loop. Thanks to the inner closed current
control loop, the drive features high dynamics to
achieve top performance control.
 To shorten the washing cycle as much as
possible, a non-recuperative braking algorithm
was used to stop the drum when it finishes a high
speed spin-dry.