Washing Machine Controller

User InterfaceWashing and drying tubsDetergent

ModelXPB05-15Washing/Spin Capacity6.2 kg/5.2 kgRate PowerWashing 360WSpin 180WNet Weight3.5 KgGross Weight4.8 KgExterior size ( LxWxH )348x348x378 mm

Fully Automatic Course Selection: Fuzzy Light/Blanket/Heavy/Wool/Economic Function: Wash/Rinse/Spin.Various Auto Programs Auto Power Off Detergent Box

Cleaning Clothes Operating a washing machine is pretty simple: There are a few things to decide before you start your load of clothes, such as how big the load is (small, medium, large, extra large), what temperature the water will be for the wash and rinse cycles (cold/cold, warm/cold, warm/warm, hot/cold), how the machine should agitate (delicate, knit, permanent press, heavy), and how long the cycles should last (number of minutes, based on how soiled your clothes are). After you fill the tub with clothes, the machine fills the tub with water, and then stirs the clothes around using an agitator. After some time agitating, the washer drains the water and then spins the clothes to remove most of the water. Then, it refills, and agitates the clothes some more to rinse out the soap. Then it drains and spins again.

Over the years, the concept of adaptive control has continued to expand and can now be found in almost every industry. The automotive sector, for example, has quite a few adaptive concepts. Probably the best known automotive adaptive system is antiskid braking.Currently, intelligent design typically involves motion systems that have control or computing capabilities, sensors, and feedback loops. However, just a single component could be intelligent. For example, it is possible for a motor to measure its own speed, or for a bearing to sense the force being applied to it.Intelligent design has also contributed to the move towards distributed motion-control systems. The trend here is to place intelligence further away from the central controller, and closer to what is being controlled.

All this is made possible by ever-shrinking microprocessors and increasing processing speed. Microprocessors and digital signal processors have more functions built into the chip, requiring fewer supporting chips, thereby taking up less board space. This makes it possible to buy motors with built-in controllers and drives.But intelligent design has progressed beyond the realm of motion control. Intelligent design, and its close cousin embedded systems (placing microprocessors and sensors in places you wouldn't imagine), are making their presence known in the world of consumer goods. For example, designers are embedding computers in refrigerators and washing machines, and putting piezoelectric materials in skis.

Philips 51LPC Microcontrollers and Triacs in White Good Applications

A washing-machine example

The HistoryIn 2002 BL-Microcontroller and BL-Power started a joint-venture, setting up a demo washing-machine for the asia market. This project is intended to push Philips microcontroller and Philips three quadrant triacs together into the market, offering the customer a ready-to-go solution. With this solution it is possible to drive a full functional top-loading washing machine.

This project is called Jiao Liu.

Customers BenefitLow sensitive Triacs simple driving circuit P87LPC764 microcontroller very few external componentsTrigger on current-zero-crossing low supply currentVery simple Power-supply

The Demo

ContentsA user-interface

A cheap and powerful microcontroller

A power-interface (Triacs)

Power devices (Valves, Pumps, Motors)

Philips SemiconductorsLPC76x Family Low System-Cost Feature-Set- 8-bit System-on-Silicon - Low -Power 2x speed C51+ core- Reduced system-cost innovations- Many high-volume applications: Lamp Ballasts, Motor Contr., HVAC, Smoke Detectors, White-Goods etc. On-Chip Memory & Peripherals - Up to 4KB OTP Program Code for Micropower applications- 128 Bytes RAM for Data- On-chip System Supervisor circuits - Multi-function LP Osc. (0-20MHz) - 6MHz Internal Osc. & Reset

LPC76x Family - Features/Applicationsdoor lock controlmirror controlwindow lift controlair quality sensorsecurity systemstemp. sensorscar communicationCD, Tape-modulesclimate control / HVACmotor controlLCD backlight controlalarm systemshead / back lightingcompassLIN slave2K OTPUART, I2C, BOD1K OTPLow Cost 14 PinUART, I2C, BOD

Functional blocks of a washing-machine example User interfaceforwardreverseSwitch on/offTumble motorWater inlet pumpSwitch on/offDrain valve

The User-InterfaceShould be simple and cheap.LED's as indicators.Buttons and switches for the user input and machine-controlE.g.:4 LEDs to indicate program-selection for four different programs.3 LEDs to indicate state of the washing-machine. (ready, washing, idle)2 Buttons. (Program-select, Start/Pause)2 Switches for machine-control. (Lid is open, water maximum reached)

The User-InterfaceThe matrix-structure allows eleven elements on seven pins

The User Interface Matrix ManagementTo ensure an even brightness of the LEDs and to guarantee a reaction time for the buttons, the scanning of this matrix should be timer-driven.Turn on the LEDs of a column immediately after the column is activated.Read the buttons and switches of a column, before switching to the next.

7 Panel StatesEnable column 1, set LEDs Program 1 and readyRead button Program selectEnable column 2, set LEDs Program 2 and washingRead button Start/PauseEnable column 3, set LEDS Program 3 and idleRead switch Lid openEnable column 4, set LED Program 4Read switch Water Level max.Leds have to be on for a certain time, so set them at the beginning of the time a column is enabled.Buttons and switches need a cartain time to set up properly. Read them at the end of the time a column is enabled.

Update TimeTo avoid a flickering of the Leds, these should be updated at least with 80Hz. This leads to an update-time of 12,5ms. In this time all seven states have to be cycled trough. The panel-update routine must therefore be accessed every ~1,8ms.

The Microcontroller circuitryThe power supply.The reset circuit.The brown-out detection.The oscillator.The voltage zero crossing detection.The current zero crossing detection.

The P87LPC76x power supply from mainsP87LPC76xCheap for Low Power2 diodes and dropper RC2 diodes and dropper R (low current)Can drive up to 80mA Gatepulses

The P87LPC76x reset circuitNone, its on chip

The P87LPC76x brown-out detectionNone, its on chipConfigurable for 2,5V or 3,8V.

The P87LPC76x oscillatorNone, 6Mhz RC-oscillator on chip.Configurable for:Internal RCExternal low frequency oscillator (20kHz-100kHz)External medium frequency oscillator (100kHz-4Mhz)External high frequency oscillator (4Mhz-20Mhz)External Clock attached to X1

Elements to control by triacs User interfaceforwardreverseSwitch on/offTumble motorWater inlet pumpSwitch on/offDrain valve

Switching the triacsThe Turn-on of triac is done at voltage-zero-crossing of the mains voltage.To avoid current-jumps, the retriggering is done at current-zero-crossing detection.

Any LPC Input except IC-pins Internal Clamping Diodes Falling Edge InterruptSchmitt TriggerSingle Current Limiting ResistorVoltage Zero Crossing Detection

Single Pin sinks 20mAHigh Drive Capability with Combined Pins (80mA) 1 Current Limiting Resistor Capability to drive several TriacsSlew Rate Control (10ns)LPC Triac Drive Circuit

Senses Current Zero Crossing Window Comparator

Gate Voltage Supervision CircuitCompares Gate VoltageSupervision of Latch StatusDetects false Commutation

Self RetriggeringDetects false CommutationAdjustable to Load

Gate Voltage Supervision Circuit

Triac BTA216-600D44W LoadPhase 43 between U and IGate Voltage / 2Voltage WindowOutput PortMains VoltageLoad CurrentCurrent Zero Crossing Detection Example

The washing-program softwareLocated in non volatile memory, e.g. code space, EEProm or IC-EEPROM etc.Sequence of basic instructions like rotate forward, open drain valve, water in etc.Wait functionality is implemented with a timer.

Structure of the commands

Basic intructions//Commands#define cWaterIn1#define cWaterStop2#define cOpenDrain3#define cCloseDrain4#define cFwd 5#define cRev 6#define cStop 7#define cEnd 8#define cBeep 9#define cWaitLevel 10#define cSpin 11Lets water inStop the water-inletOpen the drain-valveClose the drain-valveRotate forwardRotate reverseStop rotatingEnd of programDo a beep with a sounderWait until the water-level switch opensSpin

Washing program example description

The wash-program softwareCalled by the endless-loop in the main program.The working-speed is in a range of some 100ms, therefore relatively slow and not time critical.

The Demo

0.35Flash Process8KB 3V Low-Power IAP/ISP Flash512B EEPROM768B SRAM6x Accelerated 80C51 coreImproved speed, power & EMCInnovative peripheralsEnh. UART + Baudrate Generator3Mb/s SPI & 400 Kb/s I2C serial I/O16-bit Capture/Compare/PWM UnitPackages: TSSOP/PLCC/HVQFN28Low Cost DevelopmentStarter kits (around $50)In-Circuit Debugger/Compiler All-in-one Package (under $200)Full Trace Emulation (under $500)Philips Semiconductors LPC900 FamilyLow-Power 3V Flash MCU

Extra features / added valueremote control (UART)soft start (Lamps, Motors)error supervision / alarmclosed loop controlhuman interfacesensor interface (ADC)...Easy interfacing to TriacsProgrammable solution (1 circuit for multiple applications)better EMIWhy Control Triacs with Philips LPC

Easy solution to control loads at mains supply with Philips LPC and TriacsVery cheap and simple power-supply due to low supply currentOffers a universal "one-for-all" control method for any load with load supervisionNew method for detecting zero-crossing of load Current without shunt resistor in the load circuit

Phase Control and SwitchingTriac DrivingZero-Crossing DetectionTriac SupervisionSynchronization to MainsEmulation @ Mains SUPPLYPower SupplyPhase Control ExampleContinuous Conduction ExampleApplication-Note AN467:

www.semiconductors.com/mcu

Thanks for your interest

Washing machine demonstration

The demo board

Summary of technical featuresA fully functioning controller for a top-loading washing machine that uses a reversible induction motorIntegrates Philips microcontroller and triacsLow total component countCircuit optimised for reliability and low costMost triacs driven directly from microcontroller (driver IC not required)Gate triggering uses voltage zero cross detection for minimum EMIResistor-less current zero cross detection uses triac gate voltage monitoringintelligent triggering of motor triacs minimises power supply current and allows the use of the best Hi-Com triacs (highest IGT)simple, low-current 5V logic supply uses R-C dropperUser interface includes LEDs, push buttons and audible sounderSoftware provided and includes a full suite of wash programmesBoard is complete and ready to connect to your washing machine

User interfacePush buttons:PROGRAMME - steps through the five programmes in turnSTEP - selects which sections of the programme to runSTART/PAUSE - starts and pauses the programmeLight Emitting Diodes:Wash programmes: SOAK, STANDARD, GENTLE, STRONG, FASTProgramme sections: WASH, RINSE, DRAINAudible sounder:makes a short sound for every valid button pushsignals the end of the programme by five long sounds

Making it workMains power supply is 180 - 260V, 50 - 60Hz.Use instand-alone mode orconnected to a top-loading washing machine

Stand-alone mode (1)Manual water level switchreplaces the machines water level switch function.Contacts closed when full, contacts open when empty.Set to empty before starting the programme to allow fill sequence to commence.Set to full to allow programme to progress.Set to empty during drain sequence to allow programme to progress.

Stand-alone mode (2)Spin disablea machine safety feature that is activated if the load is severely unbalanced or if the lid is lifted.It shuts everything down and halts the programme for a set timeout period after the fault has cleared.It is bypassed by connecting a wire link across the spin cut-out terminals.Spin cut-out terminals must be closed for the programme to progress through a spin sequence.NOTE: 100W loads minimum must be connected to motor forward and motor reverse outputs. If a suitable motor is not available, 100W - 150W lamps are suggested.

Stand-alone mode (3)What happens if the motor load is too small?The microcontroller applies gate pulses only when the load current is close to zero and the triac is about to commutate (turn off).If the load current is very small, it will spend more time close to zero.The microcontroller must apply more gate pulses to maintain continuous conduction.More gate pulses mean more current demand from the 5V logic supply.Our demo board has a simple R-C power supply of limited current capability.A load substantially lower than 100W requires more gate pulses than the power supply can sustain.The 5V logic supply drops below the microcontrollers brownout detection threshold, causing it to reset.

Connected to a washing machineConnect the five outputs: water inlet valve, motor forward, motor reverse, power switch trip and drain valve.Drain valve output also releases the spin brake.Connect water level switch (contacts open when empty).Manual water level switch must be set to empty to open its contacts and allow the demo board to see the machines water level switch.Connect spin cut-out switch (contacts normally closed to enable spin).At end of programme, the power switch trip output is activated to switch off the power switch.

Wash programmes1. STANDARDDefault programme on power-upUsed for most everyday washingAvailable options:WASH + RINSE + DRAINWASH onlyDRAIN onlyWASH + RINSEWASH + DRAINRINSE + DRAIN

Wash programmes2. GENTLEThe most gentle programme with minimum agitation for delicate fabrics including woollensAvailable options:WASH + RINSE + DRAINWASH onlyDRAIN onlyWASH + RINSEWASH + DRAINRINSE + DRAIN

Wash programmes3. STRONGThe longest programme - more vigorous agitation, more rinses, more water and longer spins for very dirty clothesAvailable options:WASH + RINSE + DRAINWASH onlyDRAIN onlyWASH + RINSEWASH + DRAINRINSE + DRAIN

Wash programmes4. FASTThe shortest programme - very quick, with one rinse for lightly soiled clothesAvailable options:WASH + RINSE + DRAINWASH onlyDRAIN onlyWASH + RINSEWASH + DRAINRINSE + DRAIN

Wash programmes5. SOAKNormal agitation with extended soaking periods to loosen ingrained dirtAvailable options:WASH + RINSE + DRAINWASH onlyWASH + RINSEWASH + DRAIN

Demo board PCB

Demo board schematic

Power supply

Power outputs

Voltage zero cross detection

Current zero cross detection by gate voltage monitoring

User interface

Intelligent triggering of motor triacs- minimises power supply current and allows the use of the best Hi-Com triacs (highest IGT)Load currentGate current

Load currentGate currentIntelligent triggering of motor triacs- minimises power supply current and allows the use of the best Hi-Com triacs (highest IGT)

8A 1000V Hi-Com triac in SOT186A for high AC mains voltages:

BTA208X-1000BUnique to Philips!

Benefits of BTA208X-1000BHigh Commutationless risk of triac damage through uncontrolled turn-onless false triggering with difficult reactive loadsfewer protection components required (snubbers, capacitors & inductors)better control maintained at high temperatureHigh voltage blocking capabilityhigher voltage headroomhigher reliability in high voltage applicationsless risk of false triggering through overvoltageHigh IGToptimised at 50mA max for best possible commutation performanceIsolated packageprovides 2500V RMS isolation from the mounting base

BTA208X-1000B applications (general)Reversible induction motors where mains voltage is boosted by autotransformer step-up in the motor windingsHigh mains voltage suppliesApplications requiring extra voltage headroom for improved immunity to false triggering by overvoltage

BTA208X-1000B applications (specific)Top-loading washing machinesTumble dryersIndustrial motor forward/reverse controlsdoorsroller shuttersconveyorsThree-phase mains loads operating at 440V

http://www.semiconductors.philips.com/news/infocus/IntelligentControllers/

9.The rinse cycle is completed in the same manner repair. When troubleshooting a washer, you need to as the wash cycle, and after this cycle, the timer shuts down, completing the operation. have the wiring diagram for that particular washer. Normally, it is pasted to the back panel. Try starting the machine and observing its operation. Run the machine TROUBLESHOOTING.Before attempting through its cycles so you can trace the trouble to one any repair or replacement of any washing machine circuit or component. Figure 7-3 shows a typical wiring component, you must locate the trouble. Eliminate any diagram of a washing machine. The information shown guesswork. Guesswork can result in time-consuming in table 7-1 should help you troubleshoot a washing Table 7-1.Washing Machine Troublesbooting Chart TROUBLE PROBABLE CAUSE REMEDY Motor will not start. Blown fuse. Replace fuse. (No power at motor.) Broken wiring. Repair wiring. Loose connections. Tighten connections. Inoperative timer. Repair timer. Defective motor. Replace motor. Motor will not turn. Jammed water pump due to foreign matter. Clean pump. (Motor has power.) Transmission jammed. Repair transmission. Low voltage. Correct voltage. Motor runs but agitator does Belt broken. Replace belt. not. Loose pulleys. Tighten pulleys. Belt off pulleys. Replace belt on pulleys. Faulty timer. Replace timer. Inoperative clutch. Adjust clutch. Broken gear in transmission. Repair transmission. Loose connection at time or clutch solenoid. Tighten connection. Washer washes but does not Water in tub. Check operation of water pump. spin. Faulty timer. Replace timer. Faulty clutch or transmission. Replace clutch or transmission. Loose connection in spin circuit. Tighten connection. No water enters tub. Clogged screen at water valve. Clean screen. Loose connection in water valve solenoid circuit. Tighten connection. Defective solenoid. Replace solenoid. Water valve stuck. Repair valve. Defective timer. Replace timer. Water does not drain. Clogged drain valve screen. Clean screen. Defective water pump. Replace water pump. Drain hose plugged. Unplug hose. Defective timer. Replace timer. Pump belt broken. Replace belt. Noisy operation. Loose pulleys. Tighten pulleys. Cracked belt. Replace belt. Worn transmission. Replace transmission. Worn pump. Replace pump. Loose cabinet parts. Tighten parts. Agitator operates when basket Improper electrical connection at timer. Correct condition. spins. Defective clutch. Repair clutch. Washer stalls when running. Frozen bearing. Replace bearing. Transmission jammed. Replace transmission. Off-balance load. Distribute clothes evenly in tub. Improper adjustment of vibration switch. Adjust switch. Washer leaks water. Poor door or lid gasket. Replace gasket. Pump seal defective. Replace seal. Hose connection loose. Tighten connection. Machineoverloaded. Remove part of load. Too much water in tub. Check operation of water shutoff. Washer does not cycle. Faulty timer. Replace timer. Inoperative solenoids. Replace solenoids. Faulty wiring. Repair wiring. Loose circuit connections. Tighten connections. Crossed circuit wires. Check circuits with manufacturer's diagram. Broken transmission parts. Replace transmission. 7-5

2/4Kbyte OTP EPROM, 128-byte RAMHigh-speed serial programming interfaceUp to 18 I/O Pins 2.7 V to 6.0 V operating range10 MHz (2.7 - 6.0V), 20 MHz (4.5 - 6.0V)Performance as conventional C51 @ 20 / 40 MHzSOIC20 or DIP20 packageThe broad PLC-family serves many applications with dedicated peripherals from comparators over keyboard interrupt, ADC, DAC to PWM in motor applications.This presentation introduces Philips new family of 8-bit single-chip, low-voltage embedded microcontrollers based on a real six times accelerated 80C51-compatible core. Manufactured in 0.35-micron embedded Flash technology from Philips, the LPC900 family has an operating range of 2.4 to 3.6V. In addition, the family includes exceptional power management capabilities that extend battery life from months to years, and is ideally suited for hand-held battery-powered devices and other electronic peripherals. The attendees will learn how Philips has significantly enhanced the capabilities of the 80C51 with the LPC900 family. Features include increased speed, improved power management, and low electromagnetic interference (EMI). The embedded Flash process equips the devices with up to 8KB Flash memory with In-Application Programming (IAP) / In-System Programming (ISP) and fast 2ms page program/erase times. Other significant user benefits are 512 bytes of on-chip data EEPROM, and 768 bytes of SRAM.The presentation will show that the LPC900 family includes an innovative set of memory sizes and peripherals around the core, such as 16-bit capture/compare/PWM, 3Mbps SPI and 400 Kb/s I2C serial interface, enhanced UART, watchdog timer and user selectable power management functions with 2.5% internal oscillator. Philips will outfit all members of this family in consistent packages and pin-out ranging from 8- to 80-pins. This family will also enjoy full development tool support from leading 8-bit tool vendors.