Application Of Creative Design Methodology In Improved...

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com April 2017, Volume 5 Issue 4, ISSN 2349-4476

55 Sameera Mufazzal, S M Muzakkir

Application Of Creative Design Methodology In Improved

Conceptual Design Of A Top Load Washing Machine For

Better And Gentle Cleaning

Sameera Mufazzal

Department of Mechanical Engineering

Jamia Millia Islamia

New Delhi- 25, INDIA

S M Muzakkir

Department of Mechanical Engineering

Jamia Millia Islamia

New Delhi- 25, INDIA

ABSTRACT Innovative product development is an essential activity for

a manufacturing enterprise to stand in an increasingly

stiff competition in the market. Since the traditional

design methods for product development mainly focus on

the product or technical system instead of the main

objective, the designer is restricted to think within the

prescribed boundary. The job becomes even more

challenging when the objectives conflict each other. To

overcome this, the present trend of product development

employs Creative Design Methodology (CDM) for

meeting everchanging and conflicting demands of various

customers, especially when further improvement seems to

have reached its limits. Numerous innovative design tools

have been developed to support designers to handle

different engineering design problems in a better manner

and with less tedious approach. The present work

attempts to propose an innovative conceptual design of a

Top Load Washing Machine for better and gentle

cleaning action, using CDM.

Keywords— Creative design methodology, TRIZ,

Ideality, Top load washing machine, Innovative

conceptual design

I. INTRODUCTION

Innovative product design is crucial to satisfy the

ever-changing needs of the users. The product design

phase is also a technical stimulator that governs the

economic growth of a country. In India, product

design and innovation does not seem to be a key

issue, and therefore, even after a dramatic growth in

the industrial field, India is strongly dependent on

the foreign technical product designs. This has

resulted in the Indian market full of foreign products.

This has adversely affected the export performance

of the country [1].

Currently, several design methods are available to

help the designer to come up with new designs but

the problem with these traditional methods, is that

they utilize the prior knowledge of the product and

process for improvement rather than focusing on the

objectives to be achieved, thus preventing the

designer to think creatively out of the box. The

modern trend of design involves creativity in

viewing the problem from different perspectives and

applying existing knowledge to achieve the objective

in different possible ways, irrespective of the

existing system/ product [2]–[5]. This way, the

designer is not restricted to imagine within the

boundaries of existing systems or product. In this

paper, an attempt is made to use TRIZ Ideality

concept, a powerful creative design tool, for

developing a creative solution of a washing machine

impeller design to meet the emerging customer

requirements, satisfactorily. The process illustrates

the great potency of the Creative Design

Methodology (CDM) and more precisely, Ideality

concept, to provide solutions to the challenges.

II. CREATIVE DESIGN METHODOLOGY (CDM)

A. Introduction

Creative Design Methodology facilitates

innovation. The proposition of better ideas is not

solely dependent upon the extent of knowledge of

the designer. Depending upon the thinking style of a

designer, his/her knowledge extent may sometimes

adversely affect the creativity. To offer creative and

improved solution of a system, generation of ideas is

the foremost requirement. Depending on the

researcher’s thinking capability, the relationship

between creativity and knowledge can be

described[6], as shown in Fig. 1. It is observable that

creativity is likely to rise with the increase of

knowledge, for creative thinking style, whereas it

reaches saturation if the imagination follows a

conventional style.

Depending upon the nature of objective, creative

design can be classified into following four

categories[6].

1. Problem-oriented creative design: This

approach utilizes the concept of Ideality. The

ideality of the system is increased for achieving

better performance. Some incremental changes in

the system are made to remove the conflicts.

TRIZ with its contradiction matrix and 40

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inventive principles, is one of the most widely

used methods to resolve such conflicts existing in

the system.

2. Function-oriented creative design: This design

emphasizes on developing a purely new system or

process that can meet the main objective. This

type of design is usually followed when the

improvement in the main function seems to have

reached its limit. Therefore, the major focus is

made on obtaining the solution to achieve the

desired function or goals. Any consideration with

respect to improving the existing system is

avoided. This introduces creativity in finding new

possible ways to achieve main functions by

exploring scientific principles and natural laws.

3. Product-oriented creative design: This design

focuses on secondary function improvement

while keeping any improvement in the main

system at abeyance. This strategy is useful in

those situations where the product has already

earned good reputation in the market and the need

is to improve the existing product by employing

method of functions-follow-forms.

4. Form-oriented creative design: This design

involves development of new aesthetic/

form/appearance of the product to fulfill the

cultural and mental needs of the users by utilizing

non-logical but creative thinking method. This

creates a novel design and attractive appearance.

B. TRIZ

TRIZ (Theoria Resheneyva Isobretatelskehuh

Zadach) means Theory of Inventive Problem

Solving. It was developed in 1946 by Genrich

Altshuller. It is one of the most widely used creative

product design tools. TRIZ is a vast concept and

incorporates many tools for inventive thinking, but

contradiction matrix and ideality concepts are some

of the most common tools used at present.

Ideality is one of the most useful concepts of

TRIZ, for an optimal/ innovative design of a

mechanical system that generates feasible but

creative solutions. It is an index to quantify the level

of innovation and can be expressed as a ratio of

useful functions and harmful functions, as shown in

the equation below.

Useful Functions (UF) are desirable functions

expected from a product, system or process. It may

incorporate both the main useful function (MUF) of

the product for which it is meant for, as well as other

beneficial consequences on supplementary systems

and environment etc.

The Harmful Functions (HF) include undesirable

functions (waste) associated with the improvement

process. It may include weaknesses, limitations,

failures, breakdowns, energy consumptions, negative

impact on other systems and environment, for e.g.

weight, friction, misalignment, noise, vibration,

wear, etc. The third element is cost that incorporate

both the money and the time spent on production,

installment, operation and services required by the

product [7].

Ideality becomes 100% when the system contains

all positives and no negatives. Improving ideality is

the prime objective of the innovations. There are

practically three possible ways to do it [3], [8].

1. Optimization approach: In this, the attention is

focused in mitigating HFs by the suitable design

of the system and by incorporating the best

available technologies.

2. Upgradation approach: This method is intended

to augment the system functionalities, both MUF

and other beneficial functions. The existing

components are replaced by new components

with improved overall functionality.

3. Novel approach: Here, the focus is maintained

simultaneously on all the three factors, that is

improving useful function, cutting down cost

and reducing harmful function.

The ideality index gives a clear vision of

innovation and helps in promoting the efficiency of

getting the same through the direction of getting to

the IFR (Ideal Final Result) by utilizing the

backward approach from ideality to reality. By

keeping track of IFR (which is though practically

impossible to achieve), the domain of finding

solution gets broadened and hence possibility of

achieving the goal with ultimate functionalities and

least costs, is enhanced due to easy identification of

barriers and hence after, their elimination.

Creativity

Conventional Thinking

Creativity Thinking

Knowledge

Fig. 1 Relationship between Knowledge

and Creativity





In this paper, the principles of upgradation

method, optimization method as well as novel

method have been utilized, for enhancing the ideality

of a system. This method is intended to mitigate the

system undesirable effects and augment the desirable

one. An addition/substitution of a new facility in the

main system may result in improved functionality.

As a case study, the method is applied for the

functional upgradation and system optimization of a

Top Load cloth washing machine with improved

rolling over action of fabrics during wash.

III. CASE STUDY: WASHING MACHINE

A. Prior Art

With the existing new technology and modern

advances, people have less time to spend on washing

clothes by hand. Thus, the laundry washing machine

is no longer a luxury product but has become a basic

daily necessity. However, the everchanging demands

of customers are quite challenging for the companies

to meet simultaneously. For example, the advent of

high-tech fibers and expensive designer clothing has

changed the consumer mindset from simply washing

to that of fabric care without compromising with the

washing efficiency. Henceforth, any attempt at

improving machine efficiency, however small, is

likely to have a significant impact on the consumer

decision. The present research is focused on redesign

of Top Load Washing Machine (TLWM), using

ideality concept of TRIZ, to meet both the

requirements at its best without making any

compromise between the two contradictions (i.e.

better but gentle cleaning action), unlike the

traditional method.

The existing state-of-the-art designs presents a

variety of models to choose from depending upon

the many features that one may find most suitable to

his/her requirements. A summary of the current

status of technologies in the area of TLWM is

presented to comprehend the research level and to

identify the intellectual property (IP) right owners.

The major distinctive patents describing peculiar

methods available at hand are briefed below.

A variable type washing pulsator [9] invented by

Hyun and Ju (US005727403A) in Mar. 1998, shown

in Fig. 2, describes a method for preventing tangles

and twists of laundry articles. The rotation of

pulsator generates circular water current in

horizontal plane. The design incorporates, variable

pulsator which move up and down during rotation,

and simultaneously expands and shrink, in respective

motions, thereby breaking the horizontal vortex and

preventing the clothes. Consequently, the random

currents thus produced increases the washing

efficiency.

Fig. 3 describes another invention (US005829277A)

of Nov. 1998 suggested by Wunderlich [10] as an

improvement over oscillating or rotating agitators of

TLWM that mix the clothes in the wash water while

the basket remains substantially stationary. This

design consists of a pair of agitators mounted on

opposite walls of a rotatable spherical wash basket.

The agitators are driven through spur gears in

mesh with the ring gear extends around the wash

basket. The rib on agitators forces the laundry to

move within the water in the basket. During wash

and rinse cycles, the agitators rotate with the wash

Fig. 3 Side wall agitator design: US Patent

US005829277A

Fig. 2 Variable agitator design: US Patent

US005727403A





basket and during spin mode the wash basket rotates

in opposite direction and the clutch fixes the agitator

to prevent their unnecessary rotation.

In Aug. 1999, further improvement in washing

efficiency was made by Sung-Min Kim and others

[11] to provide independent and opposite motion to

the agitator and the wash baton (Fig. 4). This

improved friction between the laundry and the water

due to relative motion of the agitator and the baton

and assured thorough cleansing action. Later, in Apr

2001, a US patent [12] granted to Wunderlich and

John Broker (US6220063B1), explored a method of

opposite motion of agitators mounted on side wall

(US005829277A) on their individual drive axes, to

which gears are mounted which in turn are meshed

with the drive motor gear. Rotation of gears is

translated to the agitator in opposite directions which

creates a tumbling action of the fabrics, facilitated of

the interior concave surfaces of the agitator pans.

A shift towards improved “turning over” action

of the fabrics was described by a US patent (20040168261A1) granted to Grifith et al [13] in 2004. The action is achieved by improved agitators with helical ribs, as shown in Fig. 5, that cause lifting of fabrics and dropping them downward towards the center of the washing basket.

Another variation was disclosed in a patent (US

20090293554A1) by Hettinger [14] in 2009,

discloses an improved rib design for better roll over

action. Fig. 6 shows dedicated contoured vanes

slopes upwardly (axially) from the inward radial end

toward the apex portion and then slopes downward

(axially) from the apex portion toward the outward

radial edge. The contour is designed in this shape to

enhance better and smooth rolling over action of

fabrics and hence their cleaning efficiency.

The present design trend is consideration of

environmental friendliness. Use of ample amount of

detergents in washing machine and finally its

discharge to sewage is a cause of environmental

concerns for decades. To counter this problem,

ultrasonic based detergent free design concept has

been put forward by Japanese Sanyo Corporation

which can produce 50 million micro air bubbles

within one minute with an average frequency of 20

thousand vibrations per second [15]. The principle

involved is production of high hydraulic pressure

due to collision of the air bubbles generated by

ultrasonic waves with the surface of clothes. This

causes the fabric to vibrate and separate other loose

matters. The added advantage is absence of clothes

twist, bigger tub space and no noise (as no rotating

member is present) along with requirement of low

water as there is not much rinsing desired as in case

of detergent.

B. Problem Statement

The cleaning of dirty clothes with water primarily

require clean water, usually mixed with detergent

and thereafter agitation of clothes for cleaning of the

dirt apart from dirty clothes. Sometimes, heat is

added to washing water to enhance the cleaning rate.

Therefore, the complete cloth cleaning can be

considered as a process requiring a combination of

mechanical, chemical and thermal energy. Generally,

to obtain satisfactory cleaning, users try to add large

and strong detergent, which results in color fading

and damage to clothes. Other way round to improve

Fig. 6 Pulsator rib design for US patent

20090293554A1

Fig. 5 Helical rib design of US patent

20040168261A1

Fig. 4 A design for imparting independent motion

of agitator and wash baton: US Patent

US005931029





cleaning is enhanced turbulence/ agitation of

cleaning water to remove the already separated or

weakly bonded oil micelles. To achieve this, finned

agitators are used in current washing machine

models. However, the contact of cloth with the vanes

and thereafter its entanglement and stretching may

tear the clothes apart. A brief overview of the basic

concepts of the most common current washing

machine models is given below.

In Front Load Washing Machines (FLWMs), the

mechanical action is provided by tumbling of clothes

in the wash water while the basket rotates, whereas,

in Top Load Washing Machines (TLWMs), an

oscillating or rotating agitator mixes the clothes and

articles in the wash water while the basket remains

substantially stationary. Further, depending on the

mechanism of agitation, the TLWMs are classified

into an impeller (or pulsator) type machines and an

agitator type machines. The agitator type washing

machine, shown in Fig. 7 comprises of a vertical

finned column disposed at the center of washtub

which twist back and forth to stir the clothes around

in the wash water for thorough and even cleaning.

However, powerful wash action can be aggressive on

the delicate clothes. Also, there is a risk of catching

of garments at the central column and further

stretching and tearing.

On the other hand, the impeller type machines

contain a low profile rotating base, shown in Fig. 8,

that generates the vortex current of the washing

water in the washing tub which strikes the laundry

articles and gently agitate them to be washed.

However, use of impeller create a risk of clothes

entangled with each other resulting in clumping of

clothes which when spinning together may cause the

machine out of balance. Moreover, due to small

agitation, clothes won’t get cleaned better or may

take long wash cycle to complete cleaning.

Due to the respective advantages and

disadvantages, as outlined above, customers use to

make compromise between cleaning efficiency

(agitator type TLWM) and fabric care (impeller type

TLWM). Therefore, there is a continuing need in

washing machines improvements which may allow

laundry articles to be washed more efficiently but

with gentle action.

C. Proposed Conceptual Design Based on TRIZ

Ideality Concept

The TRIZ ideality index is be defined as:

For the stated problem, UF is the efficient dirt

removal from the clothes through water. This could

be achieved in two ways:

i. Agitating the clothes inside the wash water

ii. Tumbling of clothes for thorough cleaning

Whereas, HF includes damage made to clothes

due to the above useful functions. This usually

incorporates:

i. wearing of clothes due to direct contact of

clothes with the agitator,

ii. tangling of clothes with each other due to the

vortex formed in water, resulting in rotation

of concentrated cloth mass.

Now, to improve ideality we may work with

either improving UF (upgradation approach) or

reducing HF or cost (optimization approach) or

trying a combination of both (novel approach). After

speculating on the above requirements and

brainstorming for ideas, several solutions were

identified, for achieving the agitation and tumbling

without bringing the clothes in direct contact with

the agitator and preventing the formation of vortex.

One of the so many concepts have been discussed

below.

Fig. 8 Impeller type TLWM

Fig. 7 Agitator type TLWM





With reference to Fig. 9, a central agitator with

integrated fins is used to create heavy turbulence in

the wash water. The agitator is hollow and a plurality

of nozzles are provided along its length. A

pressurized water flow through a pump is maintained

between the agitator nozzle and the bottom of the

wash tub through connecting pipelines. The wash

water from the tub bottom goes to pump and the

pressurized water flowing out of the pump is

directed to the agitator nozzles. The forced flow of

water emanating from the rotating agitator, not only

enhances the turbulence of water but also improves

the roll over action of clothes due to pressure

difference. This means an improvement of UF

through an upgradation approach. Moreover, the

contact of clothes with the agitator would be

restricted because of the pressurized water flow

away from the central post of agitator. This way, HF

has also been reduced with the same provision.

However, the pressurized water would tend to push

the fabric to the wash tub wall, thereby increasing

possibility of rubbing with the wall. This actually

will increase the HF again. Now, to resolve this

issue, we provide an added forced flow of water

through the wash tub perforation towards the center.

This will force the clothes to move around without

touching the agitator and the wash tub wall. Because

of this, the portion of the laundry near the center of

the tub will be forced to move in two directions; one

around the agitator and other toward the bottom

(tumbling) due to downward water flow whereas the

portion of laundry near the tub wall will have a

dominant motion towards the bottom of the tub. This

difference in motion will prevent the formation of

vortex and hence tangling. Therefore, the provision

of pressurized water will help in achieving both the

UFs and mitigating both the HFs stated above. Now,

since the addition of a pump and nozzles will add to

the production cost of the system, we think forward

to reduce it. Now, as we know that every washing

machine comprises of a drain pump to drain the

water out after the completion of wash cycle, and the

wash cycle and drain process are separated in time,

the same drain pump could be used for pressurized

water flow. So, during the wash cycle, the drain

valve may be closed to allow the cyclic flow of

water from pump to wash tub and vice-versa. When

the wash cycle is completed, the drain valve is

opened to allow the flow of water out of the

machine. In this way, the same pump can be used

both for wash cycle and for the drain purpose.

Hence, the design so far conceptualized is a novel

approach towards innovation which takes care of all

the useful functions and harmful effects, to fulfill the

Fig. 9 Conceptual Design of Washing machine nozzle type impeller using Ideality concept





present requirement of the customers without much

increase in the cost.

IV. CONCLUSION

In the present research work, Creative Design

Methodology, and more precisely, the TRIZ Ideality

tool has been employed to generate alternative

solutions for achieving the objectives in a uniquely

different manner for already perfected design of a

top loading washing machine. The ideality has been

enhanced through the following ways:

• Identification of useful functions and

harmful effects parallel to the

requirement of customers

• Review of the design gaps existing in the

present system based on the above

identification

• Filling these gaps, thereby increasing the

ideality, by proposing a simple concept.

A new concept for a top loading washing

machine has been proposed. A new concept of a

hollow agitator consisting of plurality of nozzles

along its length that causes forced flow of water for

enhancing the water turbulence and roll over action

of clothes due to pressure difference has been

proposed for implementation in a top loading

washing machine. Additionally, a forced flow of

water through the wash tub perforation towards the

center is incorporated in the design that prevents the

clothes contact with the wash tub wall too. This

action facilitates the prevention of vortex and hence

tangling of clothes thereby reducing the harmful

functions.

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