WO2020256659A1 - Washing machine energy and motion systems on the drum - Google Patents
Washing machine energy and motion systems on the drum Download PDFInfo
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- WO2020256659A1 WO2020256659A1 PCT/TR2019/050466 TR2019050466W WO2020256659A1 WO 2020256659 A1 WO2020256659 A1 WO 2020256659A1 TR 2019050466 W TR2019050466 W TR 2019050466W WO 2020256659 A1 WO2020256659 A1 WO 2020256659A1
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- Prior art keywords
- drum
- water
- washing machine
- chamber
- water chamber
- Prior art date
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Classifications
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/02—Rotary receptacles, e.g. drums
- D06F37/04—Rotary receptacles, e.g. drums adapted for rotation or oscillation about a horizontal or inclined axis
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
- D06B11/0093—Treatments carried out during or after a regular application of treating materials, in order to get differentiated effects on the textile material
- D06B11/0096—Treatments carried out during or after a regular application of treating materials, in order to get differentiated effects on the textile material to get a faded look
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F23/00—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry
- D06F23/02—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about a horizontal axis
- D06F23/025—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about a horizontal axis with a rotatable imperforate tub
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F23/00—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry
- D06F23/06—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about an inclined axis
- D06F23/065—Washing machines with receptacles, e.g. perforated, having a rotary movement, e.g. oscillatory movement, the receptacle serving both for washing and for centrifugally separating water from the laundry and rotating or oscillating about an inclined axis with a rotatable imperforate tub
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/02—Rotary receptacles, e.g. drums
- D06F37/04—Rotary receptacles, e.g. drums adapted for rotation or oscillation about a horizontal or inclined axis
- D06F37/06—Ribs, lifters, or rubbing means forming part of the receptacle
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/20—Mountings, e.g. resilient mountings, for the rotary receptacle, motor, tub or casing; Preventing or damping vibrations
- D06F37/22—Mountings, e.g. resilient mountings, for the rotary receptacle, motor, tub or casing; Preventing or damping vibrations in machines with a receptacle rotating or oscillating about a horizontal axis
- D06F37/225—Damping vibrations by displacing, supplying or ejecting a material, e.g. liquid, into or from counterbalancing pockets
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F37/00—Details specific to washing machines covered by groups D06F21/00 - D06F25/00
- D06F37/26—Casings; Tubs
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
- D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00
- D06F39/04—Heating arrangements
Definitions
- the present invention relates to a washing machine for applying wet, dry, physical or chemical treatments onto materials, comprising a shaft positioned horizontally or having an angle with the horizontal axis, a perforated drum turn around a bearing system, a water chamber outside the drum wherein the water coming out of the drum is collected, moving parts placed inside or outside the drum in order to aid the working of the machine and/or increase the performance of the machine and/or provide economy of resources used by the washing machine such as water, energy, chemicals and time, motors, mechanical, pneumatic, electrical and electronic systems placed inside or outside the drum that are connected to said moving parts for moving said moving parts in a controlled manner and auxiliary equipment required by said systems and wherein energy sources such as electricity, pressurized air and steam is provided on the drum and areas where the contact of devices, instruments and equipment used in said systems placed outside of the drum in fully or partially water-free zones.
- energy sources such as electricity, pressurized air and steam is provided on the drum and areas where the contact of devices, instruments and equipment used in said systems placed outside of the
- Said washing machine may comprise a front load drum having shaft and bearings in the rear or a drum having bearings on both sides that can be loaded from the cylindrical surface.
- a front loading drum having a bearing on one circular surface and a loading opening on the other circular surface is depicted in the description and the terms front and rear are used to describe these two circular faces of the drum. It should be understood that, in the case of a drum having two shafts and a loading opening on its cylindrical surface, the terms front and rear refer to the two circular surfaces of the drum where the shafts are located.
- the machines described by this invention are generally referred to as "washing machines” because they are commonly used in households for washing laundry using water and chemicals such as detergent, bleach and fabric softener. However, they can be used for a variety of purposes and can have different capacities. Machines of this kind having a capacity between 4 and 16 kg are used in households and those having a capacity between 16 and 500 kg are used in industry. These appliances are most widely used in washing, dry cleaning, piece dyeing and stone washing. Even though they are mostly used for wet treatments, they can also be used for dry treatments in special applications such as stoning or sanding.
- Another appliance that is similar to washing machines from a technical standpoint and that is front loading and has a perforated drum is a drying machine. There are 3-4 carrying ribs on the perforated cylindrical surface of the drum to ensure that the material moves along with the rotation of the drum. The physical effect is realized by this movement caused by the rotation of the drum.
- pumice stone Some of the problems caused by the utilization of pumice stone are as follows: transportation from volcanic mines where they are produced to areas where they are used, storage, environmental issues such as transportation and dusting in the production areas, emptying the machine after stoning treatment to clear textile of pumice stone, clearing textile of pumice stone, reloading and rewashing of textile to clear away pumice dust and transport of pumice waste to safe waste areas where it won't cause environmental pollution.
- different materials were tested and different methods were evaluated for abrasive applications. All particular mechanical abrasive materials cause environmental pollution.
- Bleaching, corroding, abrasive and dye remover chemicals are used along with mechanical abrasive materials or by themselves during washing.
- a natural material, "enzyme,” is also commonly used by itself or along with pumice stones during stone washing. As it is a natural material, it is accepted to be the least harmful chemical used in denim washing. Even though different materials, methods, techniques and chemicals have been used, very few changes have occurred in the past 30-40 years in terms of industrial type stone washing machines having perforated cylindrical drums.
- mechanical abrasive materials wear down areas they come in contact with such as the drum and the ribs and the chemicals used cause chemical corrosion.
- drum inner surface (104-n) is covered by stainless steel; however, no method has been able to provide a satisfactory solution to this problem.
- Simsek describes a machine providing stone washing ability by imparting abrasive characteristics to the surface of the drum instead of loading abrasive particles therein, in 2017 by an application titled "Abrasive Stone Washing Machine” (W02017151074A1, 2017-09-08). Simsek also describes abrasive grindstones attached onto drum inner surface (104-n) in the manner to form protrusions thereon in a European patent (EP2229475, 2017-07-12). While the desired results of these applications were achieved, it was not possible for them to be utilized in practical applications.
- the reason for that is that the length of process time required to reach the desired results using these systems is 10 times longer than those using pumice stone. This means that in order to obtain the capacity of one conventional stone washing machine, ten machines with abrasive drums need to be used.
- One of the reasons for that is that while grindstone can be produced to have higher abrasive characteristics than pumice stone, there is a big difference between the two in terms of the surface area that comes in contact with the textiles. When a sufficient amount of pumice stone is added in with the textile to undergo abrasion treatment, the pumice stone gets crumbled down to dust and spreads over the surface of the textile.
- rollers having abrasive surfaces for abrading applications is known in the state of the art. Rollers having abrasive surfaces are used in many different types of machines such as potato peelers.
- the problem to be solved is mounting the mechanical and electrical systems to drive the abrasive parts such as rollers placed inside the drum at the desired speeds on the outside of the drum.
- the present invention aims to solve this problem.
- the first step to solving this problem was described in the system disclosed by Simsek in EP2229475.
- Application of the system disclosed in EP2229475 makes it possible to drain all the water that is exist in between inner and outer drum. So by application of the EP2229475 outside the inner drum and inside the outer drum is empty.
- the textile will move contacting with abrasive surface across the abrasive moving parts during the rotation of the drum and therefore the desired wearing result will be achieved hundreds of times faster.
- Parts that are moving in ways other than rotation, such as by vibration, will create a dynamic movement that will increase the physical effect obtained only by the rotation of the drum by tens and hundreds of times and decrease treatment time and as a result increase efficiency and decrease costs by providing savings in time, energy, manpower and resources and provide a more environmentally friendly process.
- Moving parts placed within the drum will increase the physical effect provided by laundry washing appliances and therefore increase the quality of the treatment while reducing treatment time and chemical consumption.
- One of these effects is rubbing the laundry against each other.
- Fraser US2002029594, 2002-02-07
- This system had some issues due to its mechanical structure and coupled with its costs, it had limited application. Its mechanical structure makes it even more difficult to adapt to industrial size appliances than to household appliances.
- Moving parts rotating, vibrating or oscillating eccentrically on the drum surface will increase the rubbing effect and the quality of washing.
- a machine having rotating brushes will be able to clean floor/dust mats and other hard material much faster.
- rollers having plastic protrusions will create rubbing effect on the laundry by rotating slowly.
- the Poly-Rib system (60) describes a protruding drum surface with reduced drum perforation to limit water discharge to circulation pump capacity.
- a large portion of the drum holes are clogged by the laundry during draining and spin extraction. Therefore, although there are multiple holes in the drum, the water discharge is irregular. The holes must be kept open at all times to ensure regular, almost constant flow and continuous water discharge from the drum even though the amount of holes is much less than that of conventional drums.
- Poly-Rib system (60) ensures that the water outlet from the drum is continuous and limited, while the Eco-Drum system (61) pump that limited water from the outer drum back to the inner drum with a proper flow rate capacity pump.
- Eco-Drum system (61) describes a pumping system to pump draining water from the tub to the drum that have higher pumping capacity than draining water from inner drum to outer drum.
- the common purpose of the two systems is to prevent the presence of water in the outer drum. So these two systems together make it possible to collect all the water in the machine in the drum and evacuate all the water out of the outer drum. The evacuation of the outer drum allowed a significant amount of water savings in the washing machines. If there is no water in the outer drum, it is appropriate to ask why still an outer drum is needed.
- Moving parts can be moved using a motor system (400) placed outside of the drum. Possibility to have motor systems (400) placed on the drum outer surface (104-s) give many different mechanical applications on the washing machines. These moving parts can also eliminate the imbalance caused by the uneven distribution of the laundry within the drum during the spin cycle and the resulting vibration of the machine.
- front-loaded horizontal washing machines providing a spin cycle have a balance system that can be summed up by two principles.
- the most commonly used balance system utilizes spherical marbles that are free to move within a circular tube or channel placed at the same rotation axis of the drum, wherein these spherical shape weights can be displaced to provide a counterweight to the imbalance.
- a system comprising two weights rotating freely around the bearing at the rotation axis may be included in this system. Many application options are suggested for this system and some of these have been applied to the front, the rear or the front and the rear of the drum are together.
- the system is based on the principle of the marbles being displaced by the eccentric motion of the drum in a manner to provide a counterweight to a possible imbalance in the drum. While this system can ameliorate the imbalance, it cannot eliminate it completely.
- Another balancing system known and used in the art is the addition of external weights to provide a counterweight. Obtaining a counterweight by adding a weight was first proposed by Kahn in 1945 (US2534267, 1950-12-19) and then developed further in 1946 and 1948 (US2534268 and US2534269).
- the balance system (300) proposed by the invention operates under the principle of counterweights driven by motors to be displaced in a controlled manner to balance the loads in the front and rear of the drum to restore the balance.
- the spinning process will be much faster compared to water-based balance systems and much more sensitive compared to ball balance systems, the balance can be maintained at high sensitivity throughout the spin cycle, the volume required to put aside for the balance system (300) will be much smaller and there will be no need for water consumption.
- Water free outer drum surface provide not only mechanical and motor system (400) application but also give possibilities apply sensors and control systems.
- Disposing Machines for determining the imbalance on parts of different weights and sizes that rotate at high speeds in order to permanently provide balance for said parts and these methods have been used in many different technical industrial applications, especially with the development of electronic systems. It is possible to commercially obtain both hardware and software products for these machines.
- the present invention aims to provide washing machines with features of "dynamic balance machines”.
- washing machines are heated by different methods using electricity and steam.
- the physical conditions of the substructure requirements cause more serious problems to increase suppling of the energy while using electricity.
- high capacity industrial machines utilize steam instead of the electricity that widely used in small machines as domestic and commercial using.
- Steam is utilized by adding it directly to the washing water or for heating the washing water in a heat exchanger indirectly.
- energy is required in laundries for heating the washing water of the washing machine and for heating the dryers and irons when necessary.
- applications where dryers and irons utilizing gas in the form of LNG, LPG or NG are used have eliminated the necessity of using steam.
- steam is mostly necessary for washing machines. Providing a practical and economic solution to heat the washing water in washing machines will also provide a solution to spend less investment to construct the infrastructure system to provide steam. Therefore, using gas to heat washing machines is additionally important in terms of finance.
- the invention proposes machines that are generally known as perforated- drum washing machines.
- the machines are designed to provide mechanical and/or chemical treatments in wet, and in some situations dry, conditions to the materials loaded into the drum.
- the physical effect provided by a drum rotating in a water tank to materials inside the drum such as mixing, dropping, rotating and rubbing aid in increasing the effect of the chemicals added to the water.
- Said machines can be produced for many purposes, starting from "small scale" machines having a drum volume of 40-100 L. for household use and can go all the way up to industrial scale machines having drum volumes up to 5000 L.
- washing machines While they are generally referred to as washing machines, they are used as dry cleaning machines in applications where chemical solutions are used instead of water, as washing machines in household and industrial applications and can also be used to wash materials other than laundry in textile applications, mechanical applications such as stone washing to abrade of textiles and chemical applications such as dyeing.
- washing machines that are defined as laundry machines
- the perforated drum is placed in a water tank that is fully sealed against water leakage from the door or around the drum shaft. While the drum is defined to be fully sealed, it is important to note that there are inlets to and outlets from the tank such as water and solid or liquid chemicals, steam inlets to the drum, a discharge system for waste water, an overflow system in case the water level in the drum rises excessively, excess steam and water vapor outlets.
- the present invention comprises systems that are suitable for adapting to any type of washing machine. Therefore, the phrase "washing machine” indicates all machines providing wet, dry, chemical or mechanical treatments in a perforated drum.
- the description and figures depict a medium-scale industrial machine in order to exemplify the applications.
- the figures depict a drum having a diameter of approximately 1600 mm and a depth of approximately 600 mm. Based on these measurements, a cylindrical drum would have a volume of 1200 L.
- the drum has a diameter of approximately 575 mm and a depth of approximately 4500 mm, having a gross volume of 110 L. and net volume of 100 L. the difference between gross and net volumes is a feature of the invention and will be explained below.
- the aim of the invention is to increase the physical effect provided by the rotation of the drum and decrease the physical effect caused by the uneven weight distribution during the spin cycle.
- moving parts that are moving inside and outside the drum have been added to the drum. Moving parts inside the drum increase the physical effect required by the treatment while the moving parts outside the drum prevent the oscillations and vibrations caused by the unbalanced weight distribution during the spin cycle. In this manner, the perforated drum of the washing machine is no longer just a cylindrically shaped canister, but gains the characteristics of a functional machine by itself.
- Moving parts inside the drum create physical effects in addition to those created by the rotation of the drum and are used to increase the physical and chemical performance inside the drum. Said moving parts are placed inside the drum, which increase the desired physical effects on the materials placed within for treatments such as washing, dyeing, stoning, polishing and brushing.
- the proposed system of the invention provides rubbing in washing machines, brushing in machines where hard materials such as dust mats are washed, and abrading of textiles without the need to use environmentally harmful pumice stone.
- the system proposed by the invention makes possible the addition of parts that are capable of rotation, oscillation, vibration or eccentric movements and axial movements in horizontal and vertical directions when driven by a motor/movement system.
- the washing machine has an extraction feature
- the addition of moving parts outside the drum provides a new solution to the problem of oscillations and vibrations caused by unbalanced load distribution during the spinning extraction cycle.
- moving parts can be moved in such a way to provide a counter weight against to the unbalanced load distributed in the drum. In this manner, the loss of balance during the spin cycle can be compensated consistently.
- the use of a known, sensitive system that is in use for providing balance to the drum during the spin cycle allows freedom from the springs attaching the drum to the chassis, the suspension systems and the weights attached to the drum chassis that were previously deemed necessary to use.
- the moving parts inside the drum aid in the operation of the machine and improve the performance of the treatments done within as well as savings the use of resources such as water, energy, chemicals and time.
- Supplying electricity and air to the drum makes it possible for all kinds of electrical and pneumatic systems to be mounted onto the drum. Aside from movement systems, devices serving particular purposes, such as valves and pistons will be functionally usable on the drum. In this manner, in the embodiments disclosed herein, it will be possible to cut off draining water from the inner drum to the outer water chamber by a valve. As the water filled into the drum will remain only inside the drum after the valve is closed, the water and chemicals added to the drum are fully used in an efficient manner therein. This means that the point reached in water and chemical savings is the highest possible level. In addition, supplying electricity to the drum allows electrical water heaters to be mounted onto the drum for heating the water in the drum and keeping the water temperature constant directly therein.
- Monitoring the process within the drum is especially very important for certain treatment processes applied in industrial type machines. It is necessary to observe the movements, conditions and changes in the material in the drum through the glass in the door used to close the entrance of the drum. However, as the inside of the drum is dark, the lighting from the door glass only illuminates a limited area. Whereas if the inside of the drum is illuminated by lighting elements mounted on the surface of the drum, a wider area can be illuminated.
- the water therein also contain added chemicals, insoluble solid particles and water soluble substances transferred to the water from the processed material inside the drum. It is inescapable that dynamic systems inside the water tank come in contact with the water containing chemicals and insoluble solid particles and that their operation be hindered due to the water. Precautions can be taken to ensure that dynamic systems inside the tank can operate without being affected by water and the chemical and physical substances in water.
- An exemplary application relating to this is a potato peeler having an abrasive roller.
- the main problem that needs to be solved is ensuring the smooth operation of motors, mechanical, pneumatic, electrical and electronic systems and moving parts in said liquid rich with chemicals and solid materials.
- Movement transfer systems such as belts, pulleys, bearings and gears for transferring movement from the motors mounted outside the drum to the dynamic systems inside the drum can be affected by solid materials that can be found in the washing water, such as thread, fabric, fuzz metal buttons, etc.
- the gears operating outside the drum in washing water may get stuck because they get tangled with the threads that have come off from the textiles.
- the use of highly acidic or basic bleaching substances leads to corrosive conditions, the use of devices and materials not produced from stainless materials is undesirable. In this case, contact of mechanical and electrical dynamic systems in the tank with water can be prevented by the application of the saving system described in EP2229475.
- the present invention proposes solutions for preventing contact between the liquid in the drum and the movement system on the drum in a practical and economic manner so that the dynamic system operates smoothly.
- the part of the washing machine called as water tank or outer drum is mainly a part that is filled with water and that contains the inner drum.
- the water tank carries the water inside the drum. When the drum is not rotating the water levels inside the drum and the tank are equalized.
- water chamber 500
- the water chamber is a chamber that surrounds only the perforated portion of the drum to collect and flow water away. That means all non-perforated parts of the drum are outside. All non-perforated external surfaces of the drum are free of water, meaning they are dry.
- the washing machines (50) with horizontal drum that are widely used comprise a perforated drum (104) that is mounted inside a water tank by a drum shaft (103) and a drum shaft bearing (102).
- the washing machines related to the present invention can be of two different types: household washing machines (57) and industrial washing machines (51). Both can have two different structures: front loading (58) and side loading (59). While washing machines designed for household or small-scale commercial use that can be produced by mass production techniques and washing machines for industry which are designed specifically for a given application are both referred to as "washing machines", there are significant differences between the two in terms of design and operating conditions.
- Household washing machines (57) that are designed for individual use having a drum diameter up to 600 mm and defined as “small scale”
- commercial washing machines (56) that are designed for laundromats.
- Commercial and industrial laundries uses industrial washing machines (51) having a diameter between 600 and 1000 mm and defined as “medium scale”.
- Industrial washing machines (51) designed for industrial use having a diameter between 1000 and 2000 mm and defined as "large scale” all provide treatment applications to materials having essentially the same features. When textiles undergo treatments in industrial washing machines, they are subjected to much greater physical effects than in household washing machines (57).
- any and all sizes required by the system of the invention may be applicable without limit.
- the outer sizes of household washing machines (57) are fixed. Due to these international standards restrictions, it may not be possible to utilize some feature of the system of the invention in household washing machines (57).
- drum perforations/holes (105) of drums (104) having a drum diameter of 400 mm or 2000 mm are kept below a certain limit as technical means allow.
- Drum perforations/holes (105) can have a maximum size of 5-6 mm.
- the minimum size of drum perforations/holes (105) is limited by production techniques.
- drum lifter ribs (107) are generally proportional to the diameter of the drum. It is obvious that ribs used for a small drum will not be able to fulfill their function in a drum having a diameter of 1500-2000 mm. While the ribs that are used in the drums of industrial washing machines (51) fulfill the function of rotating the materials along with the drum, they also cause a problem.
- the physical endurance of the textiles carried by generally triangular prism shaped drum lifter ribs (107) are similar to that of the textiles washed by household washing machines (57).
- drum lifter ribs can change their sizes as required and when the spin cycle starts, their heights can be decreased. This change in the sizes of the ribs can be realized by a motor to move parts on the drum (130) or a pneumatic system to move parts on the drum (131) to move parts that are mounted on the drum.
- Non-perforated external surfaces of the drum on the outside of water chambers (500) allow the drum to be directly heated by furnace.
- the drum is in direct contact with the washing water and the materials being treated therein. Therefore, when the drum is heated from the outside, the washing water will be heated indirectly.
- This method has many advantageous consequences.
- This technique is one of the well-known heating methods since humans started to control and use fire. We still cook and heat meals in the saucepan on the fire cooker. With a burner placed under the drum, washing water heating in the machine is looks very simple and practical. It is also very economical; there will be no need to invest in a steam boiler/generator and all expensive steam pipeline system together with all related parts and equipment.
- Industrial washing machines (51) do not solely refer to industrial textile washing machines (52). Machines having similar features are used for many different washing treatments and these machines are also defined as washing machines. Household washing machines (57) and commercial washing machines (56) are generally used for washing laundry. However, aside from industrial textile washing machines (52), large capacity industrial washing machines (51) also comprise industrial parts dyeing machines (53), industrial stone washing machines (54), final washing of the textile products of the textile manufacturing, rubber-covered dust mat washing machines and industrial heavy material (such as carpets) washing machines (55). While they are similar in terms of looks and basic structure, they have very different structural features.
- the present invention comprises many features having a technical advantage that are based on the system where a section of the drum is taken out of the water tank and/or water-free zones are formed on the outer surface of the drum using the Poly-Ribs Eco-Drum technique that explained by EP2229475.
- a section of the drum is taken out of the water tank and/or water-free zones are formed on the outer surface of the drum using the Poly-Ribs Eco-Drum technique that explained by EP2229475.
- One of the principles and preferred purposes of the invention is the presence of moving parts in the balance system (300) inside and/or outside the drum. Providing the conditions wherein moving parts (200) that can be moved in a controlled manner can be mounted onto the drum, what the moving parts may be, the advantages brought about by the moving parts and the operations possible with these machines are organized and described under the headings below.
- the most important inventive step of the invention is to directly connect electrical energy to the drum and to move all moving parts in the drum with electric motors.
- water tank or an outer drum we call the water-filled part surrounding the inner drum a "water tank or an outer drum", as well sometimes a water tub.
- Water tank and outer drum are good definition for water fill closed container. But if the chamber at the outside of the perforated inner drum is only functioning to collect drain water come through inner drum perforations, water chamber will be more suitable to define.
- the outer drum, water tank, water drum is used to describe the water container in conventional washing machines. In our system the outer chamber only for collecting water likes a chamber. So it is more appropriate to refer to this part as water chamber.
- the system described in EP2229475 aimed to save water by collecting all the water exist in the outer drum into the drum.
- the presence of water in the outer drum or even completely emptied can be controlled.
- the amount of water contained in the outer drum or even the complete discharge of the outer drum was controllable.
- the outer drum is no longer outside the drum, i.e. there is no known water tank surrounding the drum. It is enough to cover small part of the outer surface of the drum which water draining from the drum by the collection chamber to collect water from the drum.
- the drums being largely out of the water tank open the door to many new applications in the design of the washing machine.
- mechanical moving systems can be mounted inside and outside of the drum. Motors that provide these mechanical moving systems to operate can be mounted directly outside the drum. The electrical energy that enables the motors to drive said mechanical moving parts can be directly connected to the drum.
- various sensors on the drum, pressurized air systems, liquid or gas-driven equipment, liquid or gas transfer connections required for these systems can be provided. In a sense, the drum was gain freedom from coming out through outer drum. Until now, the rotating perforated cylindrical part that mounted in a water tank is called drum. After that, it will be possible to call this piece as "free- drum” and from now on, the free-drum itself can be defined as a machine.
- rollers (201) are placed as close to the surface as possible onto cylindrical perforated drum sheet (106) or into the hollows formed by protrusions on cylindrical drum surface (261), the dynamic character of the free-drum (104) will be increased without giving up drum volume.
- rollers (201) and vibrating parts (222) are abrasive for use in stoning they are referred to as abrasive rollers (202) inside free-drum and when they are used for rubbing, mixing and felting treatments they are referred to as eccentric rollers (204) inside free-drum.
- the embodiment that will stand out the most will be industrial stone washing machines (54) comprising abrasive grindstone rollers (206).
- 2- Moving parts outside free-drum f251j and balance system G300 ) outside the free-drum are described below.
- a second important application area of mounting moving parts (200) onto the free-drum is that it allows the machine to perform the spin cycle without vibration by weights placed in free-drum front circular base/opening side (109) and free-drum rear circular base/shaft side (110) of the outside of the free-drum to balance the imbalance produced during the spin extraction.
- An exemplary embodiment of said dynamic balance system (300) may be a system comprising 2-weight balance system (302) mounted front and rear side of the free-drum that contain 2 balance weights for 2-weights balance system (302). Each balance weight can move around in the balance weight bearing system (302-S) around the free-drum cylinder (104).
- balance weights (301) balancing each other when placed in opposite positions on a balance weight bearing system (302-S) on the axis of the drum that can be rotated 360° by a gear connected to motor (310) connected to a balance weight movement motor (306).
- the balance weights for 2-weights balance system (302) are placed in the front and the rear of the drum and outside of the balancing process; they are positioned in the manner to balance each other. During balancing they are displaced in order to offset the imbalance in the free-drum .
- the two weights are two balance liquid containers (331) that are positioned opposite each other and that can be rotated 360° during and outside of the balancing process without changing their positions relative to each other.
- the two balance liquid containers (331) each contain a certain amount of balance liquid to balance each other out.
- the containers are rotated together in the same direction as the imbalance load force vector while maintaining their positions opposite each other. While the containers are in this position, liquid transfers from one tank to another through balance liquid transfer connection line (334-L) so that the weight of one tank increases while the other decrease, until the counterweight to balance the unbalance load in the drum.
- Another balance system is to create an opposite force to balance the unbalance force created by the centrifugal force by moving of minimum 3 balance weight pieces for 3-weights balance system (303-P) placed on the drum independently.
- this balance system for 3-weights balance system (303-W) that able to mounted at the front and/or at the rear of the drum placed at equal distances from weight guide bearing for 3-weights balance system (304) on a threaded balance weight movement screw (305). If balance weight pieces for 3-weights balance system (303-P) move away from the rotation axis of the drum by screw turning, each create more centrifugal force.
- 3 or more weights are moved away from the axis of rotation, by separate motor driving to rotate screw to which each weight is mounted to create a counter-balance force.
- a preferred attribute of the dynamic free-drum invention is the controlled movement of moving parts inside (250) and outside (251) the drum using a motor system (400).
- a motor system 400
- said moving parts are in a water tank/outer drum (101) in a free-drum (104) rotating by a drum shaft bearing (102) and the controlled movement of moving parts (200) can be realized by at least one motor to move parts on the drum (130), it is only possible to implement the system if the problems associated with the presence of water in water tank/outer drum (101) are solved.
- Moving parts inside drum (250) of said moving parts (200) need to be connected to a motor to move parts on the drum (130) or pneumatic system to move parts on the free-drum (131) that is a drive source.
- Moving parts inside free-drum (250) need to be connected to motor to move parts on the free-drum (130) directly or via a movement transfer system (401) from the cylindrical perforated drum sheet (106), drum front circular base/opening side (109) or preferably drum rear circular base/shaft side (110).
- the electrical drive motor on fixed chassis (133), electric and electronic assembly outside the water tank/outer drum (101) and connect electrical drive motor on fixed chassis (133) to moving parts (200) via movement transfer systems (401) outside free-drum .
- the drive and dynamic system is simplified by mounting electric drive electrical drive motor on free-drum (132) directly on to the drum.
- a movement transfer system comprising movement transfer system (401) such as gears, pulleys, racks and pinions, timing belt pulleys, poly-V belt pulleys, smooth belt pulleys and V belt pulleys, mounted opposite the motor and moving parts need to be set up to transfer movement.
- the movement is transferred from motor to move parts on the free-drum (130) to these gears or pulleys via suitable movement transfer parts (402) such as belts, geared belts, chains or gears.
- Motor(s) to move parts on the free-drum (130) that are the drive source may be mounted onto fixed chassis (111) of the machine outside water chamber (500) or may be mounted directly onto free-drum (104) such that it can rotate with said drum.
- Movement transfer parts such as pulley rotated by movement transfer parts such as belts (402) connected to electrical drive motor on fixed chassis (133) that is mounted outside the water chamber (500), preferably on top of the water chamber (500), transfer the movement to the movement transfer parts (401) connected to moving parts (200) inside water chamber (500).
- both electrical drive electrical drive motor on drum (132) mounted on free-drum (104) and electrical, electronic, control systems (900) for transferring energy to said motor via electricity transfer slip ring (908) and controlling said motor need to be more sophisticated than other motors.
- electrical drive motor on fixed chassis (133) is mounted onto free-drum (104) it is necessary to either transfer electrical energy to the free-drum via electricity transfer slip ring (908) or produce electrical energy by electric dynamos in drum (904) using the rotation of the drum.
- water chamber (500) The function of water chamber (500) is to collect the water leaving the drum. Ensuring that water does not reach some sections of water chamber (500) is only possible if said sections are placed higher than the maximum possible water level in water chamber (500). In other words, the water level in water chamber (500) needs to be kept at a level where water cannot reach undesired areas.
- water-free zone (100) Controlling the amount and area of the water outside free-drum (104) can prevent water contact with parts placed outside drum (104).
- circulation pump (112) collects the draining water from the free-drum (104) through water chamber (500) and directs it back into the drum via a circulation line (113). In this manner, a large portion of the water is constantly collected in the free-drum (104).
- the stated aim is achieved when it is ensured that draining water from the drum flow on chamber surface under control and directly reaches water chamber drain outlet (503).
- measures such as water chamber barrier (511), water chamber overflow lines (511-o) and control-warning-safety systems added into water chamber (500) can be used to ensure that water does not reach the areas where parts used to drive moving parts (200) of the drum, such as belts, gear, pulleys, motors and electric-electronic control systems are placed.
- the Eco-Drum system (61) describes evacuation of the water in water chamber (500) by draining water from the free-drum (104) where the quantities and/or dimensions of holes are calculated or reduced compared to conventional drums with a limited flowrate and being pumped back into free-drum (104) by a circulation pump (112) having a larger pumping capacity that the flowrate of the water draining form drum (104). It can be deduced from the description that this systems also provides savings of water, chemicals and energy in the washing machine (50).
- Poly- Rib system (60) describes a system where protrusions placed on the surface of free-drum (104) prevent the laundry from fully blocking drum perforations/holes (105).
- protrusive cylindrical drum surface (261) The purpose of said protrusive cylindrical drum surface (261) is to hold the laundry away from drum surface and preventing the laundry from reaching drum perforations/holes (105) as much as possible.
- drum perforations/holes (105) In conventional drums, while the number and size of drain holes is large, most of them are blocked by the laundry being washed and the actual discharge of water is much less than the drain flow capacity of the holes.
- the number of drum perforations/holes (105) is reduced more than ten times in the Poly-Rib system (60), most of the holes are kept unblocked whereby protrusions on cylindrical drum surface (261) so the discharge capacity of the holes is mostly unchanged.
- drum perforations/holes (105) that are positioned in the area of influence of protrusions on cylindrical drum surface (261) by the material undergoing treatment, water flowrate from drum perforations/holes (105), which is limited compared to that of conventional drums provides under controlled water draining that is continuous but limited based on the pump flow rate capacity.
- the purpose of protrusions on cylindrical drum surface (261) is to prevent the laundry from reaching drum perforations/holes (105) and restrict the outflow of water from said drum perforations/holes (105).
- the water that has flown from free-drum (104) to water chamber (500) is pumped back into free-drum (104).
- the Eco-Drum system (61) plays a key role in providing water-free zones (100) on the surface of free-drum (104) and taking drum (104) partially out of water chamber (500).
- protrusions on cylindrical drum surface (261) are designed to prevent the materials from reaching drum perforations/holes (105), they will also prevent materials from reaching the surface of free-drum (104).
- the individual shape of the surface of free-drum (104) or other parts having different purposes (234, 240) can function as barriers between the materials and drum inner surface (104-n) without any need for protrusions on cylindrical drum surface (261) as described in EP2229475 and prevent the materials/laundry from reaching and blocking said drum perforations/holes (105).
- the water flowing from the materials being washed in free-drum (104) can pass between said parts and reach said drum perforations/holes (105) without encountering any obstacles.
- protrusions (261) can be designed so that the materials go into recess between protrusions on cylindrical drum surface (262) do not reach the surface of drum (104). It is important to take into consideration the physical characteristics of the textile being washed.
- protrusions (261, 622) or parts (234, 240) that are placed onto the surface of drum (104) prevent materials from going into the area there between, water channels (524, 621) are formed between the protrusions.
- said conically molded roller housing water channel (241) may be designed and applied.
- the water flowing in water channels without encountering any obstacles can reach the area where molded roller housing water discharge holes (235) are located, and pass through drum perforations/holes (105) that are unblocked thanks to protruding structures (261, 234, 240) around and exit free-drum (104).
- Poly- Ribs/protrusions/sheet bar/grate bars (525) are placed side by side on the drum inner surface (104-n) means also Poly-Channels exist in between said Poly-Ribs functioning water channels to flow water from no perforated areas to drain perforations.
- Water channels/Poly-Channels (524) only the area where drum perforations/holes (105) are located will be a drum wet- outer surface (104-w).
- the difference of the disclosed system from conventional washing machine (50) is providing water-free zones (100) no water at least some outside surface parts of the free-drum (104).
- perforated free-drum (104) in a water vessel fulfills the function of water collection in the form of a sink, bowl, tub or basin. As known, all these vessels are partially open water containers. According to the present invention, defined vessels functioning only to collect the water exiting from the drum will be defined as water chamber (500). In this way, the function of the water chamber is no different than sink used to wash hands every day. For example a chamber where water chamber drain outlet (503) has a good draining flow capacity to always empty out the water flowing into the chamber and therefore never overflow. In other words, the vessel ensuring that water draining from the free-drum (104) reaches water chamber drain outlet (503) without accumulation is referred to as water chamber (500).
- a water accumulation chamber (502) have to be designed having a volume, shape and depth wherein the highest level of water never reaches to the drum.
- water tank/outer drum (101) wherein free-drum (104) is made up of one piece as will be understood from the description of the tank. It is necessary to provide water chambers (500) in areas where the water draining through perforations of the drum in order to ensure that movement system that needs to be placed outside of the drum is positioned outside of said water chambers (500).
- the drum is not in a water tank/outer drum (101), described water chamber (500) surrounds only areas where water draining zones such as drum perforations/holes (105) and the gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108) will be present.
- water tank/outer drum (101) There will be some other advantages to changing the definition "in washing machines free-drum (104) is placed inside a water tank/outer drum (101)".
- water tank/outer drum (101) and weights added onto the outer drum are used to suppress the oscillations and vibrations caused by the imbalance during the high spin cycle as much as possible. Therefore it is particularly preferable that water tank/outer drum (101) is heavy. While water tank/outer drum (101) and the weights decrease the oscillations or vibrations motion of water tank/outer drum (101) trying to spin at high speeds with unbalanced weights, they also create additional loads and force to drum shaft (103) and drum shaft bearings (102).
- Figure 1 demonstrates a rear perspective view of a midsize industrial washing machine having a 2-weights balance system applied around cylindrical drum surface at both side of the drum and drain system through water collection chamber with circulation pump and having direct heating gas combustion chamber according to the present invention.
- Figure 2 demonstrates a (A) side sectional and (B) close up view of a midsize industrial washing machine having a 2-weights balance system applied around cylindrical drum surface at both side of the drum and drain system with poly-ribs through water collection chamber with circulation pump and having direct heating gas combustion chamber according to the present invention.
- Figure 3 demonstrates a (A) rear perspective and (B) close up view of a midsize industrial abrasive roller stoning washing machine with abrasive rollers in the drum driven by motors in groups and having a drain system through water collection chamber and water storage tank with circulation pump according to the present invention.
- Figure 4 demonstrates a side sectional view of a midsize industrial abrasive roller stoning washing machine with abrasive rollers in the drum driven by motors in groups and having a drain system through water collection chamber and water storage tank with circulation pump according to the present invention.
- Figure 5 demonstrates a sectional view of a midsize industrial washing machine having buckled grindstone of rollers driven by separate motors and a 2-weights balance system placed on both circular base of the drum and rotate in a water collection chamber surrounding cylindrical perforated drum surface and water storage tank with circulation pump according to the present invention.
- Figure 6 demonstrates an exploded sectional view of drum in a water collection chamber surrounding cylindrical perforated drum surface and water storage tank with circulation pump also having abrasive rollers and a balance system placed on both circular base of the drum according to the present invention.
- Figure 7 demonstrates (A) a front view and (B) a side sectional view of a drum having a balance system and cylindrical rollers according to the present invention.
- Figure 8 demonstrates (A) an exploded front view and (B) an exploded rear view of a drum chassis, a rear balance system, a conical stone washing drum having abrasive rollers with perforations in a narrow zone of the drum surface, a front balance system, a water collection tank and a water storage tank according to the present invention.
- Figure 9 demonstrates a side sectional view of (A) a midsize industrial abrasive roller stoning washing machine having a 2-weights balance system applied around cylindrical drum surface at front and rear side of the drum and discharge chamber drain system closed around perforated zone surrounded with water collection chamber directly connected with circulation pump and having direct heating gas combustion chamber and (B) water collection chamber with circulation pump and gas combustion chamber with gas burner according to the present invention.
- Figure 10 demonstrates (A) a rear view, (B) a front perspective view, (C) right-rear perspective view and (D) left-rear sectional view of a drum with rollers in a close water collection chamber together with water storage chamber according to the present invention.
- Figure 11 demonstrates (A) a drum sectional view, (B) a water storage tank rear perspective view and (C) a water storage tank front perspective of a conical stone washing drum having abrasive rollers driven by separate motors with holes in a narrow zone and circulation pump and circulation line of narrow water collection chamber according to the present invention.
- Figure 12 demonstrates a rear perspective view of an indented drum having gear pulleys connected to rollers driven by teeth belt drive by (A) single motor and (B) two motors on a fixed chassis according to the present invention.
- Figure 13 demonstrates (B) a rear perspective view on a drum of and (A) detailed perspective view of and (C) more detailed perspective view of the wrapping of a belt system travelling around idler pulleys along with gear pulleys around gear pulleys of a system driving gear pulleys attached to rollers grouped together by belts connected to gear pulleys on motors in the drum fin space according to the present invention.
- Figure 14 demonstrates (A) a rear perspective view in a closed water collection chamber of and (B) a rear perspective view outside a water tank of a drum comprising rollers attached to gear pulleys grouped together and driven by belts rotated by motors in the drum fin space according to the present invention.
- Figure 15 demonstrates (A) a rear perspective view of a drum inside a closed water collection chamber having service covers at its rear cover sheet and (B) a rear perspective view outside a whole perforated cylindrical surface drum comprising rollers driven by motors that are attached respectively to each roller and are placed in the rear of said drum according to the present invention.
- Figure 16 demonstrates (B) a rear perspective view of a drum in a rear side base opened water collection chamber wherein said drum comprises rollers attached to gear pulleys driven by a gear belt rotated by a (A) single motor and (C) two motors on a fixed chassis according to the present invention.
- Figure 17 demonstrates side sectional view of an indented drum comprising rollers having cylindrical grindstone pieces and that are attached to gear pulleys driven by a gear belt rotated by a motor on a fixed chassis and coarse grindstones in-between said rollers according to the present invention.
- Figure 18 demonstrates a simplified perspective view of a stone washing machine comprising rollers respectively connected to and driven by motors placed in the rear of a drum, a drum being placed in a half-water tank so that the rear of said drum is outside, a particle separation and injection system on a circulation line according to the present invention.
- Figure 19 demonstrates (A) a perspective view of a water tank comprising a water accumulation chamber, (B) a side sectional view of a water tank comprising a water accumulation chamber, (C) a perspective view of a water tank comprising a water storage tank and (D) a side sectional perspective view of a water tank comprising a water storage tank wherein said systems also comprises a pump circulation system according to the present invention.
- Figure 20 demonstrates (A) a perspective view and (B) a side sectional perspective view of a water tank comprising service covers at the rear side of the tank together with a water accumulation chamber and (C-D) together with a water storage tank and all having a pump circulation system according to the present invention.
- Figure 21 demonstrates (A) a perspective view and (B) a side sectional perspective view of a rear side opened half water tank comprising a water accumulation chamber (C) a perspective view and (D) a side sectional perspective view of a half water tank comprising a water storage tank having a circulation system having a circulation system according to the present invention.
- Figure 22 demonstrates (A) a perspective view and (B) a side sectional perspective view of a water collection chamber around drum and a chamber around drum opening gap and a (C) side perspective view and (D) side sectional perspective view with water storage tank comprising a circulation system connected to drum holes water collection tank having a circulation system according to the present invention.
- Figure 23 demonstrates (A) a perspective view and (B) a side sectional perspective view of a drum opening water collection chamber comprising a circulation system connected to narrow water collection chamber of drum having drum holes in a narrow zone and a (C) side perspective view and (D) side sectional perspective view with water storage tank having a circulation system according to the present invention.
- Figure 24 demonstrates a (A) front perspective view and (B) detailed view of a big size industrial washing machine having drain system comprising a circulation system connected to narrow water collection chamber of drum surround drum perforations in a narrow zone and water collection chamber placed around drum opening gap respectively separate circulation pump systems for each other and having direct heating gas combustion chamber and comprising light apparatus directly mounted on front drum base according to the present invention.
- Figure 25 demonstrates (A) a perspective sectional view of the part of the ribbed drum of a big size industrial washing machine comprising discharge chamber surround perforated narrow zone of the drum draining through narrow water collection chamber and water collection chamber placed around drum opening gap and (B) a close-up sectional side view of the water collection chamber applied around drum opening to collect drain water from gap between drum mouth to pump water separately into the drum via water inlets over drum door (C) a close-up sectional side view of water inlets inject water into the drum from pump according to the present invention.
- Figure 26 demonstrates (A) a perspective view of the narrow water collection chamber surrounding perforated narrow zone of the drum and water collection chamber applied around drum opening to collect drain water from gap together with gas flue outlet from and fan and both water collection system comprising pump to inject water into the drum and (B) a close-up perspective view of water inlets placed over drum door as shown detailed according to the present invention.
- Figure 27 demonstrates a (A) close-up sectional perspective sectional detailed view and (B) close-up sectional side view of the water collection chamber applied around drum opening to collect drain water from gap between drum mouth together with gas flue outlet from and fan and comprising circulation water inlets placed over drum door as shown detailed according to the present invention.
- Figure 28 demonstrates a schematic view of a washing machine drum (A) comprising poly ribs on cylindrical inner surface and (B) a piece of textile has fallen and lay on the surface of the drum and from (A) to (C) show forming a tent from said textile over poly ribs leaving water passage gap under the tent according to the present invention.
- Figure 29 demonstrates a side perspective view of a midsize industrial washing machine comprising a pump circulation system comprising a narrow water discharge chamber surround perforated narrow zone of the conical drum wherein the discharge outlets to drain water into the collection chamber can be operated by pneumatic piston valves according to the present invention.
- Figure 30 demonstrates a perspective sectional view of a big size industrial washing machine comprising protrusive drum and a direct gas heating system to heat drum through protrusive outer surface of the drum according to the present invention.
- Figure 31 demonstrates (A) a perspective sectional and (B) close-up rear side perspective view of a big size industrial stone washing machine drum (A) comprising cylindrical abrasive rollers applied over drum surface (B) 3 rollers drive in groups by electric motors according to the present invention.
- Figure 32 demonstrates (A) a perspective sectional view and (B) close-up sectional perspective view of a big size industrial stone washing machine comprising cylindrical abrasive rollers applied over drum surface and narrow water discharge chamber surround drum perforations in narrow zone and water collection chamber placed around water discharge chamber and having direct heating system with gas burner in combustion chamber and two rotatable weight balance system mounted at front and rear side of the cylindrical drum surface and light apparatus directly mounted on front drum base according to the present invention.
- Figure 33 demonstrates (A) a sectional perspective view and (B, C, D) close- up sectional perspective view of a drum discharge chamber comprising pneumatic piston valves surround around the drum perforations in the narrow zone on the conical drum sheet and water collection chamber around water discharge chamber according to the present invention.
- Figure 34 demonstrates (A) a general view and (B) a detailed perspective view of a machine comprising a water chamber in communication with a pump on the circulation line, a balance system, a water discharge tank controlled by a valve wrapped around the narrow band zone holes of the drum having a conical cylindrical sheet having a poly-rib formed by grate elements and (C) a second circulation system connected to a pump of the drum opening water chamber according to the present invention.
- Figure 35 demonstrates a perspective view of different roller structures and shapes wherein said rollers are driven along with neighboring rollers by a central roller (A) with geared pulley and threaded belt (B) with the details of roller with a motor directly connected to the central roller and (C) with different grindstone or brush parts of the rollers according to the present invention.
- Figure 36 demonstrates (A) a perspective view of rollers having a round brush shape placed in-between fixed brushes mounted into roller housings inside the drum and (B) a perspective view of a three roller group wherein brush rollers are used, central roller is connected directly to a motor and a roller bearing is show in sectional view according to the present invention.
- Figure 37 demonstrates (A) a perspective view from a sectional front sheet of an indented drum having rollers having buckled grindstone pieces and that are attached to gear pulleys in groups in-between said rollers and a (B) perspective view of mounting of buckled grindstone pieces rotating with neighboring rollers driven by a central roller having a geared pulley and threaded belt according to the present invention.
- Figure 38 demonstrates (A) a sectional perspective view of a roller having cylindrical grindstone pieces at rear side and spherical grindstone pieces at front side that is rotated by a motor belt pulley system and (B) a detailed sectional perspective view of frontal bearing and bearing lock mechanism of a roller having spherical grindstone pieces and (C) a detailed sectional perspective view of rear ball bearing of a roller having cylindrical grindstone pieces according to the present invention.
- Figure 39 demonstrates a perspective view of (A) the area of the drum which is isolated by a cover wherein motors rotating interlocking rollers via transfer gears and which are placed in drum fin spaces are placed and close-up view of the isolated space in wet area closed by an cover as shown (B) opened and (C) closed according to the present invention.
- Figure 40 demonstrates (A) a perspective view of the mounting of rollers having cylindrical grindstone pieces and fixed grindstone rods in roller bearings inside the drum and (B)a perspective view of the mounting of or rollers having cylindrical grindstone pieces onto a drum sheet shaped as roller bearing according to the present invention.
- Figure 41 demonstrates (A) a perspective view of mounting of interlocking rollers side by side in a drum, (B) a perspective view of grindstone pieces of interlocking rollers and (C) a perspective view of interlocking rollers according to the present invention.
- Figure 42 demonstrates (A) a perspective view of mounting of interlocking rollers side by side with movement transfer gears, (B) a perspective view of a gear system attached to a motor in the drum fin space and (C) a perspective view of grindstone pieces of interlocking rollers according to the present invention.
- Figure 43 demonstrates a perspective view of (A) grindstone rods and (B) the mounting of brush rods in the manner to be affixed along with roller bearings molded between the cylindrical grindstones rollers placed in the drum according to the present invention.
- Figure 44 demonstrates a perspective view of the mounting of (B) indented grindstone pieces placed on vibrated platforms (A) mounted on the drum surface via a spring mechanism with vibrators having electrical motors according to the present invention.
- Figure 45 demonstrates a perspective view of (A) the mounting in the drum of and (B) roller housings of the drum wherein the discharge holes at the end of the water channel of molded roller housings that are wrapped below the cylindrical rollers that is inclined towards the holes correspond to the holes in the narrow zone of the conical cylindrical sheet drum according to the present invention.
- Figure 46 demonstrates a general perspective view of (A) a drum comprising a balance system and a water channel grate made up of grate elements wherein the holes in the narrow zone on the conic cylindrical sheet the drum top water barrier in two levels around said holes can be seen and (B) closed up small part of a water channel grate area, (C) application of a water channel grate to a drum sheet having lifting ribs and (D) the distribution of water channel grate having conical grate elements wherein said a water channel grate is made up of grate elements on the conical cylindrical sheet of the drum according to the present invention.
- Figure 47 demonstrates a perspective view of the details of a drum lifter rib movable by a jack connected to an electric motor (A) highest position, (B) close to the drum surface during extraction stage and (C) in the washing position for more sensitive textile according to the present invention.
- Figure 48 demonstrates (A) a schematic perspective sectional view of the movable lifter ribs on perforated drum, (B) sectional from the side and (C) detailed perspective view of a drum rib movable by a jack according to the present invention.
- Figure 49 demonstrates (A) a schematic perspective view from sectional outer frame of a household washing machine comprising a poly ribbed drum and drum perforations shown at the rear corner of the drum from a sectional opening of water discharge chamber peripheral cover sheet and (B) an exploded perspective view of a circulation pump and line, a perforated drum in the back in a narrow zone, water tanks and motor-pulley parts of a household washing machine according to the present invention.
- Figure 50 demonstrates (A) a schematic perspective view of a circulation pump and line, a perforated drum in the back in a narrow zone and water tanks of a household washing machine and (B) a schematic perspective sectional side view of a circulation pump, circulation line, cover, water grate angled on the cylindrical sheet inside drum, water tanks and motor-pulley parts of a household washing machine according to the present invention.
- Figure 51 demonstrates an exploded perspective view of (A) a two rotatable weight balance system mounted on front side base of a household washing machine drum and (B) rear side base of a household washing machine drum according to the present invention.
- Figure 52 demonstrates a side sectional (A) front and (B) rear perspective view of a circulation pump, circulation line, cover, protrusive drum in the form of water grate angled on the cylindrical drum sheet inside drum and water collection chamber around drum perforations and water tank connected with chamber and two weight balancing system mounted at both side of the drum base of a household washing machine according to the present invention.
- Figure 54 demonstrates (A) a side sectional perspective view of front part around drum door of a household washing machine and (B) a side sectional perspective detailed view of a rear part together with balance system and sectional view of the drum bearing and water collection chamber and water storage tank of a household washing machine and a side sectional detailed perspective close-up view of rear grate around drum perforations of a household washing machine drum according to the present invention.
- Figure 55 demonstrates (A) a side sectional detailed perspective view of cover sheet wrapping around the water discharge hole inside a perforated drum volume at the rear corner and outside the drum sheet to cover said water discharge hole and water collection tank of a household washing machine from two different angles and (B) a side sectional perspective view of a drum opening water collection tank, a water collection tank and the connection there between of a household washing machine from two different angles according to the present invention.
- Figure 56 demonstrates a side sectional detailed rear perspective view of a rear balance system, balance weight rotation system connected to gears on balance motor and a water collection tank, a water storage tank and the connection there between of a household washing machine according to the present invention.
- Figure 57 demonstrates a side sectional detailed front perspective view of a rear balance system, balance weight rotation system connected to gears on balance motor and a water collection tank, a water storage tank and the connection there between of a household washing machine according to the present invention.
- Figure 58 demonstrates a side sectional detailed front perspective view of a rear balance system and the connection of the gears on the balance motors with the gears on the weight parts of a household washing machine according to the present invention.
- Figure 59 demonstrates (A) a front sectional perspective view of a drum of a household washing machine comprising grate elements forming water channels extending towards the drum holes at the rear of the drum and placed at an angle with the drum axis and (B) a side sectional perspective view of a drum of a household washing machine comprising water channel grates made up of grate elements placed at an angle according to the present invention.
- Figure 60 demonstrates a detailed perspective view of a three weight threaded bearing balance system (A) from the front of the drum and (B) having a balance weight motor and the connected weight threaded bearing of according to the present invention.
- Figure 61 demonstrates (A) a schematic back view and (B) a perspective view of motors directly connected to rollers and a two weight rear balance system according to the present invention.
- Figure 62 demonstrates a schematic view of (A) opposing forces FI and F2 created by balance weights balancing each other and (B) and the opposing force created by FI and F2 created by balance weights balancing the Fx force creating an imbalance in the drum in a two weight balance system according to the present invention.
- Figure 63 demonstrates (A) an schematic exploded view showing each balance weight system of the two rotatable balance weight separately system and (B) a front perspective view from a drum having a two weight front balance system according to the present invention.
- Figure 64 demonstrates (A) a schematic perspective view showing assembled the two weight balance system and (B) a exploded perspective view showing moving system of a two weight balancing system having two weights and balance weight movement motors with chain gear and chain connected with balance weights and (C) a view of the connection details of and (D) a close up detailed perspective view of motor-gear-chain of a two weight front balance system according to the present invention.
- Figure 65 demonstrates a perspective view of different sections (A, B, C) of a two weight front balance system according to the present invention.
- Figure 66 demonstrates a sectional perspective view of a gear belt of the gear connected to a motor driving the weight part, drive wheels carrying said weight part on the travelling path and a guide wheel ensuring that said weight remains in the guide channel of a two weight front balance system according to the present invention.
- Figure 67 demonstrates (A) a top perspective view and (B) a bottom perspective view of additional weight parts of a two weight front balance system according to the present invention.
- Figure 68 demonstrates an exploded view (A) and a sectional perspective view (B) of the mounting of gear belt of the gear connected to a motor driving the weight part on to the weight part, drive wheels for said weight part, a guide wheel ensuring that said weight remains in the guide channel and a guide wheel lock system of a two weight front balance system according to the present invention.
- Figure 69 demonstrates(A) a side sectional perspective view of a midsize industrial washing machine drum comprising poly-ribs having a two-weights balance system applied around cylindrical drum surface at the front and rear side and drain system through drum perforations collect in a narrow zone and monitoring with pneumatic valves on water discharge chamber to drain via collection chamber and having gas burner in gas combustion chamber to heat drum and (B) close-up sectional perspective view of a pneumatic valve on water discharge chamber according to the present invention.
- Figure 70 demonstrates an exploded side sectional perspective view of a mid size stone washing machine's drum having balance system to show balance weights moving system of the two weight balance system applied around cylindrical drum surface at the front and rear side on a drum comprising cylindrical abrasive rollers over the inner drum surface according to the present invention.
- Figure 71 demonstrates a perspective view of a complete two weight balance system and only moving systems of a two weight balance system comprising chain drive by geared electric motors to move balance weight according to the present invention.
- Figure 72 demonstrates (A) a perspective view of moving systems of a two weight balance system having chain move on chain guide channel and geared electric motors to drive chain to move balance weights according to the present invention.
- Figure 73 demonstrates a sectional perspective close-up view of the geared electric motor driving the balance weights on to the weight parts moving on weight guide path, drive wheels for said weight part, a guide wheel ensuring that said weight remains in the guide channel and a guide wheel lock system of a two weight balance system according to the present invention.
- Figure 74 demonstrates a perspective view of (A) mounting of both weight parts along with motors having gears, (B) mounting of weight part closest to drum sheet along with motors having gears and (C) mounting of weight part farthest from drum sheet along with motors having gears in a two weight balance system mounted on the front of a household washing machine according to the present invention.
- Figure 75 demonstrates a sectional perspective view of (A) mounting of both weight parts along with motors having gears and (B) metal weight embedded inside a plastic weight part of a two weight balance system mounted on the front of a household washing machine according to the present invention.
- Figure 76 demonstrates (A) a perspective view of two rotatable liquid container balance system comprise rotatable two counter balance container having balance liquid pump to pump liquid from one to other to create balance load mounted on roller stone washing machine drum and (B, C) perspective separate views of two rotatable liquid container balance system according to the present invention.
- Figure 77 demonstrates perspective views of one rotatable liquid container and one counter balance weight to balance empty balance container system comprise an equilibrium liquid tank that has no effect on imbalance according to the present invention.
- Figure 78 demonstrates (A) a perspective and (B) perspective close-up views of shaft and bed system of the drum mounted with sliding bed to sense movement of the drum by balance sensors according to the present invention.
- Figure 79 demonstrates (A) a perspective view of boards wherein materials and equipment that need to be placed in a board on a drum with and without a cover and a close up detailed perspective view of a slip ring ensuring that required communications for electricity and fluid transfer to the drum are realized via drum shaft and rotating fluid connection element (B) from a sectional view of bearing-pulley parts on the shaft and (C) slip ring and hose channel on the shaft according to the present invention.
- Figure 80 demonstrates a detailed perspective view of a slip ring ensuring that required communications for electricity and fluid transfer to the drum are realized via drum shaft and multiple rotating fluid connection elements connected to the hose channels opened on the shaft according to the present invention.
- Figure 81 demonstrates (A) a perspective view of a rotating drum cover for leak-proof covering of drum opening that is hinged to the drum and comprising a pneumatic lock system in a closed position and (B) a perspective view of rotatable circulation buffer on the fixed chassis security cover from the circulation inlet on the drum cover for leak-proof covering of drum opening that is hinged on the drum according to the present invention.
- Figure 82 demonstrates a side sectional perspective view of a washing machine wherein the inside of the drum is covered by water channel grates showing the inlet of circulation line to the drum via cover of drum opening and rotatable circulation buffer on the security cover according to the present invention.
- Figure 83 demonstrates (A) a close up detailed and (B) general perspective view of the open positions of drum cover of drum opening that is hinged on the drum and security cover hinged on the fixed chassis carrying the hinged cover rotatable buffer providing connection of circulation line to the drum at its center and (C) a side sectional detailed perspective view of a hinged cover rotatable buffer providing connection of circulation line to the drum cover hinged on the drum for covering drum opening via security cover hinged on the fixed chassis according to the present invention.
- Figure 84 demonstrates a side sectional perspective view of a hinged cover rotatable buffer providing connection of circulation line to the drum cover hinged on the drum for covering drum opening via security cover hinged on the fixed chassis on a washing machine according to the present invention.
- Figure 85 demonstrates (A) a side sectional perspective view and (B) a close up perspective view of a rotatable drum cover carried by security cover hinged on the fixed chassis via a rotatable bearing mechanism which covers the drum opening and is connected to circulation line according to the present invention.
- the figures illustrate a stone washing and spinning machine that is one of the important areas of application of the invention.
- rollers (201) Abrasive rollers (202) with grindstones are placed between lifter ribs (107) for stone washing.
- the rollers (201) can be rotated between bearings placed on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) of the drum sheet, at desired speeds via motors placed on drum rear circular base/shaft side (110) as in the front.
- a balance system (300) is mounted both on the rear along with the roller motors connected to moving parts (134) and on the front of the drum.
- the peripheral perforated narrow zone (510) is surrounded by a water chamber (500) on the sides, with its front and rear left uncovered.
- the front and rear sections of drum (104), which exist inside water tank/outer drum (101) in conventional machines, is removed from the tank by replacing the water tank in conventional machines with water chamber (500) that able to redesign using the system described in EP2229475.
- drum (104) has 10-20 times less number or size of holes compared to conventional drums, and said drum perforations/holes (105) prevented from being blocked by the materials by protruding structures placed on or next to said holes.
- Said drum perforations/holes (105) are positioned below rollers (201) that also serve as protruding structures within drum (104). Therefore, even though the number of holes is low, the discharge of water from drum
- One of the objects of the invention is to provide dynamism and different functionalities to a drum (104) of a washing machine (50) wherein a cylindrical shape perforated drum (104) is made from a stainless sheet, and for some applications only some parts may be made from plastic.
- So inner drum (104) is very basic, important and indispensable part of the conventional washing machine but also it is one of the simplest parts.
- Moving parts (200) drive with motors to move parts on the drum (130) by using energy such as electricity, pressurized air and steam, under control with electric, electronic, control systems (900) placed inside and/or outside drum (104) provide said drum (104), which is now more important part of a washing machine, with many new and useful functions that were previously unavailable.
- the present invention effectively overcomes the disadvantages of the drum (104) being placed in a water tank/outer drum (101) full of water.
- the question that the invention seeks to answer is how to prevent the presence of water in the regions of the movement transfer system (401) moving these moving parts outside drum (251) when there is enough water in the drum (104) and when the water in the drum is drained at the end of the washing and rinsing cycles and also during high speed extraction it is inevitable that the water leaving the drum from perforations and passes into the water tank/outer drum (101).
- the first solution to come to mind will be isolation.
- Drum (104), at least a part of the drum (104) taken out of the water tank/outer drum (101) and especially clearing water from areas where systems that are dangerous to be placed and operated in water are located has paved the way for many new useful possibilities and applications on the drum. Even though it is not necessary for the area where movement transfer system (401) is located to be free of water, it is preferable for the functionality and economy of the system.
- drum (104) is changed from a cylindrical perforated drum sheet (106) into a moving, dynamic and functional device, i.e. a machine by itself. It can be referred to as a machine, because even though the rotation of the drum stops, the systems on the drum can continue its operations which ensures that drum (104) remains functional.
- the first step is to ensure that the limits and flow paths on water chamber (508) of water in water chamber (500) are determined, that the water remains in these areas and that the water level can be controlled. In other words, it is possible to turn areas on drum outer surface (104-s), where the presence of water is not required, into water-free zones (100).
- water-free zones (100) means that there is no water inlet to the area which is partially constrained by the drum outer surface (104-s) which is referred to as water-free zones (100) of a part of the drum under all circumstances except in the case of an unintended fault, the system is out of control, despite all precautions and measures taken in the machine.
- the areas that are always kept dry on drum outer surface (104-s) the drum are water-free zones. (100).
- drum perforations/holes (105) part of drum inner surface (104-n) allowing water discharge from the drum and the gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108) that needs to be left gap around drum opening between drum and front panel (114) in-between drum (104) which is the rotating part and the fixed part unless additional precautions are taken.
- washing machines 50
- the water level in drum (104) is balanced out to the same level with the water level in water tank/outer drum (101) according to principles of communicating vessels.
- Water first fills up water tank/outer drum (101) and enters through perforations in to the drum (104) when water level reaches required quantities in the drum.
- the main function of water tank/outer drum (101) is first to fill drum (104) with water and then discharge the water exiting the drum.
- the task of the water reservoir (500) is to ensure the flow of the water leaving the drum from the shortest flow path on water chamber (508) to the circulation line (113) or the water chamber discharge line (511-d).
- the function of water chamber (500) is to ensure that water exiting the drum flows into circulation line (113) or water chamber discharge line (511-d) via the shortest flow path on water chamber (508)
- a big step will be taken in terms of providing to explain this system.
- the outer tank is no different from a sink or a bathtub. For example, similar to a sink or bathtub where the water from the tap flow out from the drain in everyday use and the drain can be blocked to fill the sink with water and opening the drain after use so that the water can be drained.
- outer drum i.e. water chamber with the new shape (500)
- water exiting drum (104) can be collected by water chamber(s) (500) placed only in areas where water discharge occurs.
- the systems according to the present invention prevent the water from passing into water-free zones (100) without need for using sealing elements such as gaskets or felts, even at the highest possible water level.
- Water build-up levels high enough to go over water chamber barrier (511) between areas containing water and water-free zones (100) and build-up of pressure enough to push water over should not be allowed.
- Structural water chamber barriers (511) are actually only barriers to direct water flow in order to keep the water in the desired area without overflowing.
- This storage tank may be a water accumulation chamber (502) or a water storage chamber (504) connected to said water chamber (500).
- Water accumulation chamber (502) or water storage chamber (504) can be used to store water for a treatment operation of the machine as well as transferring water from one treatment operation to another.
- a water accumulation chamber (502) or a water storage chamber (504) is present, the water level inside the drum can be changed in a controlled manner during the treatment operation.
- all the water in the drum can be transferred to the storage space (502, 504) to prevent water from overflowing from water chamber (500).
- seawater filling a boat from a hole can be continuously pumped out of the boat using a pump having a flowrate higher than the inlet flowrate, then the boat will not sink. It the pump is stopped intermittently and the water level in the boat rises, if the pump is operated again before the water level becomes high enough to cause the boat to sink, the water can be discharged.
- the water in water chamber (500) needs to be pumped back into drum (104) at a flowrate higher than the drain rate of water from drum (104) to water chamber (500) under any circumstances as described in Eco-Drum system (61).
- circulation pump (112) When the pumping capacity of circulation pump (112) is always greater than the drain rate of water flowing from drum (104) to water chamber (500), water chamber (500) and water accumulation chamber (502) can be completely emptied by collecting all the water in said water chamber (500) in drum (104). It should be noted that circulation pump (112) having a flowrate higher than the flowrate of the water exiting the drum is necessary not only to ensure water-free zones outside the drum remain dry but also to ensure the efficiency and sustainability of the treatment operation in the drum and also for water savings.
- the capacity of the pump used to empty water chamber (500) can be reduced by reducing the drain flow rate of water from the drum to the water tank.
- drum perforations/holes (105) in drum (104) at locations where they won't be blocked by the laundry material and reducing their number and diameter will allow circulation pump (112) required to drain the water in water chamber (500) or control the water level to have reasonable capacity and size and economic energy consumption. Reducing the number and/or size of drum perforations/holes (105) will make it possible to limit the flowrate of water exiting the tank as desired. However, it is also important to ensure that the flowrate of water exiting the tank is constant. Therefore, blockage of drum perforations/holes (105) designed to control water permeability by materials being treated in the drum must be prevented. In this case, drum perforations/holes (105) must be positioned so that the materials cannot reach and block them completely.
- drum (104) must have a structure suited to preventing the materials from reaching drum perforations/holes (105), or drum perforations/holes (105) must be placed in the hollows between the protruding structures (261, 234, 240) placed on the surface of the drum or drum perforations/holes (105) must be placed in the effective area of the protrusions so that the materials cannot block most of the said drum perforations/holes (105).
- the function of protruding structures (261, 234, 240) in drum (104) as described by the Poly-Rib system (60) must be fulfilled by other parts on drum (104) surface.
- drum perforations/holes (105) positioned beneath or in the effective area of rollers (201) inside drum, fixed grindstone pieces (216) and similar parts can ensure that drum perforations/holes (105) are open to water flow.
- Methods that are more separate than placing movement transfer systems (401) in isolated areas instead of water-free zones (100) can also be used.
- some of isolated areas in movement system (142) applied against water entry can be applied by directly isolating the isolated units in movement system (143) instead of areal applications on the drum.
- Devices used within the system can be isolated for water individually or in groups or isolated units in movement system (143) that are operational in water and chemicals may be used.
- areas outside drum (104) that are defined as water-free zones (100) may be areas on drum outer surface (104-s) where contact with water is prevented using the technical or structural precautions presented by this invention, as well as isolated areas in movement system (142) for placing the devices outside the drum that are isolated against water entry or isolated units in movement system (143) of the devices mounted on the outside of the drum.
- drum shaft (103) When it becomes possible to form water-free zones outside drum (104), the first area to be considered will be drum shaft (103) and its surrounding drum rear circular base/shaft side (110).
- sealing elements such as felt or gasket placed between drum shaft (103) and the outer drum.
- drum shaft (103) which is the point of connection between drum (104) and the outer drum, sealing system around shaft can be canceled. Shaft will become free and the simplest way to transfer energy or fluids to the drum.
- water tank/outer drum (101) and inner drum (104) need to move together, be a part of the same system, in short, be connected to each other due to the sealing elements used therein. Whereas if contact of water within the tank with the drum shaft is prevented using methods other than felt, there will be no need to use sealing elements around the drum shaft (103), inner drum (104) and water tank/outer drum (101) can be separated from each other. The separation of drum (104) and water tank/outer drum (101) allows for radical changes in washing machine design. When there is no need for drum shaft (103) felts, drum (104) can be removed from outer frame chassis (120) and moved along with drum chassis (529). Therefore water tank/outer drum (101) in the form of water chamber (500) and machine cover and drum door (118) connected to water tank/outer drum (101) become an independent chassis. This will especially provide ease or production and maintenance of large industrial washing machines (51).
- drum rear circular base/shaft side (110) where drum shaft (103) is connected to drum (104) towards the corner where drum rear circular base/shaft side (110) is connected to perforated cylindrical perforated drum sheet (106) will provide a suitable area to mount movement transfer systems (401) on drum outer surface (104-s).
- movement transfer systems (401) on drum outer surface (104-s).
- isolation precautions such as sealing, gaskets, chambers, covers and barriers to separate isolated areas in movement system (142) where motors, devices and equipment of said moving parts system (141) and parts belonging to movement transfer system that should not be in contact with water draining from the drum (104) are placed.
- the area where movement transfer system (401) is placed is suitable, it may be preferable to use an isolated area in movement system (142) that is closed to water entry instead of a water-free zone (100).
- an isolated volume will be more preferable if the appropriate region in which the movable parts are to be located within the water chamber. It is possible to surround the all moving system, devices and parts in a fully isolated area using covers for isolated areas in movement system (142-w) with gaskets. However, it is very difficult to isolate and provide maintenance for the entirety of moving parts system (141) and parts.
- the water-free zones (100) system proposed by the present invention makes it possible to place and operate under aqueous conditions even devices that are suitable for use at any place on a washing machine (50) with drum outside water chamber (500). It is obvious that the areas where moving parts system (141) is placed need to be water-free zones (100) for this to be possible.
- the present invention allows the placement of electrical drive electrical drive motor on drum (132) and/or electrical drive motor on fixed chassis (133).
- drum (104) may be water-free zones (100) in a water chamber (500) or drum (104) may be taken mostly out of water chamber (500). In both cases, it won't be wrong to say that a section of the drum is a water-free zone (100). If drum rear circular base/shaft side (110) is a water-free zone (100) even though the entirety of the drum is in water chamber (500) as shown in Figures 10,19 and 20 as no water is present in this area of water chamber (500), it will be easy to reach and provide service to moving parts system (141) and movement transfer system (401) via the openings provided by water tank service doors (121) which are kept closed for security. A water tank having service doors to reach moving parts system (141) and movement transfer system (401) on the back of the drum, looks like a conventional water tank/outer drum (101) when said doors are closed.
- moving parts (200) are the subject of the present invention.
- mechanical, electric or electronic motor system (400) and movement transfer systems (401) placed water tank/outer drum (101) to a drum (104) rotating in a water tank/outer drum (101) normally filled with water.
- the present invention allows the operation of movement transfer systems (401) needed to move moving parts system (141) inside/outside the drum in a controlled manner.
- drum (104) is taken out of water tank/outer drum (101). This eliminates the possibility of getting affected by water. As there is no closed volume surrounding drum (104), it is not possible for water to find a way to flow into areas of said drum.
- the preferred embodiment may entail keeping drum (104) in the conventional water tank/outer drum (101) by preventing water access to drum front circular base/opening side (109) and drum rear circular base/shaft side (110) without changing the structures of drum (104) and water tank/outer drum (101).
- the water level in water tank/outer drum (101) can be controlled by the Eco-Drum system (61) described in EP3252207. Therefore, water is conserved and the water in water tank/outer drum (101) is prevented from reaching drum front circular base/opening side (109) and drum rear circular base/shaft side (110).
- a perforated drum (104) which rotates horizontally or at an angle with the horizontal axis and is placed inside a water tank/outer drum (101) with drum shaft bearing (102) on closed circular base side and loaded and unloaded from the opening on other circular base, or both circular bases with drum shaft bearing (102), load and unload from the opening on cylindrical surface to assist the functioning of said drum is not a method that is known and used currently.
- Household washing machines (57), commercial washing machines (56) and industrial washing machines (51) that operate within a water tank/outer drum (101) have drums (104) made of only metal and plastic. These drums do not have moving parts or devices consuming energy, such as electricity, pressurized air or fluids, mounted thereon.
- One of the aims of the present invention is to add dynamism to the rotation motion of drum (104) by adding moving parts (200) driven by a movement transfer system (401) comprising a motor outside or both inside and outside said drum, moving parts inside of the drum (250) that are placed inside the drum (104) add processing dynamism to the machine's intended use and increase the performance of the operation and provide savings.
- Moving parts (200) mounted inside (250) and/or outside (251) drum (104) so that they can move in a controlled manner will increase the efficiency of the machine and therefore provide savings in resources such as water, energy, chemicals and time.
- a function of the invention is providing controlled movement of said moving parts (200) by motors connected to moving parts (134) or via movement transfer systems (401).
- Said moving parts outside drum (251) may be moved to rotate, oscillate or vibrate. As rotation is the easiest among these to apply and has the highest efficiency, rollers (201) providing rotational motion will be the most commonly utilized moving parts.
- Rollers will be able to realize the dynamism claimed by the system by rotating the full rotations in the cylindrical structure of the drum (104) without any limitation.
- the most important advantage of rollers (201) driven directly by motors connected to moving parts (134) is that it allows rollers (201) to be rotated at desired speeds by controlling the speed of said motors connected to moving parts (134). Rollers (201) can be completely stopped when necessary and can be rotated at very high rotation speeds within the limits of motors connected to moving parts (134) and roller bearings (205) when necessary.
- motor system (400), mechanical movement transfer system (401), electric and electronic control systems (900) need to be present on drum (104).
- the present invention proposes methods for operating movement transfer systems (401) required to move moving parts inside/outside drum (250, 251) in a controlled manner even in conditions where water is present.
- the system proposed by the present invention discloses methods for smooth operation of necessary equipment mounted on drum (104), referred to as “movement transfer system (401)” and comprising motors, pump, valves, pistons connected to drum (104) to provide controlled movement of moving parts (200) and electricity, pressurized air and steam system to use with them, movement transfer systems (401) such as pulleys, gears, belts, chains, etc. and related equipment such as sensors, control systems, electrical and electronic systems, cables, hoses and other connection equipment and auxiliary devices and electric system panels on drum (901) where these devices are placed.
- movement transfer systems (401) such as pulleys, gears, belts, chains, etc.
- related equipment such as sensors, control systems, electrical and electronic systems, cables, hoses and other connection equipment and auxiliary devices and electric system panels on drum (901) where these devices are placed.
- drum (104) All of the treatments done in drum (104) require physical effect and dynamism in varying degrees. This is the reason for the rotation of the drum. Increasing the movement within drum (104) will increase the efficiency and decrease the operation time of wet and dry treatment operations such as washing, dyeing, stoning, polishing and brushing.
- the main function of moving parts inside of the drum (250) is to increase the physical effect provided by the rotation of the drum.
- the rubbing effect obtained by the friction between the materials and dropping materials from the top of the drum during the rotation of the drum will be increased by placement of brush rollers (203) in the drum.
- moving parts (200) added into drum (104) perform functions such as, mixing, shuffling, rubbing, fluffing, stoning and brushing the materials undergoing treatment in the drum.
- rollers drive directly by the motors in controlled manner into the drum Another importance of placing the rollers drive directly by the motors in controlled manner into the drum is that the rollers can be rotated at the desired speed from very slow up to very high speed.
- Water tank/outer drum (101) placed outside drum (104) in currently available horizontal washing machines serve the purpose of collecting water draining from the drum (104) as well as filling water into said drum.
- the distance between water tank/outer drum (101) and drum (104) is kept as small as possible.
- the volume of water tank/outer drum (101) below drum (104) bottom level is as small as possible in terms of water consumption.
- the system of the present invention proposes a large storage volume under drum (104) where a certain amount of water may be collected, and all the water in the washing machine may be collected without coming into contact with drum (104) when necessary.
- a water chamber (500) surrounding drum (104) only in the manner to collect water exiting said drum (104) as around perforated surface and around drum entrance.
- water tank/outer drum (101) the main reason for the closed volume outside the drum to be referred to as water tank/outer drum (101) was that it was filled with water.
- the volume surrounding the drum should never be filled with water. Because these volumes are always empty and only serve the purpose of directing the water exiting the drum towards the discharge outlet, it is more appropriate to refer to said volumes as water chamber (500) instead of water tank/outer drum (101) to avoid confusion.
- a system according to the present invention to comprise a water accumulation chamber (502) below the water chamber (500) which has the capacity to store partially or all the water in the drum (104) when necessary.
- This storage volume may be in the form of a water accumulation chamber (502) directly inside water chamber (500) or it may be a separate volume as water storage chamber (504) in communication with a water chamber (500) with a water chamber-water storage chamber connection (507) serving the function of collecting and storing water from drum (104) when necessary.
- water accumulation chamber (502) and water storage chamber (504) are to keep water from the drum so that water chamber (500) does not overflow in case of an expected malfunction and by controlling water level in the water chamber (500) also be used to adjust the water level in the drum with circulation pump (112) control. They can also be used to change the amount of water in drum (104) and temporarily store the water required at a different stage of the treatment operation when necessary. Even if water accumulation chamber (502) is filled with all the water that can be used by the machine, it should be able to prevent water level from reaching up to overflow level.
- the water chamber (500) which provides the appropriate size and conditions, allows the water draining from the drum to reach the water chamber drain outlet (503) by preventing it from flowing out of the flow path on water chamber (508) between the water chamber barriers (511).
- Water flow paths/water ways are structures facilitating flow of water between two locations, wherein water does not go beyond their boundaries even though they are at least partially open. While pipes are closed systems, water channels are open from the top. Even though water ways are open, when they are designed and controlled carefully they can transfer water from one location to another. Water channels are water ways with defined boundaries. This is the basic principle applied on the outside of drum (104). While until today, water tanks/outer drums (101) wherein drums (104) rotate were closed systems, water chambers (500) proposed by the invention form of flow paths on water chamber (508) directing water exiting from drum (104) to the discharge outlet.
- front-load washing machines (50) having a perforated drum (104) that is rotates inside a water tank/outer drum (101).
- a water-free zone (100) adds a new dimension to washing machine design.
- water-free zones (100) can be taken out of water tank/outer drum (101). Looking at it this way, it would not be correct to talk about the existence of a water tank/outer drum (101).
- Placement of mechanical, electric, electronic devices and all auxiliary parts and equipment belonging thereto of movement transfer system (401) on drum (104) and/or moving parts system (141) outside drum in areas outside water chamber (500) will make it easier to provide periodic maintenance or repair services in case of malfunction.
- Drums (104) of conventional washing machines are generally parts that don't require a lot of maintenance.
- addition of moving mechanisms and electric and electronic movement transfer systems (401) to drum (104) will require more frequent maintenance and parts replacements. Therefore, it will be advantageous to provide service to areas easily reachable from the outside rather than areas inside a water tank/outer drum (101).
- the water drain from the drum is from the drum inlet opening gap around drum opening between drum and front panel (114), except the drum perforations/holes (105) in the cylindrical perforated drum sheet (106).
- the structure of the drum entrance/inlet opening (108) is different in household washing machines (57) and industrial washing machines (51).
- Household drum door (617) closing household drum entrance/inlet opening (608) of household washing machines is on household frame frontal sheet (618) of household outer frame (616) and there is also a flexible household drum door bellows (614) between the door and the outer drum to prevent water from leaking out of the outer drum.
- industrial washing machines do not have a door bellows and instead drum door (118) is connected to machine front panel (119) which is also the front sheet of the drum.
- the water leaving drum opening (108, 608) reaches outer drum via the space between the outer drum and drum (104, 604).
- water in water chamber (500) will not under any circumstances be collected outside of water accumulation chamber (502) placed at the bottom of said water chamber (500), presence of water chamber barrier (511) for preventing water from leaving water flow path on water chamber (508) wherein water flows from drum (104) to water accumulation chamber (502) will facilitate formation of water-free zones (100).
- movement transfer system (401) is concentrated on drum rear circular base/shaft side (110), taking this area out of water chamber (500) is the safest way to cut out fluid communication of water from the chamber with said movement transfer system (401).
- water chamber (500) for collecting the water leaving drum (104) is designed in a way to leave drum rear circular base/shaft side (110) outside, it will be a water chamber close whole wet parts of the drum surrounding drum front circular base/opening side (109) and perforated cylindrical perforated drum sheet (106) as exemplified in Figures In terms of design and appearance, said water chamber resembles a customary half water tank/outer drum (101) without a rear sheet. So from now on this water chamber surrounding whole wet parts of the drum will be referred to as a half water chamber (505)
- Said half water chamber (505) must contain water chamber barrier (511) systems designed to prevent water flowing from drum (104) to water chamber (505) at the edge portion at drum rear circular base/shaft side (110) from leaving half water chamber (505).
- drum front circular base/opening side (109) If a moving parts system (141) outside drum is present on drum front circular base/opening side (109), it would be advantageous for this section to be a water-free zone (100) as well.
- balance system (300) which is one of the systems proposed by the invention, will be mounted on the front sheet or cylindrical surface at the front part of the drum, in drums having a balance system, drum front circular base/opening side (109) must have a water-free zone (100). It is possible to create the conditions for a water-free zone (100) on drum front circular base/opening side (109) in half water chamber (505) surrounding the gap around drum opening between drum and front panel (114) where drum entrance/inlet opening (108) and drum perforations/holes (105) are.
- drum front circular base/opening side (109) also out of water chamber (500) will be a good solution.
- drum front circular base/opening side (109) it would be very advantageous for drum front circular base/opening side (109) to be easily accessible for the smooth operation of the system and for providing maintenance and repair services.
- the system applied to drum rear circular base/shaft side (110) can be applied to different sections of drum (104). In this way, other sections of drum (104) can be taken out of water chamber (500).
- water chamber (500) may be in the form of water chamber surrounding only perforated cylindrical drum surface (501) applied only to necessary areas on drum (104) to collect water exiting said drum (104).
- a water chamber around drum opening gap (506) formed to surround drum gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108) can collect the water exiting from said drum opening and directing it to water chamber surrounding partially perforated cylindrical drum surface (501) or a water accumulation chamber (502) via a water chamber- water storage chamber connection (507) pipe connected below.
- Dividing water chamber (500) into a water chamber around drum opening gap (506) for collecting water exiting from drum opening gap around drum opening between drum and front panel (114) and water chamber surrounding partially perforated cylindrical drum surface (501) for collecting water exiting drum perforations/holes (105) provides a practical solution to the problem of taking drum front circular base/opening side (109) out of water chamber (500) like drum rear circular base/shaft side (110). In this way, when the water chamber (500) is divided into two sections (501, 506), the area left between will be a water-free zone.
- water chamber around drum opening gap (506) positioned to surround drum opening gap around drum opening between drum and front panel (114) contains a water chamber- water storage chamber connection (507) below for transferring the water exiting drum (104) to a water collection or storage tank.
- drum door (118) connected to water tank/outer drum (101) must be connected directly to the front sheet, namely machine front panel (119) of the machine along with water chamber around drum opening gap (506).
- said machine front panel (119) also covers the front of water tank/outer drum (101).
- the front sheet/machine front panel (119) is directly connected to fixed chassis (111) of the machine.
- drum door (118) will be directly connected to outer frame chassis (120), in other words fixed chassis (111) of the machine.
- household drum door (617) is on household outer frame (616) in household washing machines (57) there is a household drum door bellows (614) at the household drum entrance/inlet opening (608) covering the area between the drum and household drum door (617).
- household drum opening water chamber (615) may be on household outer frame (616), i.e. on the fixed chassis system. In this case there will be no need for bellows and it will be possible to connect household drum door (617) to household drum opening water chamber (615) in household washing machines (57) as with industrial washing machines (51).
- water tank/outer drum (101) is connected to fixed chassis by spring and suspension systems and water tank/outer drum (101) moves freely due to the imbalance during the spin cycle.
- a balance system (300) is also present in the washing machine according to the present invention, said machine can be a hard mounted machine. This means that no connection element can perform an elastic movement beyond stretching within the bounds of material tolerance in the machine including the chassis.
- drum (104), water chamber (500), outer frame of the machine (117) and drum door (118) are separately mounted to fixed chassis (111), they cannot move with respect to each other and so it will be possible to decrease the gap around drum opening between drum and front panel (114) between drum entrance/inlet opening (108) and drum door (118) and water chamber around drum opening gap (506) or drum (104) and water chamber (500) compared to free standing machines wherein all said parts are on the same chassis.
- drum opening water collection chamber circulation pump (528) connected to water chamber around drum opening gap (506) will be able to pump the water exiting from drum opening gap around drum opening between drum and front panel (114) back into the drum.
- water exiting from said drum holes can be directed to circulation pump (112) pumping the water directly back to the drum or a water storage chamber (504) via a water chamber drain outlet (503).
- circulation pump (112) pumping the water directly back to the drum or a water storage chamber (504) via a water chamber drain outlet (503).
- water tank/outer drum (101) that consisted of one piece until today will be divided into two or, necessary, more sections referred to as water chamber surrounding partially perforated cylindrical drum surface (501) as exemplified in Figures 5 and 22.
- peripheral perforated narrow zone (510) can be placed on one or more positions on the drum.
- having drum perforations in peripheral zone (509) only in the area(s) surrounded by water chamber surrounding partially perforated cylindrical drum surface (501) will be advantageous is many respects.
- the cylindrical sheet of the drum will be a cylindrical drum sheet peripheral perforated narrow zone (510) wherein said drum perforations in peripheral zone (509) are placed in peripheral perforated narrow zone (510) will have the appearance of a cylindrical sheet without holes.
- Water chamber surrounding partially perforated cylindrical drum surface (501) for water exiting from drum holes can be placed around the middle, front or rear of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510). In this case, as drum perforations in peripheral zone (509) will be only in this area, it must be ensured that the water in the drum flows towards this area.
- drum sheet that is a Conical drum sheet perforated in the narrow belt zone (512) with a conical structure to ensure that said drum sheet is sloping towards the area where the holes are located will assist in the flow of water towards the area where the holes are located.
- drum holes in peripheral band zone (509) are distributed on the conical or cylindrical surface in groups in multiple peripheral perforated narrow zone (510), it will be required to utilize multiple drum-perforated area-water chambers (500).
- a flow path on water chamber (508) may be formed by structural obstacles and barriers to prevent water from overflowing outside from between water chambers surrounding drum opening and drum holes and the drum.
- overflow of the water flowing from drum (104) to water chambers surrounding around partially perforated cylindrical drum surface (501) from said water chamber limits can be blocked by a water chamber barrier (511) placed on water chamber surrounding partially perforated cylindrical drum surface (501) and corresponding external water barriers (122) placed on the drum.
- the function of the barriers on water chamber surrounding partially perforated cylindrical drum surface (501) is to prevent water at the bottom of the tank from overflowing into water-free zones (100) of water chamber surrounding partially perforated cylindrical drum surface (501) and overflowing out of water chamber surrounding partially perforated cylindrical drum surface (501).
- the function of external water barrier (122) placed on the drum is preventing water exiting the drum from overflowing past water chamber barrier (511) while being flung by the rotation of drum (104) during the spin cycle and wetting every surface of flow path on water chamber (508) in water chamber (500).
- Water barriers may be positioned in single lines opposite each other and side by side or they may have a multiple cascading structure in the form of successively positioned sets as exemplified in Figure 45, 46.
- water leaving drum (104) through drum perforations in peripheral zone (509) in the rear section of said drum (104) is collected by a water chamber surrounding partially perforated cylindrical drum surface (501) and directed towards a water chamber drain outlet (503), said water chamber surrounding partially perforated cylindrical drum surface (501) can be centered by drum shaft bearing (102) on drum shaft (103) and fixed in place by a connection to fixed chassis (111).
- water tank/outer drum (101) is connected to the frame and also serves to carry drum (104).
- drum (104) will be carried by drum shaft bearing (102) fixed on the fixed chassis (111). In this way, it will also be possible to take water chamber (500) out of drum shaft bearing (102) system.
- One of the important results of the proposed system is the separation of the drum and the tank system completely.
- FIG. 5 shows water chambers (500) connected to machine front panel (119) via tank-front panel connection (522) or to front chassis (11) simultaneously carrying the drum via fixed tank-drum chassis connection (523) at the same time.
- drum (104) does not oscillate or vibrate on the springs and suspensions during the spin cycle.
- a drum (104) rotating under fixed chassis conditions will allow the space tolerance between parts to be kept at the minimum.
- there is enough tolerance left between drum (104) and said water chambers (500) this will cease to be a problem and it will be possible to apply structures such as water-free zones (100) and water chambers (500) to said free mounted washing machines.
- a steam/gas flue fan (514) having a suitable flowrate to provide negative air pressure in drum wet-outer surfaces (104-w) must be used. Placing said steam/gas flue fan (514) so that the inlet is at the ventilation flue at the top of water chamber (500) will aid in collecting the hot water at steam that naturally moves upwards.
- Air with steam or gas can be directed outside by the steam/gas flue fan (514) via suitable discharge and steam/gas flue chimney systems (515). If there are no discharge means in the system for air with steam, the air steam mixture or is passed through a condenser, and steam is separated from air by condensing.
- This method will prevent steam from entering water-free zones (100) within water chamber (500) and from leaking out of water chamber (500).
- peripheral perforated narrow band zone (510) Placing drum perforations in peripheral band zone (509) within the boundaries forming peripheral perforated narrow band zone (510) in the rotation direction of and peripherally surrounding the drum and also within the areas where water exit from cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) is possible will make it possible to limit the size of, narrowing the width of and decreasing the volume of water chambers (500). The narrower the limits of the area where peripheral perforated narrow zone (510) where drum holes are located are, the narrower the water chamber (500) can be.
- drum perforations in peripheral zone (509) are located close to the rear sheet of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510), this will provide an advantage for application of solutions for speeding up water exit from drum (104) and sizing and mounting solutions for the water chamber.
- 19- The rotation axis of the drum having an angle with the horizontal axis and the conical structure of the perforated drum according to the present invention are explained below via Figures 8, 11, 29, 34, 45, 46, 49, 50,
- drum perforations/holes (105) are distributed homogeneously throughout cylindrical perforated drum sheet (106). This is necessary because drum outer surface (104-s) is essentially horizontal and flat. Otherwise, water discharge from drum (104) during wash and spin cycles would be inefficient and take a long time. The laundries, which is spread over the perforated drum surface during draining and spin extraction stage, causes most of the drum holes to close, blocking water outflow. On the other hand if drum perforations in peripheral zone (509) for water to exit drum (104) are only placed in one area at the rear of drum (104), the time needed for all the water that needs to exit drum (104) will cause the draining and extraction get much longer.
- drum perforated narrow band zone (510) where drum perforations in peripheral zone (509) are located While it is possible for the drum to be positioned to make an angle with the horizontal axis so that water can flow towards peripheral perforated narrow band zone (510) where drum perforations in peripheral zone (509) are located, it is also possible for the drum to be a conical drum sheet perforated in the narrow belt zone (512) so that the flow direction of water is towards where drum perforations in peripheral zone (509) are located. Both of these options will ensure that flow of water within drum (104) is towards where drum perforations in peripheral zone (509) are located.
- drum (104) having a conical shape or being positioned to make an angle with the horizontal axis is a functional solution when said drum (104) is empty, it will lose its functionality once drum (104) is filled with materials obstructing the water flow. Despite the angle created for flow, water will have to flow between the materials blocking the flow path on the drum inner surface (104-n).
- the barrier formed by materials strewn on the surface of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) will slow down the flow of water, especially during the spin cycle as the compressed materials are jammed against the drum sheet.
- the aim is to ensure that, even when drum (104) is filled with materials having high density and low water permeability, water flows towards peripheral perforated narrow band zone (510) where drum perforations in peripheral zone (509) are located and exits drum (104) via drum holes.
- a solution to this problem is forming water channels/Poly-Channels (524) on the conical drum sheet perforated in the narrow belt zone (512). Water will flow through water channels/Poly-Channels (524) without coming across any obstacles in drum (104) according to the system described in EP2229475, as explained above.
- This system preferably comprises a water channel grate (526) forming water channels along the drum inner surface (104-n) of cylindrical or conical (512) drum which are parallel to or make an angle with the rotation axis of drum (104) using Poly-Ribs/protrusions/sheet bar/grate bars (525) made of metal or plastic protrusions.
- Said water channels/Poly- Channels (524) are comprised of water channel grates (526) placed on drum outer surface (104-s) or plastic or metal conically molded roller housing (240) parts. Water flows towards the area where drum perforations in peripheral zone (509) though said water channels/Poly-Channels (524). In a conical drum sheet perforated in the narrow belt zone (512), flowrate increases with degree of the conicity of the conical drum sheet perforated in the narrow belt zone (512).
- Figures 34 and 46 show water channel grates (526) and water channels/Poly-Channels (524) formed by them in a conical drum.
- water channels/Poly- Channels (524) are shown which are side by side positioning of the sheet bar pieces suitable for lattice or the like-shaped grating, both as applied in the drum and on the conical sheet of the drum will keep the materials in the drum on water channel grate (526) and away from conical drum sheet perforated in the narrow belt zone (512) so that water channels/Poly- Channels (524) can facilitate flow of water across the length of the cylindrical surface of the drum without coming across any obstacles.
- water channel grates (526) also known as trash screens are structures that allow passing of fluids such as gases and liquids between the two volumes they are separating but prevent passing of materials that are desired to keep on one side.
- water channel grates (526) may have the structure of bars or cages of different shapes and sparsity. It is possible to use any structure that fits the general description of a water channel grate (526) and that makes it possible to keep the materials being treated away from the sheet of perforated drum and allows the flow of water on the surface of the drum beneath said materials.
- a drum comprising water channels/Poly-Channels (524)
- water can flow through said water channels/Poly-Channels (524) towards drum perforations in peripheral zone (509) without encountering any obstacles.
- Water flow channels (524) are created by Poly-Ribs/protrusions/sheet bar/grate bars (525) placed on the surface of the drum (104) to flow the water through drum perforations/holes (105) located in a region of the drum.
- the shape and dimensions of the Poly- Ribs/protrusions/sheet bar/grate bars (525) have to be suitable to form water channels/Poly-Channels (524) having enough water passageway volume to allow water to flow towards drum perforations/holes (105) on the surface of the drum.
- washing material drum also means real drum.
- the volume below water channel grates (526) extending to conical drum sheet perforated in the narrow belt zone (512) can be referred to as water flow area.
- effluent system consisting of Poly- Canals under the grids. For example, water flowing from the water grids placed on the roadside to the sewer system under the road and flowing under the streets can be given.
- Poly water channels/Poly-Channels (524) may have any structure forming indents preventing entry of materials and allowing flow of water on conical drum sheet perforated in the narrow belt zone (512) from the area without holes towards the area where drum perforations in peripheral zone (509) are located. This can be achieved by placing Poly-Ribs/protrusions/sheet bar/grate bars (525) on the surface of drum (104) or directly shaping cylindrical perforated drum sheet (106) to form water channels/Poly-Channels (524) or placing parts or covers in accordance with water channels system to conform to the Poly-Canal definition on the surface of drum (104).
- the relationship between the Poly-Ribs/protrusions/sheet bar/grate bars (525), drum inner surface (104-n) and drum holes described in existing system forming water channels/Poly-Channels (524) may be different than said protrusions.
- the textiles being laundered form a tent-like structure across Poly-Ribs/protrusions/sheet bar/grate bars (525) placed on the drum sheet to prevent to reach drum inner surface (104-n) and to block drum perforations/holes (105) completely.
- the goal is that said water flow ways and drum holes are below this tent on the protrusions (531).
- the height of Poly-Ribs/protrusions/sheet bar/grate bars (525) and the space between the protrusions must be designed with the elasticity of the textile so that the textile forming the tent on the protrusions (531) does not block the drum holes when it stretches towards the bottom of Poly- Ribs/protrusions/sheet bar/grate bars (525). If the protrusions are close enough and high enough so that even if the textile stretches it cannot reach the drum inner surface (104-n), then the placement of drum perforations/holes (105) between the protrusions is not important.
- drum holes have to be positioned close to the protrusions to accelerate the water discharge.
- drum perforations/holes (105) are positioned beneath Poly-Ribs/protrusions/sheet bar/grate bars (525), they cannot be blocked by the textiles.
- the 2 mm height Poly-Ribs/protrusions/sheet bar/grate bars (525) will allow for the desired result, provided that both drum perforations/holes (105) remain unblocked to ensure water flow through the peripheral non-perforated zones (510-n) of the drum to peripheral perforated narrow zone (510) if said protrusions have the proper shape and density.
- Water channel grates (526) having the form of grates made up of Poly- Ribs/protrusions/sheet bar/grate bars (525) placed side by side to create a channel system is an ideal solution of the invention. In this way, two areas are created in drum (104), the area above the water channel grates (526) Poly-Ribs/protrusions/sheet bar/grate bars (525) where the materials are located and the area below said water channel grates (526) where only water is located. So, the water coming out of the materials on Poly- Ribs/protrusions/sheet bar/grate bars (525) can flow freely from the non- perforated cylindrical area of drum (104) towards the holes and exit drum (104) via drum perforations in peripheral zone (509).
- new inner drum which contains laundries over Poly-Ribs/protrusions/sheet bar/grate bars (525) for washing process and the second one is called “new outer drum” which is under Poly- Ribs/protrusions/sheet bar/grate bars (525) surrounding the new inner drum which drains water and both placed in the same rotatable main drum.
- Said water channel grate bars (526) can be parallel to the conical drum sheet perforated in the narrow belt zone (512) or be in the form of angularly cut water channel grate/sheet bars (527) in order to provide a volume and a flowrate that increases towards the holes.
- Angularly cut water channel sheet/grate bars (527) are exemplified in Figures 46C and 46D. Angularly cut water channel sheet/grate bars (527) cut in this manner are lower in peripheral non-perforated zones (510-n) and higher in peripheral perforated narrow zone (510).
- the distances between grate elements constituting the grates are mostly determined by the features of the materials to be treated. While it is suitable to have a distance between 15 and 25 mm for water channel grates applied to household or industrial textile washing machines, in an industrial sock dyeing machine, this distance must be between 5 and 10 mm. In contrast, in a carpet and mat washing machine having a drum diameter between 1800 and 2000 mm, it is acceptable for this distance to be between 20 and 40 mm. Likewise, the heights of the grate elements change according to the size of the channels, i.e. the depth of drum (104). As the depth of drum (104) increases, so must the depth of the channel.
- the depth and width of Poly- Canals and the shape of Poly-Ribs/protrusions/sheet bar/grate bars (525) forming said Poly-Canals (524) should be chosen according to the type of treatment and the type of material to be treated.
- the materials to be treated can range from very thick, large and hard materials such as dust mats with rubber bottoms to small and delicate materials such as elastic socks. For this reason, it is important to take the physical properties of the materials to be treated into account when designing Poly-Canals and Poly-Grates.
- Water channel grates (526) can be made from plastic or metal and may be an integral part of drum (104), or be reversibly mountable onto drum (104).
- Water channels/Poly-Channels (524) formed such that the washing material cannot enter between Poly-Ribs/protrusions/sheet bar/grate bars (525) as described above is the ideal embodiment of the invention described.
- the water entering the channel (524) will reach drum perforations/holes (105) without any obstacles and will come out of the drum (104) as soon as possible. But it may be undesirable for a variety of reasons to implement a sufficient amount of Poly-Ribs/protrusions/sheet bar/grate bars (525) placed side-by-side to form water channels/Poly- Channels (524).
- the material transported upward falls in the drum.
- Poly- Ribs/protrusions/sheet bar/grate bars (525) will set up tents on the protrusions (531) on the protrusions. In this case, the material can reach the drum inner surface (104-n) between Poly-Ribs/protrusions/sheet bar/grate bars (525).
- the presence of Poly-Ribs/protrusions/sheet bar/grate bars (525) in the shape and size that will create space in between protrusions and the drum inner surface (104-n) to provide water flow in the drum (104) under the material is sufficient for the application of the system.
- Poly-Ribs/protrusions/sheet bar/grate bars (525) are in shape and size to accelerate water flow through the drum inner surface (104-n) and to increase the drainage rate from the drum (104) through the remaining space under the tent on the protrusions (531) created by washing materials under, around or between the protrusions to provide further advantages of the invention.
- household drum water channel grates (622) used may be fixed and detachable and made of plastic and metal. Due to production techniques, it will be preferable for household drum water channel grates (622) forming the household drum water channel/Poly-Canals (621) within the drum to be made of plastic in household washing machines (57).
- Figures 69-80 show household drum water channel grates (622) in the form of household drum water channel/Poly-Canals (621) made of household drum water channel grate bars/Poly-Ribs (623) inside the drum; however, that particular embodiment of the household washing machine does not comprise household drum lifter ribs (607). Household drum water channel grates (622) inside the drum will also fulfill the function of carrying the materials during the rotation of the drum.
- drum lifter ribs (107) in-between the water channel grates (526) as shown in Figure 63B.
- One of the most pressing goals of producers of washing machines is to increase the size of household drum (604) to be placed in a household outer frame (616) having standardized dimensions.
- the volumes allowable for washing machines are very limited. Especially as houses become smaller, the volumes allocated for washing machines also decrease.
- the width and depth of a household outer frame (616) of a household washing machine (57) must not exceed 600 mm in order to fit in the allocated spaces in the kitchens and bathrooms. Setting aside 20 mm for the frame and spaces, the outer drum to be placed inside household outer frame (616) must have a diameter below 560 mm.
- the diameter of household drum (604) will be around 520 mm. If the machine has a free oscillation body, the diameter of water tank/outer drum (101) will be around 520 mm and the diameter of household drum (604) will be around 480-485 mm.
- the balance system (300) proposed by the present invention and other features of the invention makes it possible to increase the diameter of household drum (604).
- the diameter of a household drum (604) having the highest volumetric capacity possible may be around 560 mm, taking into account the required distance between household outer frame (616) and household drum (604) and other tolerances.
- This measurement means that no place is set aside for a water chamber (500) to be placed around household drum (604).
- inclined household drum (604) is placed so that the rear section is downwards of the horizontal axis and household water chamber (611) is placed behind household drum (604) in the corner where household drum rear circular base sheet (610) and cylindrical household drum sheet (606) meet, it will be possible to collect the water exiting from household drum holes/perforations (605) at the back of household drum (604) by a water chamber placed behind the drum.
- a cylinder having the highest diameter possible to fit in rectangular box as a drum.
- drum discharge chamber water discharge valve (519) to create completely closed drum according to the present invention is explained below yia_ Figures 25, 29, 32-34, 69, 81, 82, 85.
- drum (104) When water is discharged from drum (104) through drum perforations in peripheral zone (509) on a peripheral perforated narrow band zone (510) an important embodiment is made possible.
- the aim of trying to collect a large portion of the water draining drum (104) back inside the drum by pumping said water back into the drum using a circulation pump (112) having a greater flowrate capacity than the drain flowrate of water from the drum is to save water and chemicals in the water by using them only in the drum.
- drum (104) could simultaneously be used as a water tank/outer drum (101) and the outlet of the water therein could be opened and closed as desired, and the problem will be solved at the source.
- drum (104) when drum (104) is simultaneously used as a water tank/outer drum (101), there will be no need for water to be present outside the drum.
- the present invention makes this possible.
- a drum discharge chamber (517) completely surrounding the where drum perforations in peripheral zone (509) on a peripheral perforated narrow band zone (510) on drum outer surface (104-s) on drum (104) and covering and sealing said holes the water exiting from said drum perforations in peripheral zone (509) will enter and collect in said drum discharge chamber (517).
- Said drum discharge chamber (517) will cover the areas where the holes are located by creating a small volume on the conical drum sheet perforated in the narrow belt zone (512).
- drum discharge chamber (517) Water exiting drum perforations in peripheral zone (509) will flow to drum discharge chamber (517). When the outlet from drum discharge chamber (517) is closed, drum water will be collected in the drum. However, as the volume of the discharge chamber is markedly smaller than water chamber (500) and the circulation system, the amount of water present in drum discharge chamber (517) during washing will not affect the targeted water saving values.
- drum discharge chamber water discharge valves (519) mounted on drum discharge chamber (517) can be opened and closed using an electric motor or a pneumatic piston of drum discharge chamber discharge valve (520) of drum discharge chamber discharge valve (519).
- Said pneumatic piston of drum discharge chamber discharge valve (520) of drum discharge chamber discharge valve (519) used for opening and closing the valve may be placed in a suitable position such as the spaces of drum lifter ribs (107).
- drum discharge chamber discharge valve (520) providing water outlet from drum discharge chamber (517) is closed by pneumatic piston of drum discharge chamber discharge valve (520) as shown in Figure 37B, 37C and 37D.
- Figure 36 shows four drum discharge chamber water discharge valves (519) mounted on drum discharge chamber (517). Water will pass through drum discharge chamber water discharge valves (519) to water chamber (500) due to the centrifugal force created during the spin cycle.
- drum (104) Even though there is no need to take special precautions for drum (104) discharging water by rotating, when drum (104) rotation needs to be stopped while water discharge is going on it will be necessary to stop the drum at a position where one of the open drum discharge chamber water discharge valves (519) is at the bottom.
- Hinged drum door (533) is locked by electric or pneumatic hinged drum door lock (536) systems mounted on drum (104). When said locks secure the door on the opening flange, the door is fixed onto the drum by hinged drum door gasket (538) in a leak-proof manner.
- drum (104) any technical means necessary for the door, including locking of the drum door, controlling of the locks and the position of the door and automatic opening of the door. What is important to consider is that for the door to be opened, drum (104) needs to be at the same position every time.
- a second point to consider is that as hinged drum door (533) rotates along with drum (104), there is a need for a second fixed chassis drum safety door (540) for providing security on the outer frame of the machine as exemplified in Figure 81-83.
- Rotating drum door can be fully closed; however, in embodiments where water inlet into drum is through the drum opening, rotating drum door must contain a hinged drum door water inlet hole (534).
- the water connection providing water inlet through hinged drum door water inlet hole (534) is also placed on fixed chassis drum safety door (540) corresponding to the rotation axis of the drum.
- fixed chassis drum safety door (540) carrying the water inlet line is closed, water inlet pipe/injector passes through the hinged drum door water inlet hole (534) and is positioned to provide water to the drum.
- Hinged drum door rotatable buffer (539) of water inlet circulation line (113) on the safety door in contact with the drum is designed to be rotatable.
- FIG 81B shows rotatable door being locked by a drum door lock hinged to the drum having a piston operated by two pneumatic systems to move parts on the drum (131) positioned at drum front circular base/opening side (109).
- a from rotary door carried by a door with a bearing (542) connected to a bearing for rotatable door on fixed door (541) on the rotation axis of the drum can be applied to a fixed chassis drum safety door (540). So, when the door needs to be opened, the mechanism locking from rotary door carried by a door with a bearing (542) onto the drum is opened and rotatable door and bearing for rotatable door on fixed door (541) is carried by a fixed chassis drum safety door (540) connected thereto as shown in Figure 85.
- drum (104) is covered by an inner drum door (533) hinged to drum front circular base/opening side (109)
- an additional option for water inlet besides from rotary door carried by a door with a bearing (542) may be water inlet (532) from water entrance to drum through drum shaft (103-c) or water inlet around drum door(532-a/b).
- Connecting the rotatable water inlet system on drum shaft (103) and circulation pump (112) line to drum (104) will simplify drum door (118) design and allow for a shorter pump line.
- Fresh or circulated water inlet (532) placed around drum door (532-a/b) is more suitable than both water inlet (532) from door and shaft.
- Water inlet (532) for fresh water, water inlet (532-a) for circulation water connected by water collection chamber placed around perforated drum surface and water inlet (532-b) for the drum entrance gap water collection chamber is mounted around or over the drum door. Similar as explained water entrances (532), gas inlets to inject gas into the drum are also possible to place around drum door through drum entrance opening.
- the drum In a machine where oscillation tolerances are minimized, it is possible for the drum to have a capacity of 90-100 L even if household drum (604) is placed inside a water tank/outer drum (101) and it is possible for the drum to have a capacity of 110-120 L for a washing machine having a water chamber (500) instead of a water tank/outer drum (101).
- the first step to achieve this is to prevent the oscillation of household drum (604) during the spin extraction cycle.
- water discharge chamber outside household washing machines drum sheet but inside water discharge chamber (619) is surrounded by a household water discharge chamber peripheral cover sheet (620) having the same diameter as the cylindrical drum sheet to cover the rear corner of the drum as shown Figures 55A, 56 and 57.
- Said household washing machines household water discharge chamber peripheral cover sheet (620) is circular and has the same diameter as cylindrical household drum sheet (606) and is mounted there onto in a leak-proof manner.
- FIG. 55A, 56-58 show the water discharge chamber (619) obtained by shaping of the cylindrical household drum sheet (606). Said water discharge chamber volume may be formed by different techniques and auxiliary plastic parts placed inside the drum.
- the water discharged from household drum (604) will flow through household drum water channel/Poly-Canals (621) formed by household drum water channel grates (622) in the household washing machines drum and reach household drum holes/perforations (605) on the cylindrical household drum sheet (606), wherefrom it will flow into the water discharge chamber (619).
- the water entering water discharge chamber (619) will flow on circular household water discharge chamber peripheral cover sheet (620) and into household water chamber (611). Since the household drum (604) is inclined towards backwards, the water outlet from the household drum entrance opening gap (627) will be less than the horizontal drum condition.
- the sweeping effect created by protrusions placed at an angle inside the helical structure created by household drum water channel grate bars/Poly-Ribs (623) placed at an angle determined according to the direction of rotation of household drum (604) during the spin extraction cycle will direct the water towards the rear of the drum and out of said household drum (604).
- the water will flow out from the rear corner of the drum and into household washing machines water chamber (611) wherefrom the water will flow into household water collection/storage tank (625) via household washing machines water chamber-storage tank connection (624).
- household drums (604) of household washing machines are inclined towards the rear, there will be considerably less water flow from the drum opening compared to horizontal drums.
- movement transfer system (401) placed outside of the drum to provide movement to moving parts inside drum (250) or moving parts outside drum (251) were discussed above.
- the conditions that need to be satisfied in order for movement transfer system (401) to be mounted outside drum (104) in a water-filled environment to operate within water in a water tank/outer drum (101) or water chamber (500) and the conditions for creating water-free zones (100) on drum outer surface (104-s) for movement transfer system (401) so that they don't have to operate under water were disclosed above. It is clear that moving parts inside drum (250) and all types of related parts that will also be mounted inside the drum need to satisfy the conditions of operating under water.
- the parts that are dangerous or not possible to operate under water are isolated against water using known techniques, or placed in water-free zones (100) formed by methods proposed by the invention.
- the object of mounting a movement transfer system (401) outside drum in water-free zones (100) is to ensure the operation of moving parts inside and outside the drum that are aiding in the operation of the machine.
- a preferred result of the invention is mounting moving parts inside the drum (250) that are driven by a movement transfer system (401) which is mounted outside the drum in order to create a physical effect and enhance the physical effect imparted by the movement of the drum on the materials being treated in the drum.
- Moving parts inside drum (250) to change the physical effect provided inside the drum are rotating parts whose rotation speeds can be adjusted according to the treatment operation.
- the rotating parts There are obvious technical advantages and practical application areas provided by choosing the rotating parts to be rollers (201) that are placed lengthwise inside the drum. Because rollers (201) which are placed onto cylindrical perforated drum sheet (106) side by side covering the inside of the drum can be rotated at desired speeds or not at all as required, the provide the dynamism that is the object of the invention.
- moving parts inside drum 250
- moving parts inside drum 201
- Rollers (201) placed in-between roller bearings (205) located at drum drum rear circular base/shaft side (110) on the drum shaft (103) side and at drum front circular base/opening side (109) on the drum door (118) side, parallel to the rotation axis of the drum can be rotated in the desired direction or oscillate within predetermined angular limits, at the desired speed for the desired length of time by movement transfer system (401) mounted on the front or rear circular base surface of the drum to create or enhance the physical effect required by the ongoing treatment operation within the drum.
- Rollers (201) do not need to be rotating in the same direction all the time. In cases where it is unfavorable for rollers (201) to rotate in only one direction due to technical reasons, they can periodically change direction.
- rollers (201) If the direction of rotation of the rollers is in the opposite to the direction of rotation of the drum, it will be possible to increase the mechanical effect desired in the drum. In fact, in cases where it is dangerous for rollers (201) to rotate fully, it is possible to configure rollers (201) to continually change direction and oscillate within predetermined angular limits.
- rollers (201) as moving parts inside drum (250) were disclosed above.
- moving parts do not have to be in the form of rotating parts.
- moving parts inside drum (250) can be in the form of parts that vibrate or oscillate by moving axially, freely or eccentrically in horizontal and/or vertical direction depending on the application.
- a mechanism mounted inside the drum can be driven to vibrate or oscillate by a system from outside of the drum.
- a good example for fully rotating moving parts are abrasive rollers (202) placed inside the drums of industrial stone washing machines (54).
- brush rollers (203) are used as rotating parts inside drum as shown in Figures 35 and 36, new treatment operation applications that were not possible to achieve with conventional washing machines will become available.
- Round brush rollers (203) will provide different stoning effects on the materials that are not possible to obtain by abrasive stones.
- the surface of the cylindrical rollers (201) generally referred to as brushes may be covered by bristles protrusions of different materials, shapes and sizes.
- Said protrusions can be of different hardnesses in various shapes and lengths ranging from the size of the steel bristles that can be measured by microns up to the size of the plastic bristles 3-5 mm in diameter.
- rollers (201) inside drum can be in the form of brushes made from materials used for producing brushes, such as fibers, steel, plastic etc., having different shapes, hardness and thickness to brush the materials in the drum in order to clean, wear down, felt, shine and/or shape them.
- the definition of brush used here is meant to be a general definition and indicates parts having protrusions made of any type of flexible or semi-flexible material on their surfaces.
- Round brush rollers (203) shown in Figure 36B can be used for creating surface effects such as felting and wearing down on textile products, as well as for cleaning rubber mats or similar hard and semi-hard materials by brushing during washing.
- Figure 36A shows round brush rollers (203) mounted side by side in the drum.
- Fixed brushes between rollers (208) having a semi-cylindrical shape are mounted between the rotating rollers in the manner that the brush protrusions of the fixed brush go in- between the brushes of the brush round rollers.
- the purpose of said fixed brushes between rollers (208) is to prevent the materials from getting tangled with the brush rollers.
- both the rotating and fixed brushes shown in Figure 35 and 36 are made from flexible-hard plastic material. When these brushes are used in a washing machine, they will speed up the effects of the chemicals and shorten the washing time. They also provide rubbing effect to the materials and allow the desired cleaning result to be obtained much more quickly.
- the brushes may be egg-shaped, indented or elliptical. Brush rollers having eccentric surfaces will impart a stronger physical effect to the materials. Even if the brush rollers have indented surfaces, the indentations of the fixed brushes will be placed in-between the indentations of the brush rollers to prevent the materials from getting tangled.
- Brush rollers (203) will be especially useful for washing heavily stained and dirty materials such as work uniforms and table cloths. Using brushes having a special surface structure along with chemicals will provide faster and more effective cleaning.
- rollers (201) Another feature of rollers (201) is that said rollers can be mounted to and dismounted from roller bearings (205). Therefore, the changes required by different types of treatments can be realized quickly.
- eccentric rollers (204) When the rotation axis of rollers (201) is offset from the central axis of the cylinder, the rotation of said roller (201) will be eccentric. Rotation of eccentric rollers (204) will provide a beating effect to the materials in addition to the friction effect. The same effect may be obtained by elliptical rollers as well. In conclusion, when eccentric rollers (204) whose surfaces rotate eccentrically are used in washing machines, they will provide a rubbing effect on the laundry.
- Stone washing treatments constitute a significant portion of treatments performed in industrial washing machines (51). And industrial stone washing machines (54) are the most widely sold type of industrial washing machines.
- pumice stones small enough to pass through drum perforations/holes (105) and pumice sand will need to be pumped back into drum (104) using the same circulation line.
- the pumice stone passing through the pump will cause abrasions in the pump, pump housing and pump propeller.
- pumice stones tend to aggregate and sediment in areas where water flow is weak.
- the solution to these problems is proposed by the system described in 23 rd article "Discharging water from drum via drum discharge chamber water discharge valve (519)". Water discharge valves controlling water discharge from drum (104) can be kept closed throughout the stone washing treatment process to keep pumice stones and pumice sand in the drum (104) for the duration of the treatment.
- Another disadvantage of stone-washing using conventional mechanic abrasive materials is that the abrasive materials also wear down the drum inner surface (104-n) they come in contact with and in time render some of the parts unusable. Abrasive materials used in the drum will render the drum sheet unusable in 2 to 3 years.
- the present invention eliminates this problem. If the surfaces of the moving parts in drum (250) contain the required abrasiveness, it will be possible impart the desired stoning effect to the textiles being treated.
- the desired abrasion effect on the textile can be achieved even if there are no additional abrasive materials inside the drum by covering the surface of moving abrasive parts (260) mounted on drum inner surface (104-n) with abrasive materials, mechanically or chemically treating the material constituting the surface of said moving abrasive parts (260) to impart abrasive character or choosing an abrasive material such as grindstone as surface material for said moving abrasive parts (260).
- Mechanical abraders such as pumice stone, added to drum (104) along with textiles will provide abrading and wearing down of textiles by the friction created by the textiles rubbing against each other with the rotation of the drum.
- moving parts inside drum (250) are abrasive
- abrasion by friction will take place between the textiles and said moving parts inside drum (250).
- the movement speed of these parts is very important. In some cases, increasing the movement speed is more effective, while in some cases it may be the opposite. It is therefore one of the most important features of the present invention that the speed of movement of the abrasive moving parts (260) can be controlled as desired.
- One of the most important embodiments of the invention is having moving abrasive parts (260) mounted on drum inner surface (104-n) be in the form of abrasive rollers (202).
- stone-washing of denim jeans is done in multiple steps.
- the first step is stone-washing with abrasive materials to impart a base design onto the jeans.
- the pants are dry-treated to impart the desired shapes there onto.
- One of these treatments is an application where fold marks are created on desired sections of the pants.
- This treatment application may entail creation of lines or marks on the jeans using laser technology or small grindstones rotating at high speeds. Abrasive grindstone rollers (206) rotating inside the drum will have the same effect on the jeans.
- FIG. 2 One of the most important embodiments of the moving parts inside drum (250) system is abrasive grindstone rollers (206).
- Figures 4-11, 17, 31, 32, 35, 37, 38, 40-43, 45 show different examples of abrasive rollers (202) mounted on drums (104) of industrial stone washing machines (54). It is preferable for abrasive rollers (202) to have a grindstone surface; however, it is not required. It is also possible to use abrasive rollers (202) produced by methods to obtain abrasive materials known in the art, such as covering by an abrasive material other than grindstone, being in the form of an abrasive brush and shaping metal to have an abrasive surface.
- rollers (201) may be produced from solid grindstone as abrasive grindstone rollers (206). Cylindrical abrasive grindstone rollers (206) having support materials added during the production stage to make them more durable may be mounted in the drum. Rollers (201) do not have to be produced from solid grindstone.
- Rollers (201) may comprise cylindrical (210) or spherical/buckled (211) grindstone pieces (207) mounted on a mechanical structure.
- Spherical/buckled grindstone pieces (211) may be preferred in order to prevent formation of different levels of abrasion at the folds of the textiles contacting the rollers and to impart different designs to the textile.
- Spherical/buckled grindstone pieces (211) may be preferred even though treatment time increases because abrasion in desired shapes can be obtained.
- Figure 40 shows cylindrical abrasive grindstone rollers (206), rollers comprising cylindrical grindstone pieces (210), rollers comprising spherical/buckled grindstone pieces (211) and abrasive rollers (202) covered by protrusions such as brush rollers (203) for use as abrasion agent.
- Figure 35 also exemplifies different abrasive pieces that can be used on the rollers.
- Mounting cylindrical abrasive rollers (202) that are bed housing from two ends by roller bearings (205) and that can rotate around its axis at desired speeds into the drums of stone-washing machines will speed up the stone washing process and provide many advantages to the textile industry.
- Factors such as the number of rollers (201) inside the drum, the degree of abrasiveness of the abrasive material on the surface of the rollers and the rotation speed of the rollers, diameter and surface profile of the rollers and also many other applications on rollers provide a wide variety of options that allow for customization of the treatment based on the type of material being treated, the stone-washing effect desired and the target quality of the end product.
- An embodiment of an industrial stone washing machine (54) comprising abrasive grindstone roller (206), abrasive and felting brush rollers (203), fixed grindstone pieces (216) mounted on drum inner surface (104-n) along with smooth or indented abrasive sheets (264) covering the drum surface will provide the user with many options with which to customize treatment formulas compared to treatments performed using pumice stone only.
- any mechanical or chemical stone washing, abrading and otherwise modify known in the art may be used with the systems proposed by the present invention.
- Abrasive grindstone rollers (206) can rotate at desired speeds independently of the rotation of drum (104), therefore their speed can be adjusted based on the type of material, density and distribution of desired effect on the material and the planned duration of stone washing treatment.
- Independent abrasive grindstone rollers (206) may comprise grindstones having different physical properties and each abrasive grindstone roller (206) may be rotted in different directions and speeds. There will be no need to remove pumice stones after stone washing and the washing operation necessary after stone washing treatment can be done in the same machine after rollers are stopped. In fact, if the machine has a spin cycle, it can be used after chemical washing and rinsing cycles.
- An exemplary embodiment of a stone washing machine of the invention as shown in detail in Figure 37B comprises abrasive rollers (202) comprising cornered grindstone carriers (212) serving as a shaft between roller frontal bearing (205-f) and roller rear bearing (205-r) having abrasive grindstone rollers (206) of measurement and shape suitable for said grindstone carriers (212) mounted there onto or covered by grindstone pieces mounted side by side to cover the surface of said shaft.
- the reason why grindstone carriers (212) carrying and realizing the rotation of the grindstones have a cornered structure is to facilitate the rotation of the grindstones.
- Quadrangular grindstone carriers (212-4) and hexagonal grindstone carriers (212-6) are preferable due their suitability for grindstone production methods and their ability to function as a wedge.
- the grindstone mounted onto said carriers through the central hole therein is a single piece, it is preferable that they be in multiple parts. As the different sections of grindstones covering the drum inner surface (104-n) from rear to front will be worn down at different rates, the whole part will need to be replaced based on the most worn down section. However, if pieces of grindstone are used, it is possible to only change the most worn down grindstones. As abrasive grindstone rollers (206) are made of long single pieces, they are not durable against bending and have high risk of breaking which requires them to be produced using special techniques. Additionally, a single piece of grindstone will be harder to mount that multiple grindstone pieces (207). For these and similar reasons, it is preferable to use multiple grindstone pieces (207) to form abrasive grindstone rollers (206).
- Grindstone carriers (212) may be circular shaft with one or two flat surface carrier (212-2) or quadrangular grindstone carriers (212-4) as shown in Figures 35A and 37C or hexagonal grindstone carriers (212-6) as shown in Figure 43C, as well as any polygonal shape acting as a wedge for the holes in the grindstones.
- Moving parts inside drum (250) in the form of rollers (201) are reversibly mounted on roller bearings (205) located at drum rear circular base/shaft side (110) on the drum shaft (103) side and at drum front circular base/opening side (109) on the opening side in the drum, parallel to the drum axis where they can rotate or oscillate around the axis of said bearings.
- rollers it is advantageous for the rollers to be mounted and dismounted by a practical mechanism. Therefore, it is possible to use any mechanism known in the art for practically mounting and dismounting rollers from two roller bearings (205).
- Roller frontal bearing shafts (213) providing the connection between roller bearings (205) located at drum rear circular base/shaft side (110) drum front circular base/opening side (109) can be mounted into roller bearings (205) through in roller frontal bearing shaft housing (214) and rotatable lock abrasive grindstone rollers (206) between the bearings.
- Grindstone pieces (207) on roller may be cylindrical, spherical, buckled, conical and eccentric or indented.
- Abrasive character can be imparted to the drum inner surface (104-n) by methods other than covering said drum with abrasive sheets (264).
- One such method is covering the drum with fixed grindstone pieces (216).
- covering the area of the drum in-between abrasive grindstone rollers (206) with fixed grindstone pieces (216) instead of abrasive sheets (264) will have different advantages.
- Fixed grindstone pieces (216) having an indented structure possess a larger abrasive surface area to come in contact with the textile than abrasive sheets (264). Also, it is possible to only change the parts that have been too worn down to function.
- Stone washing treatment in the drum may be performed dry or generally with the addition of water and chemicals.
- Abrasive rollers (202) may be placed on the cylindrical surface of the drum side by side in the manner that no space is left between them. This way the whole area of cylindrical perforated drum sheet (106) will be moving and abrasive and it will be possible to decrease the time needed for the stone washing treatment by adjusting the speed of the rollers.
- abrasive rollers (202) In order for abrasive rollers (202) to wear down the surface of the material, there needs to be friction between said material and rollers. If abrasive rollers (202) placed side by side are all rotated in the same direction, the materials sitting thereon would be carried by the rollers in the direction of rotation. In this case, wearing down of materials decreases significantly.
- abrasive rollers (202) placed side by side in opposite directions. Because abrasive rollers (202) placed side by side and rotating towards each other will move in a way to trap the textile between them, they may cause harm to the textile. Placement of abrasive rollers (202) side by side in the manner that no space is left between them will also cause movement transfer system (401) placed outside the drum to drive said rollers, such as gears, racks and pinions, timing belt pulleys, poly-V belt pulleys, smooth belt pulleys and V belt pulleys, to have a crowded mechanical structure.
- movement transfer system 401
- material holding parts (218) are mounted in-between the rollers.
- Said material holding parts (218) may be made of any indented material but are preferably made of abrasive materials such as fixed grindstone pieces (216) or fixed brushes between rollers (208).
- Fixed grindstone pieces (216) placed between abrasive rollers (202) will function to wear down the materials being treated as well as prevent said materials from being dragged and rolled by the rollers and aid said materials in rotating along with the drum.
- fixed grindstone pieces (216) placed between abrasive rollers (202) may be of different sizes depending on the space between said abrasive rollers (202).
- abrasive rollers When abrasive rollers are placed close together, only a fixed grindstone rod (217) or fixed brush between rollers (208) can fit between them. But when abrasive rollers are placed farther apart, larger fixed grindstone pieces (216) can fit there between.
- fixed grindstone pieces (216) are mounted to be replaceable. If they are large in size, it would be advantageous for them to have coarse protrusive surface structure of fixed grindstone (219).
- Abrasive grindstone rollers (206) comprising abrasive grindstone pieces are mounted onto cylindrical perforated drum sheet (106) side by side with no space in-between. When they are placed in this manner, it will not be possible for the materials being treated inside drum (104) to get caught between two rollers (201). However, in this embodiment grindstone pieces (207) will need to be replaced often. While it is not possible for the material to enter the space between two rollers when grindstone pieces (207) are replaced, as grindstone pieces (207) are worn down, their diameters will get smaller and the space between rollers will increase enough that the material can enter, which will cause problems.
- said rollers must have the indented structure of grindstones of recessed protruding threaded rollers (209-s) as shown in Figure 41, 42.
- each grindstones of recessed protruding threaded rollers (209-s) of recessed protruding threaded rollers (209) is comprised of two cylindrical sections referred to as tab of recessed protruding threaded roller (209-p) and recess of recessed protruding threaded roller (209-r); and these tabs and recesses are arranged on grindstone carrier (212) part of roller such that they form a male-female connecting structure, the rollers will have the appearance of being interlocked.
- drum inner surface (104-n) has a fully moving abrasive surface and the indented surface structure increases the overall abrasiveness.
- Recessed protruding threaded rollers (209) placed side by side with no space in-between as shown in Figure 39C are driven in groups by a electrical drive motor on drum (132) mounted on drum (104) via main gear of group of gears connected to motor (414) on the motor and via gears connecting to rollers and each other (418) connected thereto, wherein said gears connecting to rollers and each other (418) are mounted onto each recessed protruding threaded roller (209) in the manner to rotate every roller in the group.
- Gears connecting to rollers and each other (418) providing movement to recessed protruding threaded rollers (209) placed side by side rotate the rollers that are beside and in connection with each other in opposite directions.
- the problem of the material being dragged in the drum caused by the rollers all rotating in the same direction is solved. It is obvious that the indented cylindrical grindstone pieces forming recessed protruding threaded rollers (209) will have a much longer critical wearing down period compared to cylindrical grindstone pieces (207).
- the textile need not be wet for stone washing treatment.
- the contact-friction force between the textile and fixed grindstone pieces (216) and moving abrasive parts (260) will increase and therefore the wearing down effect will increase.
- the total load inside drum (104) increases, the amount of contact the material has with the abrasive surface decreases while the wearing down effect on the material will increase.
- the excess water will cause the weight of the textile to decrease due to buoyancy and in addition will serve as a buffer zone between the textile and the abrasive surface when the textile is carried up by drum (104) and dropped down onto said abrasive surface and decrease the wearing down effect caused by the friction between textile and abrasive surface with force of dropping.
- Placing water channels (220) in large fixed grindstone pieces (216) so that excess water can be discharged during impact of textile to decrease the buffer effect of water will provide faster and stronger contact between the textile and the abrasive surface and therefore increases the wearing down effect. While wetting the material that is desired to be stone washed, i.e.
- water accumulation chamber (502) is very important.
- the amount of water in drum (104) may be adjusted using said water accumulation chamber (502) and therefore the wearing down of the material can be controlled.
- the textile After the stone washing treatment, the textile will need to be washed with the addition of chemicals. It is beneficial for the stone washing and chemical washing treatments to be completed in the same machine, one after the other without delay.
- moving abrasive parts (260) are stopped and the amount of water within drum (104) is increased to decrease the abrasiveness of the drum inner surface (104-n) so that chemical washing treatment can proceed without changing the stoning effect on the textile.
- the ability to continue washing operation in the same machine as the stone washing operation will be advantageous in terms of cost, manpower and time.
- rollers (201) With protrusions on protruding parts in rollers (227) on the surface will allow the material to move, mix, agitate, rub and animate. Many times, by moving the treated material creates an effect to accelerate the process but sometimes on the contrary, enables to decrease the process speed to be controlled in a controlled manner. Since the abrasive rollers (202) rotate very speedily, if they contact with the material at the same point they cause non-homogeneous wear on the contact surface. In this case, it is necessary to prevent the abrasive rollers (202) and treated materials being kept constant for more than a moment time in the same position.
- protruding parts in rollers (228) between the abrasive cylindrical grindstone pieces (207) in the abrasive rollers (202) will solve the problem as the material will be displaced during the rotation by contacting with said protrusions.
- These protruding parts in rollers (228) can be mounted on the same roller (201) with the abrasive pieces, or as separate rollers which provide movement between the said abrasive rolls.
- increasing the movement of water in the drum rather than increasing the movement of the washed material may be more beneficial for the chemical process.
- direct chemical interaction processes such as dyeing, bleaching, and softening, it will be more efficient to spray, agitate, inject and atomize water powerfully towards to washing material.
- movable abrasive parts (260) on drum inner surface (104-n) are mounted to said drum inner surface (104-n) surface via motors connected to moving parts (134) or movement transfer system (401) or mechanisms that are connected to a drive source on the rotating rollers and that oscillate eccentrically.
- Moving parts inside drum (250) may be in the form of vibrating parts (222) vibrating on a linear plane.
- the movement of grindstones mounted on drum inner surface (104-n) instead of fixed grindstone pieces (216) will contribute to the dynamism desired to be created inside drum (104).
- vibrating parts (222) are abrasive, they will also function to wear down the material like the abrasive rollers that are rotating axially.
- vibrating parts (222) in the form of grindstones attached to vibrating part platforms (224) mounted onto drum (104) via vibrating part connection springs (223) instead of grindstones affixed onto drum (104) of industrial stone washing machine (54) and having said platforms be in connection with a vibrating part vibrator (225) placed outside drum (104) in order to vibrate, is an efficient method.
- indented grindstones mounted in this manner are activated by vibrating part vibrator (225), they will provide much more active abrasion than their fixed counterparts.
- Said vibrating parts (222) can be used along with abrasive rollers in the drum or by themselves without any additional moving part.
- FIG 38 shows a detailed side sectional view of a roller comprising abrasive grindstone pieces.
- a roller (201) mounted in drum (104) comprises two roller bearings (205) connected to frontal and rear sheets respectively, a grindstone carrier (212) reversibly mountable between said two roller bearings (205), roller frontal bearing shafts (213) connecting said grindstone carrier (212) and said roller bearings (205), a roller frontal bearing lock system (215) facilitating connection of at least one roller frontal bearing shaft
- roller frontal bearing shaft (213) to grindstone carrier (212) and roller shaft locks (226) for locking grindstone carrier (212) in place in corresponding roller bearing (205).
- roller frontal bearing shaft (213) of grindstone carrier (212) should be able to be pulled into roller frontal bearing shaft housing
- Roller frontal bearing shaft (213) should comprise a mechanism placed in roller frontal bearing shaft housing (214), said mechanism facilitating compression of roller frontal bearing lock system (215) ensuring roller frontal bearing shaft (213) remains within roller frontal bearing shaft housing (214) and therefore ensuring that roller frontal bearing shaft (213) enters into roller frontal bearing shaft housing (214).
- said shaft can be gradually removed from said bearing and inserted into said housing using a tool having a suitable diameter to be inserted into roller shaft pulling bore as shown in Figure 47.
- roller grindstone pieces (207) will be possible to use the same drum for different purposes by changing the roller grindstone pieces (207) within with those having different functions or different degrees of effect for the same function.
- they will get worn out faster than other parts of drum (104) due to their physical activity, they will be easily replaceable when needed.
- the same machine can be used as a stone-washing machine using abrasive grindstone rollers (206) and fixed grindstone rod (217) pieces on roller or a washing machine using brush rollers (203) and semi-circular fixed brushes between rollers (208).
- rollers (201) Quick dismounting and mounting of rollers (201) is important in terms of time conservation. Regardless of whether the rollers are made of brushes, grindstones or other materials, it will be advantageous both in terms of production and application for rollers to comprise pieces placed side by side. Grindstone pieces (207), brush rollers (203), eccentric, helical, indented plastic rubbing or mixing pieces perforated in the middle in the axis of rotation corresponding to the profile of the carrier part are placed side by side on said carrier part. Roller bearings (205) ensuring that said rollers (201) rotate around their axis may be made by a variety of methods from a variety of materials depending on the rotation speed of the roller.
- roller frontal bearing (205-f) to be inserted to the housing on drum front circular base/opening side (109) and a stainless roller rear bearing (205- r) to be inserted to the housing on drum rear circular base/shaft side (110) are exemplified in Figures 47 and 48.
- Sealing elements such as roller shaft seal ring (232) need to be used at the ball bearing to prevent water from drum (104) from entering the area where roller ball bearings (231) are located. In case there is water leakage in spite of this, it will be useful to have a roller bearing water discharge hole (233).
- Roller rear bearing (205-r) comprises a roller rear bearing shaft (230) having an end in the drum and one end out of the drum.
- Rotating rollers (201) within drum (104) are connected to shaft-roller connection (230-f) of roller rear bearing shaft (230).
- This end of the shaft comprises a shaft-roller cornered lock structure (230-fl) or shaft-roller wedged lock structure (230-f2) for rotatably connecting and locking a roller (201) or similar part.
- Movement transfer system (401) mounted outside and to the rear of the drum is connected to shaft-movement system connection (230-r) at the end of said shaft sticking out of the drum.
- protrusive surface structure of drum (266) according to the present invention are explained below via Figures 3, 4, 12A, 17, 37, 44A
- adding structures such as protrusions on cylindrical drum surface (261) and/or recess between protrusions on cylindrical drum surface (262) will increase drum inner surface (104-n) area in contact with the material and the surface area of the moving parts that can be mounted thereon in addition to providing the necessary protuberant structure of the Poly-Rib systems (60) described by EP2229475.
- the protuberant structure of drum inner surface (104-n) will prevent drum perforations/holes (105) from being blocked by the materials, so there will be no unexpected significant changes to water discharge from drum (104). Water discharge having a limited flowrate will not overflow and will flow through water chamber (500) to water storage chamber (504) or drum opening water collection chamber circulation pump (528).
- Said additional abrasive parts can be fixed grindstone parts (216) or vibrating parts (222) wherein grindstones can move in a vibrating motion.
- the advantage of increasing drum inner surface (104-n) by indentations is making space for moving parts and additional parts to be used with them.
- protrusions on cylindrical drum surface (261) will ensure that the textile is spread evenly across drum inner surface (104-n), that the textile moves along with drum (104) and that water discharge is controlled and will also result in an increase in the contact surface area between moving abrasive parts (260) and/or fixed grindstones on inner drum surface (216) due to increase in surface area thereof.
- Stone-washing is a treatment done in the presence of water. Increasing the weight of the textile by wetting will increase the friction between the textile and the abrasive material and lead to an increase in efficiency. However, there is always some excess amount of water in the drum, although it is not required. When the textile falls on a fixed grindstone part having a flat surface, the water between the textile and the grindstone surface will act as a buffer and reduce the friction between them, causing a decrease in wearing down of the textile.
- the structure described has a similar function to water channels on surface of the tires of vehicles. Similar to how the road grip of a tire decreases as the tire gets worn down and the risk of the vehicle slipping on a wet road increases; the grip of grindstones will decrease as they are worn down.
- Drum perforations/holes (105) having reduced number and water permeability are positioned in the recesses between the protrusions of drum inner surface (104-n) so that water can reach drum perforations without coming across any obstacles.
- Drum perforations/holes (105) are placed in a corresponding position to the holes in the recesses between protrusions of fixed grindstone pieces (216) on the surface of drum (104).
- Drum perforations in peripheral zone (509) in drum (104) being located only in a designated region of the drum and methods to ensure that water from other regions of the drum can flow to said holes without coming up against any obstacles was explained above.
- Water channels/Poly-Channels (524) on the drum surface were previously disclosed to be formed by water channel grates (526); however, they are also possible to be formed by water channels (220) on grindstone pieces.
- grindstones having water channels (220) are placed side by side in such a way that said water channels (220) correspond to each other, they will form water channels/Poly-Channels (524) covering drum (104) from one end to another.
- Roller side bumper prevent material entrance (244) and molded roller housing structures to prevent tangling around rollers according to the
- a drum (104) comprising moving parts inside drum (250) may be defined as a dynamic drum.
- An obvious application for a dynamic drum is in industrial washing machines (51).
- materials of textile type are treated in industrial washing machines (52).
- the first issue that needs to be addressed when textiles are physically and/or chemically treated like washing, dyeing, stoning, bleaching, coating, softening in a drum (104) comprising cylindrical rotating parts, such as rollers (201) is the textiles getting tangled up in said rollers (201).
- Rollers such as abrasive rollers (202) and brush rollers (203) mounted side by side on cylindrical perforated drum sheet (106) will move the textiles under them towards said cylindrical perforated drum sheet (106).
- recessed protruding threaded rollers (209) comprising indented surfaces that can engage with each other can be used to solve this problem.
- rollers are cylindrical and buckled and mounted apart from each other, it is unavoidable that the rollers gets tangled with the material and gets stuck. To prevent this, the sided of the rollers must be covered to block the textiles from going under the rollers.
- part of the rotating parts must be covered in a way to not permit entry for any material being treated in drum (104), especially textiles. This is possible by a variety of methods.
- roller side bumper prevent material entrance (244) The simplest way to prevent the materials from entering under the rollers (201) is to place roller side bumper prevent material entrance (244) on the drum inner surface (104-n) to cover the sides of the rollers as shown in Figures. This method is also the most practical and feasible solution in that it allows the roller side bumper prevent material entrance (244) to be approached in a desired manner to the rollers (201).
- roller side bumper prevent material entrance (244) method will cause increased water consumption problem due to space remaining beneath the rollers (201) and also will cause residual pollution problems caused by material particles that will accumulate under the rollers.
- molded roller housings (234) having a cylindrical housing suitable for the diameter of the roller and preferably made of plastic, aluminum or a similar material may be placed under the rollers as shown in Figures. Molded roller housings (234) are molded to fit against cylindrical perforated drum sheet (106) at the bottom and against the surface of the roller at the top and placed under the rollers, spaced apart just enough that no materials can enter there between.
- molded roller housings (234) comprise molded roller housing water discharge holes (235) required for water discharge from drum (104). Molded roller housing water discharge holes (235) are positioned within molded roller housings (234), in order for rollers (201) to prevent the materials from reaching the holes.
- molded roller housings (234) Another function of molded roller housings (234) is serving as fixed part housing in molded roller housing (236) for fixed parts such as fixed grindstone pieces (216) or fixed brushes between rollers (208) when they are placed between the rollers.
- said molded roller housings (234) are reversibly mounted like rollers (201) and fixed grindstones on inner drum surface (216), they are exchangeable for different purposes.
- the materials being dragged by the rotation of roller (201) can also be prevented by using specially shaped molded roller housings (234) without having to use additional blocking parts.
- molded roller housings (234) are placed side by side in an interlocking manner so that molded roller housing water discharge holes (235) correspond to drum perforations/holes (105) on cylindrical perforated drum sheet (106).
- Molded roller housing lock system (237) provides interlocking of molded roller housings (234).
- Molded roller housings (234) are screwed on drum (104) via molded roller housing-drum connection (238) or another method and mounted by locking each other and the fixed parts between the rollers in place.
- molded roller housing water discharge holes (235) of molded roller housings (234) are important to keep the flowrate of water exiting drum (104) under control. As said molded roller housing water discharge holes (235) are covered by rollers, the material being treated inside drum (104) can never block water flow therethrough. Having molded roller housing water discharge holes (235) always open will ensure that the maximum flowrate of water exiting drum (104) will remain constant depending on the rotation speed of drum (104) as explained with Poly-Rib system (60) in EP2229475. It is important to know the maximum flowrate of water exiting drum (104) in order to determine the operating conditions of circulation pump (112).
- molded roller housings (234) Other types of buffers from different materials may be used in place of molded roller housings (234) to prevent the materials being treated to get tangles in the rollers. Even simply placing a shaped sheet roller (239) under the roller to serve as roller housing will prevent textiles from going under the roller. Moreover, fixed grindstones (243) mounted next to the abrasive roller will block the material without needing a special buffer. Said molded roller housings (234) or barriers/buffers must be selected according to the physical features of the material, such as thickness and touch. If the textile is jeans, as the fabric is thick denim, a few mm of distance between the buffer and housing will be sufficient. However, for thinner materials, such as socks, it will be necessary for the barriers to cover the area around the roller completely, such as fixed brushes between rollers (208) the ends of which contact the roller.
- Methods used to ensure that water in drum (104) flows towards the holes without coming against any obstacles in cases where drum perforations/holes (105) are located at a certain region of drum (104) in a peripheral perforated narrow zone (510) on cylindrical perforated drum sheet (106) were disclosed previously.
- Methods used with drums having rollers may be added to previously disclosed methods of inclined placement of the drum, using a conical drum, having water channel grates (526) on perforated cylindrical perforated drum sheet (106), using water channels on the grindstones.
- rollers (201) and molded roller housings (234) can be placed in a parallel manner to the conical structure of the drum so that the water can flow to the area of roller housings where discharge holes are located.
- rollers (201) may be placed in a cylindrical structure even in a conical drum sheet perforated in the narrow belt zone (512). In this case, the space between rollers (201) and the conical structure of the drum will increase towards the area where the discharge holes are located. The space can be covered by roller housings.
- conically molded roller housings (240) In a drum (104) having a conical drum sheet perforated in the narrow belt zone (512), conically molded roller housings (240) must be used as roller housings. Having a conically molded roller housing water channel (241) extending towards the discharge holes parallel to conical drum sheet perforated in the narrow belt zone (512) will provide water flow within the roller housings.
- Figure 45B shows a conically molded roller housing water channel (241) extending towards area of the base of the roller housing where drum perforations in peripheral zone (509) are located.
- Another method of preventing the materials from being tangled in the rollers is shaping cylindrical perforated drum sheet (106) to form drum sheet in the form of roller housing (242) for said rollers, as shown in Figure 51. It is possible to form cylindrical indentations on cylindrical perforated drum sheet (106) using a press and place the rollers therein.
- One of the most important gains of the invention is, of course, that it makes it possible to mount the electrical drive motor on drum (132) directly on the drum (104). Electrical drive motors on drum (132) that provide movement for moving systems (200) on the drum can work with electricity or pressure air.
- Every washing machine comprises a drum rotation motor (115) for rotating drum (104) and it is possible to use said drum rotation motor (115) to drive moving parts inside drum (250) as said parts are rotated while drum (104) is rotated.
- this embodiment does not require an additional motor, however, using the same drum rotation motor (115) for drum (104) and moving parts inside drum (250) means that the rotation speed of moving parts inside drum (250) is determined by that of drum (104) and rotation of moving parts inside drum (250) is stopped when drum (104) stops.
- the left-right rotation direction of drum (104) will determine the rotation direction of moving parts inside drum (250). Therefore, it is evident that the exemplary embodiment will not provide the expected benefits from the system of the invention.
- the second embodiment comprises at least one electrical drive motor on fixed chassis (133) mounted on fixed chassis (111) outside drum (104) to drive moving parts (200) as shown in Figures 12B, 16, 17.
- movement is transferred from the motor via a movement transfer part such as belt (402) and a movement transfer system such as pulley on drum (104).
- the advantage of this embodiment is that moving parts (200) may be moved independent of the rotation or speed of drum (104). With this application, it will be possible to achieve movement for moving parts independently of the drum motor. Despite this, it is possible to accept that there is a lot of limitations in the application, although it is possible to transfer the movement that achieved from a motor mounted outside the drum.
- the third and most practical embodiment involves mounting a drum movement system motor to move parts on the drum (130) directly onto drum (104).
- moving parts be driven in groups (132) or individually (133) by electrical drive motors mounted on the drum as shown in Figures 3, 5-8, 13-15, 18, 31, 42B.
- each group or part can be controlled individually and their speeds and rotation directions can be determined separately.
- the areas where motors are mounted on drum (104) are outside water chamber (500), it will be easy to control the system and provide maintenance service thereto. If motors are mounted inside water chamber (500), they should be water proof.
- drum (104) comprises electrical systems using electrical drive motors on drum (132) will have many advantages.
- Electrical drive motors connected to moving parts (134) mounted on drum (104) may be directly connected to moving parts (200) or may applied in groups or regionally (413). Connecting an independent motor directly connected to roller (412) directly to each moving part will simplify the system and make it easier to control. There are many advantages of having an independent motor directly connected to roller (412) regardless of whether a motor operating in a water-free zone (100) inside water chamber (500) is used or the motor is taken completely out of water tank/outer drum (101). When each roller is driven by an independent motor directly connected to roller (412) such as an AC, DC, universal or servo motor, their speeds and directions can be controlled separately as desired.
- This embodiment allows rollers (201) to have different features. It will be possible to apply rollers (202) comprised of grindstone pieces (207) and to apply brush rollers (203) having different featured brushes or brush type protrusions in the drum and to control them at different rotation speeds and directions.
- one roller is directly connected to the motor while the two adjacent rollers are connected to the main roller by a movement transfer part such as belt (402) and pulley (401) system or gear/chain system, forming a three roller system driven by one motor driving multiple movable parts (413) as exemplified in Figure 35B, 36B, 37B.
- a movement transfer part such as belt (402) and pulley (401) system or gear/chain system, forming a three roller system driven by one motor driving multiple movable parts (413) as exemplified in Figure 35B, 36B, 37B.
- the number of rollers in a group connected to a motor may be increased. As the size of the motor will have to increase along with the number of rollers connected thereto, it may not be possible to mount these motors on the rear of the drum as with smaller motors.
- One of the embodiments shown in Figure 13 comprises 42 rollers operated by 3 motors divided into groups.
- 14 rollers are driven by a separate motor.
- the biggest benefit of this application is that it allows the desired group to be rotated in the desired condition according to the position of the drum. It may not be appropriate to activate the abrasive rollers when in contact with the textile. If the abrasive surface begins to rotate in contact with the garment, it will cause more damage than high-speed rotation conditions. In this case, during drum rotation the roller group passing through the top of the drum, which is not in contact with the textile, starts to rotate first. With the rotation of the drum, said group will reach the targeted rotation speed before the textile contact.
- Industrial type drums generally comprise three or four drum lifter ribs (107).
- drum lifter ribs (107) are located in the area where discharge holes on cylindrical perforated drum sheet (106) are located, and the water chamber (500) sides of drum lifter ribs (107) are generally open, in drums (104) where drum holes are not located in a peripheral perforated narrow zone (510) the area where the motor is mounted will be wet.
- an isolated area in movement system (142) system must be used for the motor.
- Figures 39 show a case where the water chamber (500) sides of drum lifter ribs (107) are sealed to be waterproof. When the opening left for mounting the motor is covered by a leak-proof cover, the area will be completely isolated.
- a motor driving multiple movable parts (413) placed in the rib space may be connected to the adjacent geared pulleys for transferring movement to rollers (415) on two sides as shown in Figure 13. If connected in this manner, the belt will zig zag between the pulleys which will increase the contact surface of the belt with the pulley and the pressure exerted on the pulley by the belt.
- the back side of the belt moves along a idler pulleys (417) that is moving on the shaft via idler pulley bearings (416) to prevent said belt from affecting the rotation of the following pulley while rotating a pulley.
- the motor rotates half of the rollers on both sides while the other half are rotated by a motor placed in the other drum rib space. Therefore, rotating adjacent rollers in opposite directions, the advantages of which were explained above, will be possible.
- roller rear bearing shafts (230) will be too close together to be able to connect a motor directly or via a pulley/belt system.
- the present invention provides a different solution to drive such types of rollers. First, all rollers are connected together by a gear connecting rollers to each other (418).
- lubrication systems are applicable on drum (104).
- moving systems especially systems moving at high speeds may require lubrication.
- a lubrication station mounted on drum (104) may provide automatic and controlled lubrication to required locations via distribution lines.
- Movement transfer system outside drum (401) comprising belts, pulleys, bearings, gears and similar mechanical systems are in a position that is easy to reach and also provide maintenance and repairs, and that has no contact with water so they will be long-lasting and require less maintenance.
- movable parts operate when necessary, in a controlled manner, at the necessary speed and for the necessary period of time.
- movable parts need to be driven by an electrical drive motor on fixed chassis (133). In this way, while the movement of the movable parts moved using the rotation of drum (104) depends on the rotation speed of drum (104), the speed of the movable parts drive by movable belts for drum peripheral rotation pulley (411) driven by a motor can be adjusted as needed.
- rollers (201) mounted inside drum (104) are rotated by such an electrical drive motor on fixed chassis (133) as shown in Figures said rollers (201) can be rotated at the desired speeds and it will also be possible to synchronize the speed of the motor with the rotation speed of drum (104), thereby making the rollers motionless relative to the drum and rendering then nonfunctional.
- the pulleys may be driven by one or multiple movable belts for drum peripheral rotation pulley (411) and pulleys placed side by side as shown in Figure 16B may be used. This increases the contact surface between drum peripheral rotation pulley (403) and movable belt for drum peripheral rotation pulley (411) and reduces the chance of the belt slipping on the pulley.
- rollers (201) that are mounted side by side rotate in opposite directions will allow the desired effect to be obtained from treatments based on friction such as stone-washing and brushing.
- an electrical drive motor on fixed chassis (133) and movable belt for drum peripheral rotation pulley (411) system can needed to rotate adjacent pulleys in opposite directions, as shown in Figure 12B. Therefore pulleys can be rotated in the same direction at different speeds and in opposite directions at desired speeds.
- Driving movable parts by a belt-pulley system as explained above may be preferable due to its cost efficiency.
- Driving the movable parts of machines wherein drum (104) comprises electrical systems using electrical drive motors on drum (132) will have many advantages.
- Waterproof electrical drive motors on drum (132) may be mounted on a drum (104) rotating in a water tank/outer drum (101). It is not mandatory to place electrical drive motors on drum (132) to be mounted outside drum (104) to rotate abrasive rollers (202) comprised of grindstone pieces (207) in water- free zones (100) of the drum.
- abrasive rollers (202) inside drum (104) can be rotated at desired speeds. Unless it is necessary to do otherwise, it is advantageous to provide conditions wherein electrical drive motors on drum (132) on the drum and the equipment thereof do not come in contact with water to provide ease of maintenance services, application and material choices.
- Electrical drive electrical drive motor on drum (132) mounted on drum (104) may be motors connected to moving parts (134) or may be applied in groups or regionally (413). Connecting an independent motor directly connected to roller (412) directly to each movable part will simplify the system and make it easier to control. There are many advantages of having an independent motor directly connected to roller (412) regardless of whether a waterproof motor mounted inside water tank/outer drum (101) is used, a motor operating in a water-free zone (100) inside water chamber (500) is used or the motor is taken completely out of water tank/outer drum (101).
- rollers (201) used in drum (104) can have different features. It will be possible to use abrasive rollers (202) comprised of grindstone pieces (207) and brush rollers (203) having different brush or similar type of protrusions in the drum and to control them at different rotation speeds and directions.
- one roller is directly connected to the motor while the two adjacent rollers are connected to the main roller by a movement transfer part such as belt (402) and pulley (401) system or gear/chain system, forming a three roller system driven by one motor directly connected to roller (412-3) as exemplified in Figure 35B.
- a movement transfer part such as belt (402) and pulley (401) system or gear/chain system, forming a three roller system driven by one motor directly connected to roller (412-3) as exemplified in Figure 35B.
- the number of rollers in a group connected to a motor may be increased. As the size of the motor will have to increase along with the number of rollers connected thereto, it may not be possible to mount these motors on the rear of the drum as with smaller motors.
- drum lifter ribs (107) for rotating the material being treated along with drum (104) and to drivably connect movable parts (200) located in the area from said drum rib to the next drum rib to said motor via a movement transfer system as exemplified in Figure 13.
- Industrial type drums generally comprise three or four drum lifter ribs (107).
- drum lifter ribs (107) are located in the area where discharge holes on cylindrical perforated drum sheet (106) are located, and the water chamber (500) sides of drum lifter ribs (107) are generally open, in drums (104) where drum holes are not located in a peripheral narrow belt the area where the motor is mounted will be wet.
- an isolated areas in movement system (142) must be used.
- Figures 39 show a case where the water chamber (500) sides of drum lifter ribs (107) are sealed to be waterproof. When the opening left for mounting the motor is covered by a leak-proof cover, the area will be completely isolated.
- a motor driving multiple movable parts (413) placed on a rib may be connected to the adjacent geared pulleys for transferring movement to rollers (415) on two sides as shown in Figure 13. If connected in this manner, the belt will zig zag between the pulleys which will increase the number of gears in contact with the pulley and the pressure exerted on the pulley by the belt.
- the non-geared side of the belt moves along an idler pulley (417) that is movable on the shaft via idler pulley bearings (416) to prevent said belt from affecting the rotation of the following pulley while rotating a pulley.
- the motor rotates half of the rollers on both sides while the other half are rotated by a motor placed in the other drum rib space. Therefore, rotating adjacent rollers in opposite directions, the advantages of which were explained above, will be possible.
- roller rear bearing shafts (230) When rollers in drum (104) are placed close together, or in an interlocking manner as explained above, roller rear bearing shafts (230) will be too close together to be able to connect a motor directly or via a pulley/belt system.
- the present invention provides a different solution to drive such types of rollers.
- all rollers are connected together by a gear connecting rollers to each other (418).
- a gear connecting rollers to each other (418) is connected to the motor in said drum lifter ribs (107) via a gear connected to motor, said motor driving multiple movable parts (413) will be able to drive all the rollers.
- gears mounted on the rollers may be made of metal or plastic. If drum rear circular base/shaft side (110) is located outside water chamber (500), maintenance can be easily provided to the gears. Also, it will be possible to provide lubrication to the gears using a variety of methods, including spraying, by completely closing off the area where said gears are located.
- lubrication systems are applicable on drum (104).
- moving systems especially systems moving at high speeds may require lubrication.
- a lubrication station mounted on drum (104) may provide automatic and controlled lubrication to required locations via distribution lines.
- balance system One of the most important aspects of the invention is the balance system.
- One of the main issues of washing machines (50) performing high speed spin extraction cycles is that when drum (104) enters the high spin extraction, the material that is unbalanced distributed therein causes oscillations at low spin speeds and vibrations at high spin speeds.
- drum (104) enters the high spin extraction
- vibrations at low spin speeds For as long as machines having extraction cycles have been around, possible solutions to this problem have been investigated, however, so far no system that can fully solve this problem have been developed.
- "dynamic balance system” technique has been known and used for many years in “dynamic balance machines” wherein measurements are taken for allowing addition of balance weights to eliminate balance problems. The vibration problems caused by the unbalanced weight distribution are eliminated by means of the balance weights added to the parts.
- the present invention has made it possible to directly mount a dynamic balance system onto the drum by providing electrical connections and water-free zones (100) on the drum whereby balance weight movement motors (306), moving system and parts together with control systems can be mounted onto said drum.
- a balance system inside a water tank/outer drum (101) by water proof it against water. For example, if drum front circular base/opening side (109) is still in water tank/outer drum (101) while drum rear circular base/shaft side (110) has been taken out of water tank/outer drum (101), water will continue to flow out of drum door opening gap around drum opening between drum and front panel (114).
- a balance system (300) mounted to drum front circular base/opening side (109) can be sealed off.
- Balance weight movement motors (306) to be used with balance system (300) may be produced to be waterproof or may be placed in an isolated area in movement system (142).
- Another difficulty in applying balance systems to washing machines having a conventional water tank/outer drum (101) and drum (104) system was the mechanical moving interaction between said water tank/outer drum (101) and drum (104).
- the different construction stretches between the rotating drum (104) and the stationary water tank/outer drum (101) made it difficult to accurately measure the unbalance load to be compensated, which is necessary for the "dynamic balance system" to determine the unbalanced load distribution.
- the inner and outer drum must be combined in one body.
- the rotating drum (104) is mounted with the drum shaft (103) located from one side of drum rear circular base/shaft side (110), to water tank/outer drum (101) via drum bearing system (102) located on the outer drum frame. Fixing the drum (104) by just one side causes the drum to stretch in the water tank/outer drum (101) under the influence of unbalanced load forces. In order to determine the unbalanced load distribution inside the rotating drum, measurements are made from the non rotating outer drum. Uncontrolled stretching of the drum affects the accuracy of the measurement from the outer drum. Separating drum (104) from water tank/outer drum (101) eliminates this problem and makes it possible to measure unbalance conditions directly from inner drum and apply the dynamic balance technique directly to the system.
- the system proposed by the invention provides water-free zones (100) where balance system (300) can be mounted, which have made it much simpler to use said system. Thanks to mounting motor to move parts on the drum (130) driven moving parts outside drum (251) together with electricity connection, electric and electronic control systems (900) which can be placed in rear and frontal sections of the drum, made it possible to apply dynamic balancing techniques on the washer extractor machine.
- the drum proposed by the invention can be defined as a mechanism, device or system that is capable of operating independent from the machine.
- the balancing system applied to the drum is essentially a controlled movement of at least one counterweight to compensate for imbalance.
- the position and magnitude of the imbalance are determined by the sensors.
- the master assembles a lead piece which creates the same magnitude of force against the detected imbalance.
- the tire does not cause vibration during high spin speed on the vehicle at high speeds.
- balance weights (301) having different structures and properties placed on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) in different ways in a controlled manner to restore the balance and maintain the balance by changing the positions of balance weights (301) during the spin cycle.
- the machine comprising the balance system proposed by the invention will save the energy normally spent on the oscillations and vibrations of drum (104), water tank/outer drum (101) and weight connected thereto.
- balance system proposed by the invention only on drum front circular base/opening side (109) or drum rear circular base/shaft side (110)
- two independently operating balance systems 300) on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) respectively in order provide total balance to the drum and eliminate imbalance during the spin cycle.
- balancing drum (104) on one side only will partially fix the imbalance issues, it may not be sufficient enough to completely discard sphng/suspension/shock absorber/weight systems used in conventional washing machines.
- balance weights (301) normally placed on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) or on the front and rear of cylindrical perforated drum sheet (106) to balance each other out will be moved by balance weight movement motor (306) in order to balance the imbalance in drum (104). Therefore, at last one balance weight (301) each must be present on either side of drum (104).
- the mechanical balance system (300) described by the present invention comprises essentially of a balance control system (300-C) and at last one balance weight system (301-W) placed on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110).
- Balance system (300) may comprise one or two balance weights (301) on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110). In cases where there are balance systems (300) on both drum front circular base/opening side (109) and drum rear circular base/shaft side (110), it will be understood that four balance weights (301) are present.
- Each balance system (300) comprises at least one balance weight (301), balance weight handling and rotation structure (308) whereby said balance weight (301) is carried and rotated, a balance weight movement motor (306) to provide rotation and a movement transfer system for transferring this rotation motion.
- Each balance system (300) is capable to rotate around the rotation axis at least one balance weight (301) to a position to provide balance of the drum.
- Said balance weight movement motor (306) may be an electrical, pneumatic or other type of motor.
- Balance systems (300) comprising moving balance weights (301) may be mounted on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) as well as any two positions on the drum shaft (103) system.
- one balance system (300) may be placed in front of or behind drum pulley (116) mounted on drum shaft (103) before drum shaft bearing (102) and another balance weight (301) may be placed on any position on drum shaft (103) or drum (104) on the opposite side of drum shaft bearings.
- the two balance weights (301) on each side of the drum (104) are mounted on balance weight handling and rotation structure (308) so that the two balance weights are positioned in the home position to compensate each other mutually. Except from the balancing process, their masses are good to create equal centrifugal force when they are mutually positioned against each other. Therefore, there is no imbalance effect created by these weights in all other washing processes.
- the two balance weights (301) have their own movement systems with a balance weight handling and rotation structure (308) driven by separate balance weight movement motor (306) so that they can move independently around their own path.
- Said balance system may be positioned on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110) or on the front and/or on the rear of cylindrical perforated drum sheet (106) so that the axis of rotation of drum (104) is also the axis of rotation of balance weights (301).
- Frontal balance system (300-f) at drum front circular base/opening side (109) is mounted around drum cylinder at front side as shown Figure 32 or at drum front circular base, around drum entrance/inlet opening (108) as shown Figure 63.
- Rear balance system (300-r) at drum rear circular base/shaft side (110) is mounted around drum cylinder at rear side as shown Figure 1, 69 or at drum rear circular base, around drum shaft (103) as shown Figure 61.
- Figure 70 shows an exploded view of balancing systems mounted around drum cylinder and Figure 8 shows an exploded view of balancing systems mounted on drum circular base surfaces.
- Figures 64-68 provide detailed images of the balance system from different angles.
- Each balance weight system comprises a balance weight handling and rotation structure (308) to rotate each balance weight (301) 360° around drum (104) rotation axis independent of the others.
- Balance weight handling and rotation structure (308) comprises weight bearings for balance weight bearing system (302-S) and a weight guide path (307) in the form of a rail or channel for guiding the movement of said weights on said bearings.
- Balance weights (301) are positioned on balance weight bearing system (302-S) to be rotatable 360°.
- a sliding or rotating balance weight handling and rotation structure (308), such as a sled, wheel or pulley will ensure that a balance weight (301) moving along a suitable path will move to rotate on drum front circular base/opening side (109) and drum rear circular base/shaft side (110).
- the system in order to keep the weight within said weight guide path (307), the system must comprise a weight-guide path lock system (309) for locking said weight into weight guide path (307).
- said weights must be connected to gear connected to motor (310) driven by a gear chain/belt (311) transmitting movement from balance weight movement motor (306).
- Weight position detection sensors (312-p) of the system will monitor the positions of the weights and transmit this information to the balance control system (300-C).
- Weight position detection sensor (312-p) may be an "n-coder" connected to balance weight movement motor (306) or any gear connected with gear chain/belt (311) or any other sensor capable of monitoring the positions of balance weights for 2-weights balance system (302).
- drum (104) and systems rotating along with said drum (104) will be connected to a drum bearing chassis (313) that is connected to fixed chassis (111) via a drum shaft (103) and drum shaft bearing (102) system.
- Balance sensor (312-b) may be positioned between said drum bearing chassis (313) and fixed chassis (111), so that the control system can determine the position and magnitude of the imbalance in drum (104).
- drum chassis (529) is connected to fixed chassis (111) in a moving or fixed manner depending on balance sensors (312-b). If drum chassis (529) is connected to fixed chassis (111) in a moving manner balance sensors (312-b) are sensors measuring the movement and if drum chassis (529) is connected to fixed chassis (111) in a fixed manner balance sensors (312-b) are sensors measuring the force caused by the load imbalance in drum.
- said connection may be realized by flexible wedges, steel springs or airbags and said balance sensors may be proximity sensors or the like.
- balance sensors (312-b) may be sensors measuring the force created by unbalance in drum or the stress imparted on fixed chassis (111) by said load.
- balance weight movement motors (306) controlling balance weights for 2-weights balance system (302) will move said balance weights (301) together, keeping the 180° angle between them constant to preserve their balance position, to the position where the direction of the centrifugal force created by balance weights (301) is perpendicular to the imbalance force of the unbalanced load. Therefore, the imbalance force will fall in the middle balance weights (301).
- balance weight movement motors (306) move balance weights (301) at equal angles to create a balancing force against the unbalance force created by the unbalanced load, as shown in Figure 87B.
- Balance weights for 2-weights balance system (302) will be moved towards each other until they create a force equal to the unbalance force (F x ) against the unbalanced load and until the vector average of the force created by said balance weights is equal to the magnitude of the imbalance force.
- FIGS. 65-73 show an exploded view of a balance system applied to an industrial washing machine.
- Said balance system comprises a separate balance weight movement motor (306) for each balance weight for 2-weights balance system (302) positioned on drum front circular base/opening side (109) and drum rear circular base/shaft side (110), means for transferring movement from said balance weight movement motor (306) such as gear chain/belt (311) driven by a gear, a gear chain/belt guide channel (314) to ensure that said chain or belt follow the circular path passing through the connection point in a taut manner, a gear chain/belt-weight connection (315) for connecting the weight to gear chain/belt (311), a weight-guide path lock system (309) for locking the weight in the bearing, a push mechanism comprising a weight-lock pin spring (318) placed in a weight-lock pin housing (317) embedded in the balance weight to push a weight-guide path lock wheel (316) whereby the balance weight travels on the lock path into the lock bearing and a weight- lock pin (319), a weight bearing for 2-weights balance system (302) such as a circular channel or rail acting as a
- balance weights (301) of 2-weights balance system (302) may be placed parallel to drum front circular base/opening side (109) and drum rear circular base/shaft side (110), they may also be placed around the drum on cylindrical perforated drum sheet (106), where balance weights (301) have a cylindrical shape suited to the shape of said cylindrical perforated drum sheet (106) as shown Figures 73. Placing the balance system around drum entrance/inlet opening (108) on drum front circular base/opening side (109) causes said drum inlet opening to be deep. If increasing the diameter of drum (104) does not cause a problem in terms of machine size or design, it would be beneficial especially to place the front balance system (300-f) on the cylindrical perforated drum sheet (106) in front of the drum.
- balance weights (301) are farther away from their axis of rotation, because balance weights, which have the same mass of the balance weight, create more centrifugal forces than the same mass of the balance weight which are close to the rotation axis.
- both balance weights (301) go into the home position to balance each other.
- the movements are monitored by an encoder or similar position tracking sensor so that during the balancing operation, the position of the weights will be known by the balance control system (300-C).
- FIGs 74 and 75 show an example of a 2-weights balance system applied to the drum of a household washing machine.
- the weight providing portion of plastic molded balance part (630) may consist of plastic or may also include an additional single metal weight (631).
- the weights When the weights are made of a metal having high density, they will take up less space and can be used by embedding them into plastic molded parts.
- single metal weights (631) on plastic molded balance part are embedded into plastic, the balance part will appear as a plastic molded balance part (630).
- the weight part may be a single plastic molded balance part (630) on plastic molded balance part or alternatively, two weight parts (632) on plastic molded balance part (630).
- Plastic molded balance part (630) comprises a balance part bearing wheel (634) system for the balance part to rotate along balance part bearing (633).
- balance part movement motors (635) to rotate balance parts via rotating system on the bearing are embedded on balance motor housings on drum sheet (636) on drum front circular base/opening side (109) and drum rear circular base/shaft side (110).
- balance motor movement gears (637) are mounted to be engaged with balance part movement gear (638), they can move the balance part to the desired position.
- the working principle is the same as for industrial machines.
- balance machine There are many systems known in the art for determining the position and magnitude of a force created by an unbalanced load at drum front circular base/opening side (109) and drum rear circular base/shaft side (110) during the spin cycle. There are hundreds of types of balance machines referred to as “dynamic balance machine” wherein these systems are implemented. It is possible to use electronic sensors, hardware and software used in these known systems for checking the balance and determining the position of the counterweights with the embodiments of the present invention. Some of the required parts will be mounted outside and some will be mounted inside of drum (104). The parts of balance control system located inside and outside drum (104) operate together and communicate using electronic connected or wireless communication systems.
- drum front circular base/opening side (109) and drum rear circular base/shaft side (110) where the balance system is located is outside of water tank/outer drum (101)
- the addition and removal of balance weights (301) can be done easily and quickly depending on the loading and operating conditions of the machine.
- the amount of the unbalanced load generated in drum (104) during the extraction cycle may vary a lot depending on the type and amount of material being treated therein. If the drum (104) is fully loaded, the chances of the material being distributed homogeneously in the drum (104) are higher than the drum loaded with fewer amounts.
- the material in the drum comprises large and heavy pieces containing rubber such as carpets, rugs and dust mats that are not easily distributed, there is a larger chance of unbalanced load distribution compared to a laundry washing machine operating at full capacity.
- the washing machine will be used, and as said purpose and conditions can change over time, if it is not possible to make adjustment when needed, it is most advantageous to design the washing machine considering the worst possible conditions. If the balance weights (301) mounted to the balance system (300) during manufacturing are selected according to the worst loading condition and load distribution, the machine will use much more energy to rotate these extra weights with the drum.
- the washing machine comprising said balance system does not need to contain parts such as springs, suspensions, vibration wedges, air bags, etc.
- said washing machines may be in the form of machines known as fixed chassis machines having limited speed spin cycles.
- a fixed chassis machine capable of vibrationless spin cycles at high speeds will provide many advantages in terms of application areas.
- a balance system comprising two balance liquid container (331) placed opposite each other according to the present invention is explained below, via
- Liquid container weight balance system (330) is a balance system, similar to balance system (300) described above utilizing balance weights (301), where two balance liquid container (331) placed opposite each other are used as balance weights.
- Liquid container weight balance system (330) having two balance liquid containers (331) are mounted on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110).
- Two balance liquid containers (331) are positioned opposite each other and are connected by two balance liquid transfer connection lines (334-L), where one balance liquid transfer connection line (334-L) has a balance liquid pump (333).
- balance liquid transfer connection lines (334-L) between two balance liquid containers (331) is a balance liquid transfer connection line (334-L) providing balance liquid (337) transfer while the other is an air transfer connection line (334-G) providing the air replacing the displaced balance liquid (337).
- balance liquid transfer connection line (334-L) a balance liquid transfer connection line (331) along balance liquid transfer connection line (334-L) until the amount of balance liquid (337) is equal in both balance liquid containers (331).
- Each volume of a balance liquid container (331) is large enough to be able to contain all balance liquid (337) in the system.
- Balance liquid (337) is distributes equally between balance liquid containers (331) at the beginning of the extraction cycle, other than when balance is taken, therefore, they do not cause imbalance in drum (104) because they have equal weights.
- the direction of the unbalanced load vectors in drum (104) is determined by balance control system (344) in drum front circular base/opening side (109) and drum rear circular base/shaft side (110).
- Balance control system (344) rotates balance liquid container moving chassis
- balance liquid container movement transfer system (336) is mounted onto drum (104) via a bearing so that their axes of rotation overlap.
- Balance liquid container movement transfer system (336) can rotate more than 180° on the bearing and ensures one balance liquid container (331) is positioned to balance the unbalanced load in drum (104).
- Balance liquid container movement transfer system (336) is driven by balance liquid container movement motor (335) and may comprise gear to gear, chain to pulley or chain to balance liquid container movement transfer system (336).
- balance liquid container movement transfer system (336) When balance liquid container movement transfer system (336) is rotated by balance liquid container movement motor (335) the centrifugal force vector (Fi) of one of balance liquid containers (331) overlap with the imbalance force vector (F x ) and the centrifugal force vector (F 2 ) of the other is positioned 180° away from said imbalance force vector (F x ). Because equal amounts of balance liquid (337) is present in each balance liquid container (331), there is initially no change in the balance conditions caused by the imbalance force of the unbalanced load in drum (104). At this stage, balance liquid pump (333) pump the necessary amount of balance liquid (337) to balance the imbalance force of the unbalanced load in drum (104) from the first balance liquid container (331) where imbalance force vector is to the second balance liquid container (331).
- balance liquid transfer connection lines (334-L) need to be blocked so that balance liquid (337) cannot flow back. If stopping the operation of balance liquid pump (333) is not enough to block balance liquid transfer connection lines (334-L), a balance liquid valve (338) needs to be installed on said block balance liquid transfer connection line (334-L).
- balance liquid pump (333) is capable of pumping balance liquid (337) from one balance liquid container (331) to the other in two directions, then rotating balance liquid containers (331) 180° around the axis of rotation of drum (104) will be sufficient for the imbalance force of the unbalanced load in drum (104) and balance liquid container axis (339) to overlap.
- the direction and magnitude of the imbalance force of the unbalanced load in drum (104) will change during the spin cycle due to the materials being displaced within drum (104) and water discharge from the materials. It is possible to change the position of balance liquid containers (331) and, if necessary, transfer balance liquid (337) between balance liquid containers (331), depending on the position of the changing imbalance force of the unbalanced load in drum (104).
- the magnitude of the imbalance force of the unbalanced load in drum (104) will decrease during the spin cycle as water is discharged from the materials.
- balance liquid (337) transferred to the other balance liquid container (331) will need to be transferred back. This can be achieved using balance liquid pump (333) or opening balance liquid valve (338) so that balance liquid (337) can flow back.
- balance liquid valve (338) can be opened to balance the amount of balance liquid (337) in the two balance liquid containers (331). If the volume of balance liquid containers (331) is large enough, it is possible to supply additional balance liquid (337) to said balance liquid containers (331) during the balancing process.
- a balance system comprising one rotatable balance liquid container (340) according to the present invention is explained below via Figures 77.
- This system utilizes an equilibrium weight (341) positioned opposite rotatable balance liquid container (340) to balance it.
- the necessary amount of balance liquid (337) can be transferred from an equilibrium liquid container (342) to rotatable balance liquid container (340).
- the liquid transferred to rotatable balance liquid container (340) is returned to equilibrium liquid container (342) at the end of the spin cycle.
- balance liquid (337) may be supplied by balance liquid fittings (343) connected to drum (104). Water fed to drum (104) and used as balance liquid (337) in rotatable balance liquid container (340) can be removed via the discharge line during and/or at the end of the extraction cycle.
- An exemplary system is a system comprising bodies of equal weight that can balance each other when positioned equal angles apart on weight guide bearing for 3-weights balance system (304) as close to weight starting position for 2-weights balance system (322) as possible.
- Threaded balance weight movement screw connected to balance weight movement motors (306) positioned close to cylindrical perforated drum sheet (106) as shown in Figure 85 is passed through threaded holes on balance weights to provide bearing on the drum sheet for said balance weights.
- Figures only show an embodiment comprising worm gears as bearings for the balance weights on drum (104).
- Other embodiments may comprise any bearing system known in the art wherein balance weights can move thereon. When worm gear is rotated by the motor, the balance weight moves away from the rotation axis and towards the edge of the cylinder.
- the generated centrifugal force will increase.
- the system comprises at least three balance weights, two weights can be moved together depending on the position of desired counterweight force vector if needed to create a force vector of desired direction and magnitude. Therefore, counterweight force of desired direction and magnitude may be created using weights that are displaced to different degrees towards the outside of drum (104).
- the highest imbalance load possible to be generated in drum (104) for the spin cycle must be determined beforehand. It is possible to increase the proportion of the counterweight force to the total weight by dividing the weights into smaller weights and increasing the number of weights while keeping the total weight constant. However, it should be taken into account that each weight requires its own motor gear system.
- the balance systems must comprise at least two weights. Said two weights are mounted opposite each other close to the rotation axis of the drum on the frontal and/or rear section of the drum on a bearing system capable of rotating 360° as in the first example. Different to the two-weight balance system described above, in this embodiment while one weight is fixed in position near the center, the other weight can move towards cylindrical perforated drum sheet (106) as in the three-weight balance system. In the balancing step, the system rotates until the moving weight is positioned against the imbalanced load. The moving weight then moves towards cylindrical perforated drum sheet (106) until a counterweight equal to the imbalanced load is generated.
- the mechanical and electrical systems of the balance systems are placed in water-free zones (100) of drum (104), said balance system is also applicable to currently available drums (104) rotating in water tank/outer drum (101).
- the motors used in the system are chosen from among motors capable of operating in water or the whole of the balance system including the motors are isolated against water. When the balance system is isolated in this manner, it can be used with drums (104) rotating in water tank/outer drum (101).
- the "mechanical and dynamic balancing method" described in detail for washing machines with a drum can be applied to any type of weight rotating at high speed and having changing imbalance conditions. It is to be noted that systems rotating horizontally or at an angle with the horizontal axis also include centrifuge machines rotating at high speeds at a 90° angle with the horizontal axis. While these vertically rotating systems do not have the resonance issues associated with horizontally rotating systems, it is known that said vertical systems used for spin cycles also have significant balance issues. In vertically rotating centrifugal spinning machines, the water exiting drum (104) is discharged from the machine directly via a discharge channel; therefore precautions for protecting the balance system against water can be easily taken.
- pneumatic or hydraulic hardware are necessary for cases where means such as covers, pistons and valves are used on the drum. Therefore, hoses and connections and related fluid based control, directing, opening/closing systems need to be present on the drum so that said systems can operate. While it is possible to use different systems such as pressurized air, steam, hydraulic oil or water systems; pressurized air systems are most preferable as they are sufficient, economic and easy to use.
- the pressurized air required by the pneumatic systems may be provided via drum shaft (103). However if the amount of air required is small enough to be generated on the drum, an air source such as a small air compressor/pump (907) would be sufficient.
- drum shaft (103). Electricity may be transferred to the drum by a continuous cable system having a slip ring for electric, electronic cables (902, 908).
- said slip ring comprises a slip ring copper ring (909) on drum shaft (103) that is rotatable along with said drum shaft (103), a cable connected to said ring, and a mechanism on the fixed side comprising a slip ring spring mechanism (910) providing a strong connection to said copper slip ring and having a slip ring conductive coal (911) connected to an energy source from the other end.
- a slip ring spring mechanism (910) providing a strong connection to said copper slip ring and having a slip ring conductive coal (911) connected to an energy source from the other end.
- Transfer of fluids such as air and steam to drum (104) may be done by a rotatable fluid connection element (912) operating with similar basic principles.
- the suitable connection point for said rotatable element will be the rotation axis of drum shaft (103) at the outside end of said drum shaft (103).
- the rotatable element may be used to convey one or more fluids. Therefore, it is possible to transfer different fluids to the drum at the same location.
- drum shaft (103) After energy transfer via electricity transfer slip ring (908) and fluid transfer via rotatable fluid connection element (912) to drum shaft (103) are realized, they are transferred to drum surface via holes inside the shaft or by connecting to the surface of the shaft.
- a suitable solution would be to embed them in hose/cable recess (915) or positioning them on holes made on the surface, under parts such as pulleys, bearings and ball bearings between the location where hoses/pipes embedded in drum shaft (903) are embedded in hose/cable recess (915) on drum shaft (103) and the drum.
- pressurized water or other fluids may be needed on the drum.
- Pressurized fluid connection may be realized by a rotatable fluid connection element (912) allowing transfer of pressurized water on the shaft, same as the pressurized air connection.
- the main issue with transferring fluids such as air and water via rotatable elements is sealing. The seals must be constantly maintained and replaced over time.
- having electrical energy on drum (104) allows for generation of pressurized water on drum (104), just like pressurized air. Having reasonable pressurized water requirements makes it possible to fulfill said requirements by a pump and pressure tank on the drum.
- the pressurized fluid connection to the drum as proposed by the present invention also allows the heating requirement common to many treatments in drum (104) to be fulfilled efficiently and directly inside the drum.
- Pressurized steam is conveyed to drum (104) via fluid transfer line (912, 903) and enters inside through suitable places on the drum sheet and provides heat in a controlled manner to drum (104), materials being treated in said drum and the present fluids. Steam may be conveyed into the drum from one position or via multiple pulverizers distributed inside the drum. If the directly or indirectly heated drum (104) is desired to be isolated, it will be possible to isolate drum outer surface (104-s) using a suitable isolation system, will provide energy savings as well as decrease the time required for heating and increase efficiency.
- An embodiment of the invention as shown in Figure 116 comprises drum heating elements (913) mounted inside drum (104) can heat both the water and the textiles inside drum (104) by direct contact at the desired speed and, as they are monitored by sensors, allow water and textiles to remain at the desired temperature.
- drum heating elements (913) mounted inside drum (104) are applied to cover large surfaces, they can be operated at low temperature differences so that they do not harm the material inside the drum through contact.
- heating can be done directly via drum heating steam injection system (914) or indirectly by steam passing through a steam jacket placed in a no-hole region of the drum.
- drum heating elements (913) placed in drum (104).
- drum heating elements (913) require electrical systems and fittings to supply the required energy, which increases with drum capacity and can therefore only used with machines having low capacity. It was stated before that machines with high capacity require use of steam for heating.
- Gas burner (921) system is also applicable for all drum types that has peripheral perforated narrow zone (510).
- a combustion chamber (923) needs to be created; starting from the gas burner (921) and encompassing the areas where heat transfer leaves/fins (922) placed on the surface of drum (104) are located.
- a tank that is similar to drum discharge chamber (517) used for water leaving drum (104) from drum perforations in peripheral zone (509) is placed surrounding the area where areas where heat transfer leaves/fins (922) are placed on the surface of drum (104) as a combustion chamber.
- the hot air mixture passes between heat transfer leaves/fins (922) placed on the surface of drum (104) and rises to the top of drum (104) through said combustion chamber.
- Said combustion chamber comprises a fume hood and flue connection (924) for collecting flue gases. It is clear that there needs to be an opening between the combustion chamber and drum (104).
- a combustion chamber flue fan (925) is positioned in the combustion chamber at the flue connection (924) to create negative pressure so that flue gases do not escape through this opening.
- Heating the water and materials within drum (104) directly is a preferable method due to its practicality and low cost as well as its speed.
- its application requires that a large section of drum (104) be non-perforated and that drum perforations in peripheral zone (509) are located in a peripheral perforated narrow zone (510).
- this heating system may be applied to water chamber (500), half water chamber (505) or water tank/outer drum (101) instead of directly to drum (104).
- the water leaving drum (104) is collected by water chamber (500) or water tank/outer drum (101) and discharged.
- water chamber (500), water storage chamber (504), water chamber discharge line (511-d), half water chamber (505) or water tank/outer drum (101) can be heated by one of the heating methods described above.
- the present invention makes possible many applications in drum (104) that were not possible until now.
- Mounting monitoring and control systems that have so far not been used directly on the drum interior surface in order to closely monitor and control conventional applications and allow for new and more sensitive applications and makes close monitoring and control of the conditions of the ongoing treatment in drum (104) and the effects of said treatment on the materials therein possible.
- the state of the treated materials can be monitored by sensors inside the drum instead of taking samples by regularly stopping the operation of the machine.
- FIG. 115 shows an embodiment comprising a lighting system comprising lighting units inside drum (918) dispersed on drum inner surface (104-n) surface, wherein said lighting system can be programmed so that only the lighting units having the desired angle based on the position of drum is turned on during rotation of drum, thereby providing optimum lighting for visual monitoring of the drum interior.
- Necessary fluids, such as chemicals are transferred to drums (104) rotating in fully closed water tank/outer drum (101) via said water tank/outer drum (101).
- liquid or gaseous chemicals are directly injected into the drum via drum door (118).
- As water does not enter drum (104) via water tank/outer drum (101) according to the present invention it is generally not possible to convey fluids via drum door (118) and circulation system. If homogeneous and fast distribution of the chemical within drum (104) and homogeneous contact of the chemical with the material is desired, it would be advantageous to inject the chemical from multiple locations.
- the proposed invention makes it possible to provide chemical inlet from every surface of drum (104).
- the desired chemicals are conveyed to drum (104) via drum shaft (103) using rotatable fluid connection element (912) and hose/pipe embedded in drum shaft (903) and transferred to a distribution system in order to reach pulverizing nozzle inside drum (919) placed along drum outer surface (104-s) and are injected into the drum as shown in Figure 105.
- Fluid may be injected into drum (104) by pulverizing nozzles inside drum (919) adjusted to the pressure required by the treatment.
- the chemical to be injected may be concentrated or dissolved in water or another suitable solvent.
- Flaving the water inside drum (104) be drawn out, pressurized and injected back onto the materials by pulverizing nozzle inside drum (919) will aid in increasing the physical effect imparted during the treatment.
- a high pressure pump mounted on drum (104) will direct the water exiting the drum that is collected in drum discharge chamber (517) via the pressurized water line at its outlet to pulverizing nozzles inside drum (919) whereby it is injected back into the drum.
- This embodiment is advantageous for industrial textile washing machines (52) and industrial parts dyeing machines (53).
- hoses/pipes embedded in drum shaft (903) can be used for different functions at different times as in the embodiment shown in Figure 104A.
- Hoses/pipes embedded in drum shaft (903) may be used for transferring steam to the drum (104) to provide heating at the beginning of the treatment may be used for transferring chemicals later on in the process.
- multiple hoses/pipes embedded in drum shaft (903) must be used.
- a gradually rotatable fluid connection element (912) is placed on drum shaft (103).
- a wider hose/cable recess (915) in drum shaft is needed in order to accommodate the multiple hoses/pipes embedded in drum shaft (903) having different diameters that need to be placed on drum shaft (103).
- Fluids are transferred to the drum via each rotatable fluid connection element (912) placed on the rotation axis of drum shaft (103), through hoses/pipes embedded in drum shaft (903) placed in hose/cable recess (915) in drum shaft and reach drum outer surface (104-s) surface by passing under drum pulley (116), drum shaft bearing (102), drum shaft ball bearing (102-b), electricity transfer slip ring (908) on drum shaft (103).
- the fluids are transferred into drum (104) in a controlled manner via distribution lines and injectors or pulverizing nozzles inside drum.
- drum is directly connected to fixed chassis (111).
- the mechanical structures required by a system wherein the drum is connected to a fixed chassis by bearings is vastly different than that required by a drum (104)-water tank/outer drum (101) connection system.
- Conventional machines with a fixed chassis have a simpler structure compared to machines having high speed spin cycles; however, they must have a strong drum (104)-water tank/outer drum (101) connection due to the stretching during low speed spin cycles. In freestanding machines wherein drum (104) and water tank/outer drum (101) have a flexible structure, this connection must be even stronger.
- Eccentric rollers oscillating in left-right direction will have a wide range of applications in washing machines for providing rubbing effect. This is why it is important to place molded roller housing water discharge holes (235) described above at the bottommost sections of the molded housing where the materials being treated cannot reach them.
- Drum shaft 402 Movement transfer part such as belt
- Drum front circular base /opening side 418 Gear connecting to rollers and each other
- Machine front panel 508 Flow path on water chamber
- Cylindrical or conical drum sheet having holes in Pneumatic system to move parts on the drum 512
- Roller frontal bearing shaft 537 Hinged drum door rotatable buffer gasket
- Roller frontal bearing shaft housing 538 Hinged drum door gasket
- Roller frontal bearing lock system 539 Hinged drum door rotatable buffer
- Vibrating part platform 605 Household drum holes/perforations
- Roller shaft lock 607 Household lifter ribs
- Roller rear bearing shaft 612 Household circulation pump
- Roller shaft seal ring 618 Household frame frontal sheet
- Molded roller housing water discharge hole 621 Household drum water channel / Poly-Canals Fixed part housing in molded roller housing 622 Household drum water channel grate
- Molded roller housing lock system 623 Household grate bars / Poly-Ribs
- Shaped sheet roller housing 625 Household water collection/storage tank
- Roller side bumper prevent material entrance 631
- 2-weights balance system 900 Electric, electronic and control systems-w Balance weights for 2-weights balance system 901 Electric system panel on drum
- Weight guide path 909 Slip ring copper ring
- Weight-guide path lock system 911 Slip ring conductive coal
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Abstract
The present invention relates a washing machine (50) for performing wet, dry, physical or chemical treatments on materials, comprising a front loading (51) or side loading (52) perforated drum (104) which is mounted respectively by means of a drum shaft (103) at the rear or by means of the drum shafts (103) at both sides horizontally or having an angle with the horizontal axis to a drum shaft bearing (102) system so as to rotate around the bearing axis. Said machine (50) comprises a drum (104) having at least one water-free dry zone (100) which cannot be accessed or contacted by the water draining from the drum (104) on at least one outer surface (104-S) of the drum (104) during all wet treatment application processes carried out by the washing machine (50) with water.
Description
WASHING MACHINE ENERGY AND MOTION SYSTEMS ON THE DRUM
Technical Field of the Present Invention
The present invention relates to a washing machine for applying wet, dry, physical or chemical treatments onto materials, comprising a shaft positioned horizontally or having an angle with the horizontal axis, a perforated drum turn around a bearing system, a water chamber outside the drum wherein the water coming out of the drum is collected, moving parts placed inside or outside the drum in order to aid the working of the machine and/or increase the performance of the machine and/or provide economy of resources used by the washing machine such as water, energy, chemicals and time, motors, mechanical, pneumatic, electrical and electronic systems placed inside or outside the drum that are connected to said moving parts for moving said moving parts in a controlled manner and auxiliary equipment required by said systems and wherein energy sources such as electricity, pressurized air and steam is provided on the drum and areas where the contact of devices, instruments and equipment used in said systems placed outside of the drum in fully or partially water-free zones. Said washing machine may comprise a front load drum having shaft and bearings in the rear or a drum having bearings on both sides that can be loaded from the cylindrical surface. In order to not cause confusion, a front loading drum having a bearing on one circular surface and a loading opening on the other circular surface is depicted in the description and the terms front and rear are used to describe these two circular faces of the drum. It should be understood that, in the case of a drum having two shafts and a loading opening on its cylindrical surface, the terms front and rear refer to the two circular surfaces of the drum where the shafts are located.
Background of the Present Invention
The machines described by this invention are generally referred to as "washing machines" because they are commonly used in households for washing laundry using water and chemicals such as detergent, bleach and fabric softener. However, they can be used for a variety of purposes and can have different capacities. Machines of this kind having a capacity between 4 and 16 kg are used in households and those having a capacity between 16 and 500 kg are used in industry. These appliances are most widely used in washing, dry cleaning, piece dyeing and stone washing. Even though they are mostly used for wet treatments, they can also be used for dry treatments in special applications such as stoning or sanding. Another appliance that is similar to washing machines from a technical standpoint and that is front loading and has a perforated drum is a drying machine. There are 3-4 carrying ribs on the perforated cylindrical surface of the drum to ensure that the material moves along with the rotation of the drum. The physical effect is realized by this movement caused by the rotation of the drum.
Stone Washing
One of the treatments requiring physical effect is the "stone washing" treatment that was first used on denim jeans in the 1970s and became more widespread in the 1980s to impart a used and worn appearance to textiles such as denim products. Currently, stone washing utilizing different mechanical or chemical abrasive materials is still widely used for textile products. The first and most commonly used technique in mechanical abrasive treatments is pumice stone. Pumice stone is a natural porous volcanic stone and is light in addition to being abrasive so it is advantageous in wearing treatments because it can float in washing water. However, it gets crumbled in the treatment water and loses its floating ability and causes
serious pollution in the environment starting with the waste water system. Some of the problems caused by the utilization of pumice stone are as follows: transportation from volcanic mines where they are produced to areas where they are used, storage, environmental issues such as transportation and dusting in the production areas, emptying the machine after stoning treatment to clear textile of pumice stone, clearing textile of pumice stone, reloading and rewashing of textile to clear away pumice dust and transport of pumice waste to safe waste areas where it won't cause environmental pollution. In order to eliminate the issues arising from the use of pumice, different materials were tested and different methods were evaluated for abrasive applications. All particular mechanical abrasive materials cause environmental pollution. Bleaching, corroding, abrasive and dye remover chemicals are used along with mechanical abrasive materials or by themselves during washing. A natural material, "enzyme," is also commonly used by itself or along with pumice stones during stone washing. As it is a natural material, it is accepted to be the least harmful chemical used in denim washing. Even though different materials, methods, techniques and chemicals have been used, very few changes have occurred in the past 30-40 years in terms of industrial type stone washing machines having perforated cylindrical drums. During the abrasive stoning treatment, mechanical abrasive materials wear down areas they come in contact with such as the drum and the ribs and the chemicals used cause chemical corrosion. In order for the drum to be resistant to chemical corrosion, drum inner surface (104-n) is covered by stainless steel; however, no method has been able to provide a satisfactory solution to this problem.
One of the first solutions that was tried in order to replace pumice stone was placing materials having abrasive properties on the surface of the drum. For this purpose, Wadek has proposed in their 1981 application FR2514793
(1983-04-22) the most suitable solution possible which was covering the interior of the drum used for stone washing with abrasive grindstones. Afterwards, similar systems were proposed by Juergen in 1987 (DE3710723, 1988-09-29), Wasinger in 1994 (US5471692, 1995-12-05) and Kingsford in 2001 (W003006728, 2003-01-23) wherein grindstones are placed in the drum. A different approach was proposed by Sights in 1996 (US5782111, 1998-07-21) wherein the object was to distress textiles using nails placed on the surface of the drum. However, none of the above mentioned suggestions were able to be utilized in practical applications.
The inventor of the present invention, Simsek, describes a machine providing stone washing ability by imparting abrasive characteristics to the surface of the drum instead of loading abrasive particles therein, in 2017 by an application titled "Abrasive Stone Washing Machine" (W02017151074A1, 2017-09-08). Simsek also describes abrasive grindstones attached onto drum inner surface (104-n) in the manner to form protrusions thereon in a European patent (EP2229475, 2017-07-12). While the desired results of these applications were achieved, it was not possible for them to be utilized in practical applications.
The reason for that is that the length of process time required to reach the desired results using these systems is 10 times longer than those using pumice stone. This means that in order to obtain the capacity of one conventional stone washing machine, ten machines with abrasive drums need to be used. One of the reasons for that is that while grindstone can be produced to have higher abrasive characteristics than pumice stone, there is a big difference between the two in terms of the surface area that comes in contact with the textiles. When a sufficient amount of pumice stone is added in with the textile to undergo abrasion treatment, the pumice stone gets
crumbled down to dust and spreads over the surface of the textile. Therefore, as the drum rotates and the textiles rub against each other, the textile is both abraded and works as an abrasive material. In contrast, when abrasive quality is imparted on the surface of the drum, the abrading effect is only realized when the textiles that come in contact with the abrasive drum surface. If a drum having a diameter of 1500 mm and a depth of 1000 mm is used for abrasion 50 pairs of pants, and each pair of pants is assumed to have a i m2 surface area; while the abrasive surface using pumice stone is 50 m2, the drum area is only 3 m2. In addition, because as the abrasion strength of the drum surface increases it becomes more adhesive which prevents the slipping of the textile against the surface and decreases the abrasion effect. For this reason, abrasion treatments using abrasive drums surface take much longer than those using pumice stone and cannot be utilized despite all the other advantages. As it is not possible to increase the surface area of the drum, the solution is to increase the friction between the abrasive surface and the textile in the time when they are in contact. To achieve this, a dynamic movement needs to be created inside the drum aside from the rotation of the drum itself that will increase friction. This can be provided by moving parts placed within the drum, providing vibration or rotation. For example, grindstones in the shape of rollers rotating at 200 up to 5000 rpm would be able to increase the speed of abrading imparted onto the textiles by hundreds of times. Use of rollers having abrasive surfaces for abrading applications is known in the state of the art. Rollers having abrasive surfaces are used in many different types of machines such as potato peelers. The problem to be solved is mounting the mechanical and electrical systems to drive the abrasive parts such as rollers placed inside the drum at the desired speeds on the outside of the drum. The present invention aims to solve this problem. The first step to solving this problem was described in the system
disclosed by Simsek in EP2229475. Application of the system disclosed in EP2229475 makes it possible to drain all the water that is exist in between inner and outer drum. So by application of the EP2229475 outside the inner drum and inside the outer drum is empty.
Previous applications have shown that the abrasiveness of the grindstones used as abrasive agent is very important. Abrasiveness increases with increasing size of the abrasive particles on the abrasive surface and decreasing friction. In this case, the wear on the textile increases, however, undesirable surface damage is also inflicted onto the textile. In contrast, when the particles are too small, abrasiveness decreases so the process will take a long time. Therefore both the abrasiveness of the grindstone and the friction are two very important parameters. It is important to provide the fastest friction movement with surface having highest abrasiveness that would not harm the textile. Even though the abrasiveness of a surface is constant, it may be adjusted by changing its surface contact speed.
The textile will move contacting with abrasive surface across the abrasive moving parts during the rotation of the drum and therefore the desired wearing result will be achieved hundreds of times faster. Parts that are moving in ways other than rotation, such as by vibration, will create a dynamic movement that will increase the physical effect obtained only by the rotation of the drum by tens and hundreds of times and decrease treatment time and as a result increase efficiency and decrease costs by providing savings in time, energy, manpower and resources and provide a more environmentally friendly process.
Moving parts placed within the drum will increase the physical effect provided by laundry washing appliances and therefore increase the quality of the treatment while reducing treatment time and chemical consumption. One of
these effects is rubbing the laundry against each other. In 2001, Fraser (US2002029594, 2002-02-07) has proposed a system providing the rubbing effect within the drum and this system was also adapted for commercial use. This system had some issues due to its mechanical structure and coupled with its costs, it had limited application. Its mechanical structure makes it even more difficult to adapt to industrial size appliances than to household appliances. Moving parts rotating, vibrating or oscillating eccentrically on the drum surface will increase the rubbing effect and the quality of washing. A machine having rotating brushes will be able to clean floor/dust mats and other hard material much faster. Similarly, rollers having plastic protrusions will create rubbing effect on the laundry by rotating slowly.
In order to have moving parts inside the drum, electrical or pneumatic motors for driving said moving parts should be mounted inside or outside the drum. Considering that the drum is placed in an outer water drum that also name as water tub, it is vital that the mechanical, electrical or pneumatic dynamic systems outside the drum be protected from water damage. It is possible to drive the moving systems inside the drum by motors that placed outside the drum. In order for the drive motors to work in water, they need to be water proof or water contact must be prevented. The best solution is to ensure there is no water in the areas where the motors are located, if possible. To achieve this, the area where water exits the drum should be limited and water should be prevented from entering the areas where the motors are located. It is possible to limit the flowrate of the water exiting the drum and the area where water exits the drum using the "Poly-Ribs/EP2229475" and "Eco-Drum/EP3252207" systems disclosed by Simsek. The Poly-Rib system (60) describes a protruding drum surface with reduced drum perforation to limit water discharge to circulation pump capacity. In conventional drums, a large portion of the drum holes are clogged by the laundry during draining
and spin extraction. Therefore, although there are multiple holes in the drum, the water discharge is irregular. The holes must be kept open at all times to ensure regular, almost constant flow and continuous water discharge from the drum even though the amount of holes is much less than that of conventional drums. Poly-Rib system (60) ensures that the water outlet from the drum is continuous and limited, while the Eco-Drum system (61) pump that limited water from the outer drum back to the inner drum with a proper flow rate capacity pump. Eco-Drum system (61) describes a pumping system to pump draining water from the tub to the drum that have higher pumping capacity than draining water from inner drum to outer drum. The common purpose of the two systems is to prevent the presence of water in the outer drum. So these two systems together make it possible to collect all the water in the machine in the drum and evacuate all the water out of the outer drum. The evacuation of the outer drum allowed a significant amount of water savings in the washing machines. If there is no water in the outer drum, it is appropriate to ask why still an outer drum is needed. Together with this question and the systems described in EP2229475, has enabled many applications to be opened in a new era in washing machines. With the invention in subject, if we do not need an outer drum to cover the inner drum completely, it will be possible to take out most of the outer surface of the drum from the outer drum. Therefore it is possible to prevent the drum outer surface (104-s) from being in water. Thanks for these two systems make it possible to have dry outer surface areas of the inner drum to apply water sensitive mechanical, electrical or pneumatic appliances.
Balance
Moving parts can be moved using a motor system (400) placed outside of the drum. Possibility to have motor systems (400) placed on the drum outer
surface (104-s) give many different mechanical applications on the washing machines. These moving parts can also eliminate the imbalance caused by the uneven distribution of the laundry within the drum during the spin cycle and the resulting vibration of the machine. As is known, front-loaded horizontal washing machines providing a spin cycle have a balance system that can be summed up by two principles. The most commonly used balance system utilizes spherical marbles that are free to move within a circular tube or channel placed at the same rotation axis of the drum, wherein these spherical shape weights can be displaced to provide a counterweight to the imbalance. A system comprising two weights rotating freely around the bearing at the rotation axis may be included in this system. Many application options are suggested for this system and some of these have been applied to the front, the rear or the front and the rear of the drum are together. The system is based on the principle of the marbles being displaced by the eccentric motion of the drum in a manner to provide a counterweight to a possible imbalance in the drum. While this system can ameliorate the imbalance, it cannot eliminate it completely. Another balancing system known and used in the art is the addition of external weights to provide a counterweight. Obtaining a counterweight by adding a weight was first proposed by Kahn in 1945 (US2534267, 1950-12-19) and then developed further in 1946 and 1948 (US2534268 and US2534269). This technique was further developed by Starr in 1958 (US3117926, 1964-01-14 and US3214946, 1965-11-02) and by Pellerin in 1992 (US5280660, 1994-01-25). In 1998, the inventor of the present invention, Simsek, developed a water-balance system that presents an improvement over systems providing balance by adding water to three carrier ribs in the drum by adding water to water compartments placed in the front and the rear of the drum (US6510715, 2003-01-28). The proposed system provides a much more sensitive balance
system because the imbalance is balanced from the front and the rear. The solution proposed by the present invention provides a system where the balance weights are displaced, which is completely different from the aforementioned two systems. The balance system (300) proposed by the invention operates under the principle of counterweights driven by motors to be displaced in a controlled manner to balance the loads in the front and rear of the drum to restore the balance. As the displacement of the weights happens very fast in this balancing system, the spinning process will be much faster compared to water-based balance systems and much more sensitive compared to ball balance systems, the balance can be maintained at high sensitivity throughout the spin cycle, the volume required to put aside for the balance system (300) will be much smaller and there will be no need for water consumption. Water free outer drum surface provide not only mechanical and motor system (400) application but also give possibilities apply sensors and control systems.
Hundreds of patent applications have been filed disclosing machines known as "Dynamic Balance Machines" for determining the imbalance on parts of different weights and sizes that rotate at high speeds in order to permanently provide balance for said parts and these methods have been used in many different technical industrial applications, especially with the development of electronic systems. It is possible to commercially obtain both hardware and software products for these machines. The present invention aims to provide washing machines with features of "dynamic balance machines".
Heating
One of the most important consequences of eliminating the need for an outer drum is undoubtedly the heating system for the washing water. As is known, washing machines are heated by different methods using electricity and
steam. The physical conditions of the substructure requirements cause more serious problems to increase suppling of the energy while using electricity. For this reason, high capacity industrial machines utilize steam instead of the electricity that widely used in small machines as domestic and commercial using.
Steam is utilized by adding it directly to the washing water or for heating the washing water in a heat exchanger indirectly. Especially in the textile industry and in high capacity industrial laundries where industrial machines having large capacities are used, the consumption of gas increases annually worldwide. Energy is required in laundries for heating the washing water of the washing machine and for heating the dryers and irons when necessary. In recent years, applications where dryers and irons utilizing gas in the form of LNG, LPG or NG are used have eliminated the necessity of using steam. Nowadays, steam is mostly necessary for washing machines. Providing a practical and economic solution to heat the washing water in washing machines will also provide a solution to spend less investment to construct the infrastructure system to provide steam. Therefore, using gas to heat washing machines is additionally important in terms of finance.
Summary of the Present Invention
The invention proposes machines that are generally known as perforated- drum washing machines. The machines are designed to provide mechanical and/or chemical treatments in wet, and in some situations dry, conditions to the materials loaded into the drum. Generally, the physical effect provided by a drum rotating in a water tank to materials inside the drum such as mixing, dropping, rotating and rubbing aid in increasing the effect of the chemicals added to the water. Said machines can be produced for many purposes, starting from "small scale" machines having a drum volume of 40-100 L. for
household use and can go all the way up to industrial scale machines having drum volumes up to 5000 L. While they are generally referred to as washing machines, they are used as dry cleaning machines in applications where chemical solutions are used instead of water, as washing machines in household and industrial applications and can also be used to wash materials other than laundry in textile applications, mechanical applications such as stone washing to abrade of textiles and chemical applications such as dyeing. In washing machines that are defined as laundry machines, the perforated drum is placed in a water tank that is fully sealed against water leakage from the door or around the drum shaft. While the drum is defined to be fully sealed, it is important to note that there are inlets to and outlets from the tank such as water and solid or liquid chemicals, steam inlets to the drum, a discharge system for waste water, an overflow system in case the water level in the drum rises excessively, excess steam and water vapor outlets.
The present invention comprises systems that are suitable for adapting to any type of washing machine. Therefore, the phrase "washing machine" indicates all machines providing wet, dry, chemical or mechanical treatments in a perforated drum. However, the description and figures depict a medium-scale industrial machine in order to exemplify the applications. Unless specified otherwise, the figures depict a drum having a diameter of approximately 1600 mm and a depth of approximately 600 mm. Based on these measurements, a cylindrical drum would have a volume of 1200 L. For example depicting small scale machines for household use, the drum has a diameter of approximately 575 mm and a depth of approximately 4500 mm, having a gross volume of 110 L. and net volume of 100 L. the difference between gross and net volumes is a feature of the invention and will be explained below.
The aim of the invention is to increase the physical effect provided by the rotation of the drum and decrease the physical effect caused by the uneven weight distribution during the spin cycle. For this purpose, moving parts that are moving inside and outside the drum have been added to the drum. Moving parts inside the drum increase the physical effect required by the treatment while the moving parts outside the drum prevent the oscillations and vibrations caused by the unbalanced weight distribution during the spin cycle. In this manner, the perforated drum of the washing machine is no longer just a cylindrically shaped canister, but gains the characteristics of a functional machine by itself.
The addition of dynamic parts inside and outside the drum also requires drive sources and drive transfer means (mechanical systems) to be added as well. It is clear that electrical and electronic systems are required to drive and control the mechanical systems. It can be deduced that, even though it is normally possible for said systems to apply on conventional washing machines to operate between the inner and outer drum, i.e. in water, applications of this kind have associated problems. To overcome these problems, it must be ensured that areas outside the drum where said systems are situated are as water-free zones (100) as possible.
While the presence of electrical, electronic and pneumatic systems required for mechanical systems are not a mechanical requirement but this invention will also allow application of electrical or electronic systems together with mechanical dynamic systems to drive and control.
Moving parts inside the drum create physical effects in addition to those created by the rotation of the drum and are used to increase the physical and chemical performance inside the drum. Said moving parts are placed inside the drum, which increase the desired physical effects on the materials placed
within for treatments such as washing, dyeing, stoning, polishing and brushing.
The proposed system of the invention provides rubbing in washing machines, brushing in machines where hard materials such as dust mats are washed, and abrading of textiles without the need to use environmentally harmful pumice stone. The system proposed by the invention makes possible the addition of parts that are capable of rotation, oscillation, vibration or eccentric movements and axial movements in horizontal and vertical directions when driven by a motor/movement system.
All these are possible by applying Poly-Ribs/protrusions/sheet bar/grate bars (525) inside of the cylindrical drum inner surface (104-n). Protrusions on the perforated surface hold washing materials away from drum surface to keep holes open and also create water channels to flow water from any area of the drum till to perforated area at the end of the washing and during the extraction. This means from now on no more need to spread the perforations on the whole drum surface for draining efficiency. So even if the holes were only within a certain area of the drum surface, the water in other regions was able to flow through the channels formed under the protrusions and reach the holes quickly. This allows the drum holes to be located in a limited area on the drum surface.
If the washing machine has an extraction feature, the addition of moving parts outside the drum provides a new solution to the problem of oscillations and vibrations caused by unbalanced load distribution during the spinning extraction cycle. In this method, moving parts can be moved in such a way to provide a counter weight against to the unbalanced load distributed in the drum. In this manner, the loss of balance during the spin cycle can be compensated consistently. The use of a known, sensitive system that is in
use for providing balance to the drum during the spin cycle allows freedom from the springs attaching the drum to the chassis, the suspension systems and the weights attached to the drum chassis that were previously deemed necessary to use.
The moving parts inside the drum aid in the operation of the machine and improve the performance of the treatments done within as well as savings the use of resources such as water, energy, chemicals and time.
As electricity connected with the drum, it will become possible to mount all types of electrical and electronic devices, systems and sensors onto the drum. Electrical connection of the drum can be realized by any method known in the art as well as application of the systems of the invention as disclosed below. In this manner, sensors directed to getting desired information from the materials undergoing treatment in the drum and control systems for evaluating the measurements and interfering when necessary can be mounted onto the drum. The new system will facilitate access to the external surface of the electricity connected drum, making it easier for service and maintenance.
Supplying electricity and air to the drum makes it possible for all kinds of electrical and pneumatic systems to be mounted onto the drum. Aside from movement systems, devices serving particular purposes, such as valves and pistons will be functionally usable on the drum. In this manner, in the embodiments disclosed herein, it will be possible to cut off draining water from the inner drum to the outer water chamber by a valve. As the water filled into the drum will remain only inside the drum after the valve is closed, the water and chemicals added to the drum are fully used in an efficient manner therein. This means that the point reached in water and chemical savings is the highest possible level.
In addition, supplying electricity to the drum allows electrical water heaters to be mounted onto the drum for heating the water in the drum and keeping the water temperature constant directly therein.
Monitoring the process within the drum is especially very important for certain treatment processes applied in industrial type machines. It is necessary to observe the movements, conditions and changes in the material in the drum through the glass in the door used to close the entrance of the drum. However, as the inside of the drum is dark, the lighting from the door glass only illuminates a limited area. Whereas if the inside of the drum is illuminated by lighting elements mounted on the surface of the drum, a wider area can be illuminated.
It is inescapable that the motor(s), movement transfer systems, mechanical, electrical and electronic systems required for the operation of the dynamic, mechanical parts that will be mounted onto the drum and all or some of the control systems dedicated to these systems be placed immediately outside of and in communication with the drum. This means that in conventional machines where a water tank full of water is present outside the inner drum, some of said systems need to be positioned and operate in the water tank in contact with water.
According to the characteristics of the process in the drum, the water therein also contain added chemicals, insoluble solid particles and water soluble substances transferred to the water from the processed material inside the drum. It is inescapable that dynamic systems inside the water tank come in contact with the water containing chemicals and insoluble solid particles and that their operation be hindered due to the water. Precautions can be taken to ensure that dynamic systems inside the tank can operate without being affected by water and the chemical and physical substances in water. An
exemplary application relating to this is a potato peeler having an abrasive roller. However, the main problem that needs to be solved is ensuring the smooth operation of motors, mechanical, pneumatic, electrical and electronic systems and moving parts in said liquid rich with chemicals and solid materials. Movement transfer systems such as belts, pulleys, bearings and gears for transferring movement from the motors mounted outside the drum to the dynamic systems inside the drum can be affected by solid materials that can be found in the washing water, such as thread, fabric, fuzz metal buttons, etc. The gears operating outside the drum in washing water may get stuck because they get tangled with the threads that have come off from the textiles. Especially in industrial applications, as the use of highly acidic or basic bleaching substances leads to corrosive conditions, the use of devices and materials not produced from stainless materials is undesirable. In this case, contact of mechanical and electrical dynamic systems in the tank with water can be prevented by the application of the saving system described in EP2229475. Even if a water-free zone is provided in the volume between the water tank and the inner drum, a sealed volume formed by noncorrosive materials that is insulated from other parts of the tank that will not be affected by high temperature water, corrosive chemicals and steam need to be provided for said devices. The present invention proposes solutions for preventing contact between the liquid in the drum and the movement system on the drum in a practical and economic manner so that the dynamic system operates smoothly.
If a portion of the water tank can be water-free completely and permanently, it is understood that this part is practically not functioning. For example, if water does not reach up to the drum shaft within the tank, then use of conventional shaft sealing systems, such as sealing rings and felts, between the tank and the drum shaft are not necessary. In other words, if a part of
the tank can be cleared of water, it is possible to eliminate said part. Elimination of a part of the tank means that said section of the drum will be taken out of the tank. Commonly, the part of the washing machine called as water tank or outer drum is mainly a part that is filled with water and that contains the inner drum. The water tank carries the water inside the drum. When the drum is not rotating the water levels inside the drum and the tank are equalized. In the proposed system water is not filled up to the level of the drum, therefore it would not be suitable to call this part as water tank. For this reason, a tank not fully surrounding the drum or not filled up to the level of the drum will be referred to as a water chamber (500). The water chamber is a chamber that surrounds only the perforated portion of the drum to collect and flow water away. That means all non-perforated parts of the drum are outside. All non-perforated external surfaces of the drum are free of water, meaning they are dry.
The washing machines (50) with horizontal drum that are widely used comprise a perforated drum (104) that is mounted inside a water tank by a drum shaft (103) and a drum shaft bearing (102). Before the details of the invention are disclosed, it is to be noted that the washing machines related to the present invention can be of two different types: household washing machines (57) and industrial washing machines (51). Both can have two different structures: front loading (58) and side loading (59). While washing machines designed for household or small-scale commercial use that can be produced by mass production techniques and washing machines for industry which are designed specifically for a given application are both referred to as "washing machines", there are significant differences between the two in terms of design and operating conditions.
The most important difference is the difference in size. Household washing
machines (57) that are designed for individual use having a drum diameter up to 600 mm and defined as "small scale", commercial washing machines (56) that are designed for laundromats. Commercial and industrial laundries uses industrial washing machines (51) having a diameter between 600 and 1000 mm and defined as "medium scale". Industrial washing machines (51) designed for industrial use having a diameter between 1000 and 2000 mm and defined as "large scale" all provide treatment applications to materials having essentially the same features. When textiles undergo treatments in industrial washing machines, they are subjected to much greater physical effects than in household washing machines (57).
As there is no limit on the outer size of industrial washing machines, any and all sizes required by the system of the invention may be applicable without limit. However, the outer sizes of household washing machines (57) are fixed. Due to these international standards restrictions, it may not be possible to utilize some feature of the system of the invention in household washing machines (57).
Some measures to be applied in perforated drum washing machines (50) are changed in proportion with the size of the machine; however, some of them do not. The diameters of drum perforations/holes (105) of drums (104) having a drum diameter of 400 mm or 2000 mm are kept below a certain limit as technical means allow. As it is known that the smaller the size of drum perforations/holes (105), the less harm is done to the textile, so only technical and economic considerations are taken into account when determining the diameter of the holes. Drum perforations/holes (105) can have a maximum size of 5-6 mm. As the thickness of the cylindrical perforated drum sheet (106) increases with increasing drum (104) size, the minimum size of drum perforations/holes (105) is limited by production
techniques. It is not possible to scale up a 5 mm drum perforations/holes (105) of a 400 mm drum (104) to 25 mm for a drum having 5 times the diameter. The reason for this is that the textiles undergoing treatment in both drums have the same features with same limitations. As the size of the holes increases, the sharp edges of the holes cause more damage to the textiles. On the other hand if drum size is increased mechanical effect is also increased, meaning the holes in the large diameter drum are more harmful than the same size holes of the smaller drum. However, the size of drum lifter ribs (107) rotating along with the laundry inside the drum should be changed in proportion with the size of the drum. As the loading capacity of the drum (104) increases with drum volume, the measurements of drum lifter ribs (107) are generally proportional to the diameter of the drum. It is obvious that ribs used for a small drum will not be able to fulfill their function in a drum having a diameter of 1500-2000 mm. While the ribs that are used in the drums of industrial washing machines (51) fulfill the function of rotating the materials along with the drum, they also cause a problem. The physical endurance of the textiles carried by generally triangular prism shaped drum lifter ribs (107) are similar to that of the textiles washed by household washing machines (57). However, tens of kilograms of textile materials on a sheet that is stretched between high ribs in a manner where there is empty space below, like a tent on the protrusions (531), will create forces in the magnitude of double digit tons during the spin cycle, due to the centrifugal forces that are 400 times greater than gravity force. As it is not possible for a sheet that is stretched between high ribs in a manner where there is empty space below to carry that much weight, it is unavoidable that it will tear or deform by stretching. For this reason, the size of drum lifter ribs (107) of industrial textile washing machines (52) must be optimized very carefully. In spite of this, the spin cycle speed of industrial textile washing
machines (52) must be limited. Limiting the spin cycle speed causes the textile to remain wetter than necessary which leads to longer drying times and energy consumption during the drying process that is much higher than the energy consumption during the spin cycle. Using dynamic systems in the drums will eliminate this problem as well as the requirement that drum lifter ribs be stationary. During washing, drum lifter ribs can change their sizes as required and when the spin cycle starts, their heights can be decreased. This change in the sizes of the ribs can be realized by a motor to move parts on the drum (130) or a pneumatic system to move parts on the drum (131) to move parts that are mounted on the drum.
It is not preferable to add steam directly to the washing water in industrial washing machines (51) during heating. When steam is directly added to water, the amount of steam to be added is dependent on the initial water temperature and the desired water temperature. When steam is mixed with water, it condenses into water, which leads to a change in the amount of water in the drum. This is undesirable, especially for processes where the ratio of chemicals and water is important. Especially for processes such as dyeing where all conditions have to be controlled in industrial parts dyeing machine (53), a change in the amount of water will lead to a lot of issues. Therefore, indirect heating by heat exchangers are used in industrial parts dyeing machines (53) used for these types of processes, even though they are more costly. Another disadvantage of mixing steam directly into water is the danger of foreign materials entering from the steam system and fixtures carrying with steam. Steam fixtures need to be constantly kept clean, otherwise foreign materials entering along with steam may cause problems with the quality of the material being processed. Steam obtained using a steam boiler or steam generator also has an economic disadvantage. The whole boiler with full of steam needs to be heated even when a small amount
of steam is needed. This process takes a long time and produces more steam than is needed which causes unnecessary energy consumption that is costly.
Non-perforated external surfaces of the drum on the outside of water chambers (500) allow the drum to be directly heated by furnace. The drum is in direct contact with the washing water and the materials being treated therein. Therefore, when the drum is heated from the outside, the washing water will be heated indirectly. This method has many advantageous consequences. This technique is one of the well-known heating methods since humans started to control and use fire. We still cook and heat meals in the saucepan on the fire cooker. With a burner placed under the drum, washing water heating in the machine is looks very simple and practical. It is also very economical; there will be no need to invest in a steam boiler/generator and all expensive steam pipeline system together with all related parts and equipment. On the other hand if there is no further need for steam, the leftover steam in the steam boiler will condense into water, which leads to an energy loss, especially in plants that are not operating continuously. On the other hand, if the drum is heated directly by any fuel in the required amount, only the necessary amount of energy is consumed and maximum efficiency is obtained. In the proposed invention, water in the drum is heated directly; therefore the need for water fixtures containing heat exchangers and pumps is eliminated. As a result, there will be no need for a costly investment and a system comprising elements requiring maintenance such as heat exchangers, pumps, fitting parts, valves and filters is eliminated. In addition, heat losses related to the heat exchanger and related fixtures are also eliminated.
While details such as household drum holes/perforations (605) and the space between drum and water tank opening at household drum entrance/inlet
opening (608) of household washing machines (57) are designed with the fact that socks will be washed in the machine in mind, it must also be taken into account thousands of socks will be dyed together in the drum of an industrial parts dyeing machine (53) having a diameter 5 times greater and drum capacity 25 times greater when designing the space at drum entrance/inlet opening (108).
Describing all machines under the title washing machines regardless of their different capacities may lead to some confusion while disclosing the invention. While some embodiments of the invention can be applied to household washing machines (57), commercial washing machines (56) and industrial washing machines (51), others may only be applied to one type of washing machines. The main targets of the invention are first and foremost commercial washing machines (56) and industrial washing machines (51). For this reason, the descriptions below are given for medium and large capacity machines. Sections specifically related to household washing machines (57) and industrial washing machines (51) must be evaluated by taking this into account.
Industrial washing machines (51) do not solely refer to industrial textile washing machines (52). Machines having similar features are used for many different washing treatments and these machines are also defined as washing machines. Household washing machines (57) and commercial washing machines (56) are generally used for washing laundry. However, aside from industrial textile washing machines (52), large capacity industrial washing machines (51) also comprise industrial parts dyeing machines (53), industrial stone washing machines (54), final washing of the textile products of the textile manufacturing, rubber-covered dust mat washing machines and industrial heavy material (such as carpets) washing machines (55). While
they are similar in terms of looks and basic structure, they have very different structural features.
The present invention comprises many features having a technical advantage that are based on the system where a section of the drum is taken out of the water tank and/or water-free zones are formed on the outer surface of the drum using the Poly-Ribs Eco-Drum technique that explained by EP2229475. However, it has become necessary to organize the disclosure to cover all the features, because they have features that complete each other in application, one feature makes it possible for another feature to be used, using the features together lead to advantages greater than their individual advantages and the details of their applications can be described by embodiments that are realized by using multiple features together. One of the principles and preferred purposes of the invention is the presence of moving parts in the balance system (300) inside and/or outside the drum. Providing the conditions wherein moving parts (200) that can be moved in a controlled manner can be mounted onto the drum, what the moving parts may be, the advantages brought about by the moving parts and the operations possible with these machines are organized and described under the headings below.
The most important inventive step of the invention is to directly connect electrical energy to the drum and to move all moving parts in the drum with electric motors.
We call the water-filled part surrounding the inner drum a "water tank or an outer drum", as well sometimes a water tub. Water tank and outer drum are good definition for water fill closed container. But if the chamber at the outside of the perforated inner drum is only functioning to collect drain water come through inner drum perforations, water chamber will be more suitable to define. In this description, the outer drum, water tank, water drum is used
to describe the water container in conventional washing machines. In our system the outer chamber only for collecting water likes a chamber. So it is more appropriate to refer to this part as water chamber.
Summary
The system described in EP2229475 aimed to save water by collecting all the water exist in the outer drum into the drum. For this purpose, the presence of water in the outer drum or even completely emptied can be controlled. For this purpose, the amount of water contained in the outer drum or even the complete discharge of the outer drum was controllable. In fact, if there is no water in the outer drum in any circumstances, what is the reason for the outer drum existence? The outer drum is no longer outside the drum, i.e. there is no known water tank surrounding the drum. It is enough to cover small part of the outer surface of the drum which water draining from the drum by the collection chamber to collect water from the drum. The drums being largely out of the water tank open the door to many new applications in the design of the washing machine. Thus, mechanical moving systems can be mounted inside and outside of the drum. Motors that provide these mechanical moving systems to operate can be mounted directly outside the drum. The electrical energy that enables the motors to drive said mechanical moving parts can be directly connected to the drum. In addition, various sensors on the drum, pressurized air systems, liquid or gas-driven equipment, liquid or gas transfer connections required for these systems can be provided. In a sense, the drum was gain freedom from coming out through outer drum. Until now, the rotating perforated cylindrical part that mounted in a water tank is called drum. After that, it will be possible to call this piece as "free- drum" and from now on, the free-drum itself can be defined as a machine.
1- Moving parts f25C0 inside the free drum 104") and industrial stone
washing machine f54j are described below.
The main idea of the machine subject to the invention is the moving parts
(200) that give dynamism to the free-drum. The addition of moving parts inside of the drum (250) in order to increase the mechanical and chemical effects onto the materials being treated will increase the performance of the treatment and decrease operation time. Cylindrical rollers (201) that can complete a full rotation around their rotation axes and grindstones placed on vibrating parts (222) are given as example for the practical applications to explain methods wherein the moving parts (250) inside of the free drum (104) mounted in the drum. Rollers having abrasive surfaces have been and are currently used in a variety of applications spanning from potato peelers, to woodworking machines and metal processing machines. When rollers
(201) are placed as close to the surface as possible onto cylindrical perforated drum sheet (106) or into the hollows formed by protrusions on cylindrical drum surface (261), the dynamic character of the free-drum (104) will be increased without giving up drum volume. When said rollers (201) and vibrating parts (222) are abrasive for use in stoning they are referred to as abrasive rollers (202) inside free-drum and when they are used for rubbing, mixing and felting treatments they are referred to as eccentric rollers (204) inside free-drum. The embodiment that will stand out the most will be industrial stone washing machines (54) comprising abrasive grindstone rollers (206).
One of the problems solved by the presence of moving parts inside drum (250) is the ability of lifter ribs (107) to change shape and size, as described above.
2- Moving parts outside free-drum f251j and balance system G300 ) outside the free-drum are described below.
A second important application area of mounting moving parts (200) onto the free-drum is that it allows the machine to perform the spin cycle without vibration by weights placed in free-drum front circular base/opening side (109) and free-drum rear circular base/shaft side (110) of the outside of the free-drum to balance the imbalance produced during the spin extraction. An exemplary embodiment of said dynamic balance system (300) may be a system comprising 2-weight balance system (302) mounted front and rear side of the free-drum that contain 2 balance weights for 2-weights balance system (302). Each balance weight can move around in the balance weight bearing system (302-S) around the free-drum cylinder (104). During balanced conditions of the drum spinning, two balance weights (301) balancing each other when placed in opposite positions on a balance weight bearing system (302-S) on the axis of the drum that can be rotated 360° by a gear connected to motor (310) connected to a balance weight movement motor (306). The balance weights for 2-weights balance system (302) are placed in the front and the rear of the drum and outside of the balancing process; they are positioned in the manner to balance each other. During balancing they are displaced in order to offset the imbalance in the free-drum . In a similar system is two liquid container weight balance system (330), the two weights are two balance liquid containers (331) that are positioned opposite each other and that can be rotated 360° during and outside of the balancing process without changing their positions relative to each other. The two balance liquid containers (331) each contain a certain amount of balance liquid to balance each other out. During the balancing process, the containers are rotated together in the same direction as the imbalance load force vector while maintaining their positions opposite each other. While the containers are in this position, liquid transfers from one tank to another through balance liquid transfer connection line (334-L) so that the weight of one tank
increases while the other decrease, until the counterweight to balance the unbalance load in the drum. Another balance system is to create an opposite force to balance the unbalance force created by the centrifugal force by moving of minimum 3 balance weight pieces for 3-weights balance system (303-P) placed on the drum independently. We named this balance system for 3-weights balance system (303-W) that able to mounted at the front and/or at the rear of the drum placed at equal distances from weight guide bearing for 3-weights balance system (304) on a threaded balance weight movement screw (305). If balance weight pieces for 3-weights balance system (303-P) move away from the rotation axis of the drum by screw turning, each create more centrifugal force. Thus, when 3 or more weights are moved away from the axis of rotation, by separate motor driving to rotate screw to which each weight is mounted to create a counter-balance force.
3- The presence of a movement transfer system outside free-drum f401 ) is described below.
A preferred attribute of the dynamic free-drum invention is the controlled movement of moving parts inside (250) and outside (251) the drum using a motor system (400). In the case where the embodiment is applied to machines suited to be defined as washing machines, considering that said moving parts are in a water tank/outer drum (101) in a free-drum (104) rotating by a drum shaft bearing (102) and the controlled movement of moving parts (200) can be realized by at least one motor to move parts on the drum (130), it is only possible to implement the system if the problems associated with the presence of water in water tank/outer drum (101) are solved. Moving parts inside drum (250) of said moving parts (200) need to be connected to a motor to move parts on the drum (130) or pneumatic system to move parts on the free-drum (131) that is a drive source. Moving parts
inside free-drum (250) need to be connected to motor to move parts on the free-drum (130) directly or via a movement transfer system (401) from the cylindrical perforated drum sheet (106), drum front circular base/opening side (109) or preferably drum rear circular base/shaft side (110). According to a preferred embodiment of the invention, it is possible to place the electrical drive motor on fixed chassis (133), electric and electronic assembly outside the water tank/outer drum (101) and connect electrical drive motor on fixed chassis (133) to moving parts (200) via movement transfer systems (401) outside free-drum . In order to eliminate complex motion transfer systems from motor mounted outside of the water tank/outer drum (101) to moving parts in the free-drum , the drive and dynamic system is simplified by mounting electric drive electrical drive motor on free-drum (132) directly on to the drum.
If motor to move parts on the free-drum (130) is not directly connected to moving parts (200), a movement transfer system comprising movement transfer system (401) such as gears, pulleys, racks and pinions, timing belt pulleys, poly-V belt pulleys, smooth belt pulleys and V belt pulleys, mounted opposite the motor and moving parts need to be set up to transfer movement. The movement is transferred from motor to move parts on the free-drum (130) to these gears or pulleys via suitable movement transfer parts (402) such as belts, geared belts, chains or gears.
Motor(s) to move parts on the free-drum (130) that are the drive source may be mounted onto fixed chassis (111) of the machine outside water chamber (500) or may be mounted directly onto free-drum (104) such that it can rotate with said drum. Movement transfer parts such as pulley rotated by movement transfer parts such as belts (402) connected to electrical drive motor on fixed chassis (133) that is mounted outside the water chamber
(500), preferably on top of the water chamber (500), transfer the movement to the movement transfer parts (401) connected to moving parts (200) inside water chamber (500). In the cases where the driving source is inside water chamber (500) both electrical drive electrical drive motor on drum (132) mounted on free-drum (104) and electrical, electronic, control systems (900) for transferring energy to said motor via electricity transfer slip ring (908) and controlling said motor need to be more sophisticated than other motors. In addition, it is possible to mount the mechanisms driving the moving parts using the rotation of the drum onto the drum. In cases where electrical drive motor on fixed chassis (133) is mounted onto free-drum (104) it is necessary to either transfer electrical energy to the free-drum via electricity transfer slip ring (908) or produce electrical energy by electric dynamos in drum (904) using the rotation of the drum.
It is important to ensure that moving parts inside drum (250) are driven by movement transfer system (401) placed in the rear of the drum and are operating reliably. The contact between the water containing chemicals required for the treatment, in some cases highly corrosive acids and solid materials mixed into the water during the treatments, that may exit the drum even when the required amount of water is present in the drum, and electrical drive motor on fixed chassis (133) and movement transfer system (401) must be prevented. For this reason, water-free zones placed outside the free-drum where movement transfer system (401) and electrical, electronic, control systems (900) are located away from water will make the application of the system easier. There are two possible methods to prevent the washing and extraction water draining from the drum through the drum holes from affecting electrical drive electrical drive motor on drum (132) and movement transfer system (401). These are preventing entry of water into areas of water chamber (500) wherein the drum is rotating where the
movement transfer system is located, or taking these areas out of water chamber (500).
4- The presence of the movement system outside the free-drum in the water-free zones is described below.
When physical or chemical treatments such as washing, stone washing and dyeing are performed in the free-drum , the chemicals and solid substances in the water will harm mechanical, electric and electronic systems providing movement outside the free-drum. For this reason, either said devices and equipment need to be produced to be waterproof and resistant to corrosive chemicals or these sections of free-drum (104) need to be water-free zones (100) that are fully free from water. The function of water chamber (500) is to collect the water leaving the drum. Ensuring that water does not reach some sections of water chamber (500) is only possible if said sections are placed higher than the maximum possible water level in water chamber (500). In other words, the water level in water chamber (500) needs to be kept at a level where water cannot reach undesired areas. It is possible to limit the amount water in water chamber (500) so that it only takes up a small volume at the bottom of water chamber (500) or even empty out water chamber (500) entirely. When this is achieved, the large portion of water chamber (500) aside from this small portion at the bottom can be referred to as water-free zone (100). Controlling the amount and area of the water outside free-drum (104) can prevent water contact with parts placed outside drum (104).
It can be ensured that the water inside washing machine (50) with perforated free-drum (104) remains at the bottom region of water chamber (500) and inside free-drum (104). It will be sufficient to pump the water from water chamber (500) also defined as water tank/outer drum (101) in the Eco-Drum
system (61), back into the inner free-drum (104) by a circulation pump (112) having a pumping flowrate that is higher than the drain flowrate of water exiting through drum perforations into the water chamber (500). In other words, circulation pump (112) collects the draining water from the free-drum (104) through water chamber (500) and directs it back into the drum via a circulation line (113). In this manner, a large portion of the water is constantly collected in the free-drum (104). The stated aim is achieved when it is ensured that draining water from the drum flow on chamber surface under control and directly reaches water chamber drain outlet (503). In addition, measures such as water chamber barrier (511), water chamber overflow lines (511-o) and control-warning-safety systems added into water chamber (500) can be used to ensure that water does not reach the areas where parts used to drive moving parts (200) of the drum, such as belts, gear, pulleys, motors and electric-electronic control systems are placed.
When the water chamber (500) is applied as described, it is not possible for the water to reach the water-free zones (100). Since the water-free zones of the free-drum surface are completely exposed, it is not possible to reach the water in these areas. In other words if the water flows out of the water chamber (500), it also means that water flows out of the machine, in which case water cannot wet the water-free zones (100) of the drum even though it wets the environment of the machine.
5- Limiting the drain water from drum fl04) at a steady flowrate and at pump capacity is described below.
It is possible control the volume and amount of water exist at the outside of the drum (104) using the Eco-Drum system (61) described in EP3252207. Protrusions on cylindrical drum surface (261) placed around drum perforations on cylindrical perforated drum sheet (106) of the Poly-Rib
system (60) described in the EP2229475 may prevent the materials undergoing treatment from reaching and fully or partially blocking drum perforations/holes (105). The Eco-Drum system (61) describes evacuation of the water in water chamber (500) by draining water from the free-drum (104) where the quantities and/or dimensions of holes are calculated or reduced compared to conventional drums with a limited flowrate and being pumped back into free-drum (104) by a circulation pump (112) having a larger pumping capacity that the flowrate of the water draining form drum (104). It can be deduced from the description that this systems also provides savings of water, chemicals and energy in the washing machine (50). Poly- Rib system (60) describes a system where protrusions placed on the surface of free-drum (104) prevent the laundry from fully blocking drum perforations/holes (105). The purpose of said protrusive cylindrical drum surface (261) is to hold the laundry away from drum surface and preventing the laundry from reaching drum perforations/holes (105) as much as possible. In conventional drums, while the number and size of drain holes is large, most of them are blocked by the laundry being washed and the actual discharge of water is much less than the drain flow capacity of the holes. On the other hand, even though the number of drum perforations/holes (105) is reduced more than ten times in the Poly-Rib system (60), most of the holes are kept unblocked whereby protrusions on cylindrical drum surface (261) so the discharge capacity of the holes is mostly unchanged. By preventing the blockage of drum perforations/holes (105) that are positioned in the area of influence of protrusions on cylindrical drum surface (261) by the material undergoing treatment, water flowrate from drum perforations/holes (105), which is limited compared to that of conventional drums provides under controlled water draining that is continuous but limited based on the pump flow rate capacity. The purpose of protrusions on cylindrical drum surface
(261) is to prevent the laundry from reaching drum perforations/holes (105) and restrict the outflow of water from said drum perforations/holes (105). The water that has flown from free-drum (104) to water chamber (500) is pumped back into free-drum (104). If the capacity of said pump is higher than the highest possible flowrate of water being discharged into water chamber (500), it will not be possible for the water level in water chamber (500) to rise high enough to reach free-drum (104). Therefore, the drum outer surface (104-s) is prevented from coming into contact with water. The Eco-Drum system (61) plays a key role in providing water-free zones (100) on the surface of free-drum (104) and taking drum (104) partially out of water chamber (500). When protrusions on cylindrical drum surface (261) are designed to prevent the materials from reaching drum perforations/holes (105), they will also prevent materials from reaching the surface of free-drum (104). In certain embodiments of the invention, it may not be necessary to employ protrusions on cylindrical drum surface (261) to prevent the materials from reaching drum perforations/holes (105). The individual shape of the surface of free-drum (104) or other parts having different purposes (234, 240) can function as barriers between the materials and drum inner surface (104-n) without any need for protrusions on cylindrical drum surface (261) as described in EP2229475 and prevent the materials/laundry from reaching and blocking said drum perforations/holes (105). In this case, the water flowing from the materials being washed in free-drum (104) can pass between said parts and reach said drum perforations/holes (105) without encountering any obstacles. Because drum perforations/holes (105) are not blocked, as long as enough water flows from the materials, the flowrate of water leaving free- drum (104) will be stable and acceptable with respect to the pumping capacity. The shape and height of and the distance between protrusions (261) can be designed so that the materials go into recess between
protrusions on cylindrical drum surface (262) do not reach the surface of drum (104). It is important to take into consideration the physical characteristics of the textile being washed. When said protrusions (261, 622) or parts (234, 240) that are placed onto the surface of drum (104) prevent materials from going into the area there between, water channels (524, 621) are formed between the protrusions. When there are no protrusions (261, 622) or parts (234, 240) to form water channels (524, 621) on the surface of free-drum (104), said conically molded roller housing water channel (241) may be designed and applied. The water flowing in water channels without encountering any obstacles can reach the area where molded roller housing water discharge holes (235) are located, and pass through drum perforations/holes (105) that are unblocked thanks to protruding structures (261, 234, 240) around and exit free-drum (104). If Poly- Ribs/protrusions/sheet bar/grate bars (525) are placed side by side on the drum inner surface (104-n) means also Poly-Channels exist in between said Poly-Ribs functioning water channels to flow water from no perforated areas to drain perforations. By means of water channels/Poly-Channels (524) only the area where drum perforations/holes (105) are located will be a drum wet- outer surface (104-w).
6- Taking the drum out of water tank/outer drum (101) and water chambers is described below.
The difference of the disclosed system from conventional washing machine (50) is providing water-free zones (100) no water at least some outside surface parts of the free-drum (104).
In the disclosed washing machines system, perforated free-drum (104) in a water vessel fulfills the function of water collection in the form of a sink, bowl, tub or basin. As known, all these vessels are partially open water
containers. According to the present invention, defined vessels functioning only to collect the water exiting from the drum will be defined as water chamber (500). In this way, the function of the water chamber is no different than sink used to wash hands every day. For example a chamber where water chamber drain outlet (503) has a good draining flow capacity to always empty out the water flowing into the chamber and therefore never overflow. In other words, the vessel ensuring that water draining from the free-drum (104) reaches water chamber drain outlet (503) without accumulation is referred to as water chamber (500). In some washing conditions, useful water in the drum has to be decreased for a short time. If it is desired to decrease water in the drum, to collect said portion of the water discharged from the free-drum (104), a water accumulation chamber (502) have to be designed having a volume, shape and depth wherein the highest level of water never reaches to the drum.
In conventional washing machines (50) water tank/outer drum (101) wherein free-drum (104) is made up of one piece as will be understood from the description of the tank. It is necessary to provide water chambers (500) in areas where the water draining through perforations of the drum in order to ensure that movement system that needs to be placed outside of the drum is positioned outside of said water chambers (500). In this case, the drum is not in a water tank/outer drum (101), described water chamber (500) surrounds only areas where water draining zones such as drum perforations/holes (105) and the gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108) will be present. There will be some other advantages to changing the definition "in washing machines free-drum (104) is placed inside a water tank/outer drum (101)". As is known, for high speed spinning extra weights are added on outer drum. Water tank/outer drum (101) and weights added onto the outer drum are used to suppress the
oscillations and vibrations caused by the imbalance during the high spin cycle as much as possible. Therefore it is particularly preferable that water tank/outer drum (101) is heavy. While water tank/outer drum (101) and the weights decrease the oscillations or vibrations motion of water tank/outer drum (101) trying to spin at high speeds with unbalanced weights, they also create additional loads and force to drum shaft (103) and drum shaft bearings (102). But if the problem of imbalance of the drum is solved by balancing the drum, the need for extra weights on water tank/outer drum (101) is eliminated and it will be possible to make water tank/outer drum (101) as light as possible and the mechanical structure of the shaft and bearing carrying the drum can be simplified. In a balancing system, the total weight of the rotating object to be balanced is important. In some of the conventional applications, free-drum (104) is carried by a water tank/outer drum (101) chassis having a flexible structure. The principle that the flexible mass used as a tool to suppress oscillations and vibrations is systems other than the springs connecting the flexible drum chassis to fixed chassis (111) must be as heavy as possible will have the opposite effect in a machine having a balancing system. For balancing the drum first of all we have to determine the magnitude and position of the existing imbalance force by monitoring the drum system using proper sensors. As water tank/outer drum (101) and all weights on water tank/outer drum (101) will be counted among the rotating weight to be balanced, they affect the monitoring sensitivity of the balancing operation. Also, the counter forces created the centrifugal force by the unbalanced load in free-drum (104) and the water tank/outer drum (101) where the counter load to suppress said force is attached may cause stretching in the mechanical parts of the machine. Therefore, as with drum shaft bearing, water tank/outer drum (101) and free-drum (104) need to have higher than necessary mechanical strength. For this reason, detaching
all manner of parts, such as water chamber (500) and parts directly connected to drum aside from drum and attaching them directly to the fixed chassis side will increase the monitoring sensitivity of the balance system.
7- Electric, electronic and control systems in the drum are described below.
When the drum is directly connected to electrical energy, a door opens to different paths. It would be possible to mount electrical devices of all kinds, including but not limited to motor to move parts on the drum (130) required for movement transfer system (401) ensuring movement of moving parts (200) on free-drum (104) or electric, electronic, control systems (900), directly onto the drum. This allows close and direct monitoring and control of processes happening in the drum and also makes it possible to apply systems required by the treatments, such as drum heating element (913) and lighting units (918) inside drum, directly into the drum.
Brief Description of the Technical Drawings
Figure 1 demonstrates a rear perspective view of a midsize industrial washing machine having a 2-weights balance system applied around cylindrical drum surface at both side of the drum and drain system through water collection chamber with circulation pump and having direct heating gas combustion chamber according to the present invention.
Figure 2 demonstrates a (A) side sectional and (B) close up view of a midsize industrial washing machine having a 2-weights balance system applied around cylindrical drum surface at both side of the drum and drain system with poly-ribs through water collection chamber with circulation pump and having direct heating gas combustion chamber according to the present invention.
Figure 3 demonstrates a (A) rear perspective and (B) close up view of a midsize industrial abrasive roller stoning washing machine with abrasive rollers in the drum driven by motors in groups and having a drain system through water collection chamber and water storage tank with circulation pump according to the present invention.
Figure 4 demonstrates a side sectional view of a midsize industrial abrasive roller stoning washing machine with abrasive rollers in the drum driven by motors in groups and having a drain system through water collection chamber and water storage tank with circulation pump according to the present invention.
Figure 5 demonstrates a sectional view of a midsize industrial washing machine having buckled grindstone of rollers driven by separate motors and a 2-weights balance system placed on both circular base of the drum and rotate in a water collection chamber surrounding cylindrical perforated drum surface and water storage tank with circulation pump according to the present invention.
Figure 6 demonstrates an exploded sectional view of drum in a water collection chamber surrounding cylindrical perforated drum surface and water storage tank with circulation pump also having abrasive rollers and a balance system placed on both circular base of the drum according to the present invention.
Figure 7 demonstrates (A) a front view and (B) a side sectional view of a drum having a balance system and cylindrical rollers according to the present invention.
Figure 8 demonstrates (A) an exploded front view and (B) an exploded rear view of a drum chassis, a rear balance system, a conical stone washing drum
having abrasive rollers with perforations in a narrow zone of the drum surface, a front balance system, a water collection tank and a water storage tank according to the present invention.
Figure 9 demonstrates a side sectional view of (A) a midsize industrial abrasive roller stoning washing machine having a 2-weights balance system applied around cylindrical drum surface at front and rear side of the drum and discharge chamber drain system closed around perforated zone surrounded with water collection chamber directly connected with circulation pump and having direct heating gas combustion chamber and (B) water collection chamber with circulation pump and gas combustion chamber with gas burner according to the present invention.
Figure 10 demonstrates (A) a rear view, (B) a front perspective view, (C) right-rear perspective view and (D) left-rear sectional view of a drum with rollers in a close water collection chamber together with water storage chamber according to the present invention.
Figure 11 demonstrates (A) a drum sectional view, (B) a water storage tank rear perspective view and (C) a water storage tank front perspective of a conical stone washing drum having abrasive rollers driven by separate motors with holes in a narrow zone and circulation pump and circulation line of narrow water collection chamber according to the present invention.
Figure 12 demonstrates a rear perspective view of an indented drum having gear pulleys connected to rollers driven by teeth belt drive by (A) single motor and (B) two motors on a fixed chassis according to the present invention.
Figure 13 demonstrates (B) a rear perspective view on a drum of and (A) detailed perspective view of and (C) more detailed perspective view of the
wrapping of a belt system travelling around idler pulleys along with gear pulleys around gear pulleys of a system driving gear pulleys attached to rollers grouped together by belts connected to gear pulleys on motors in the drum fin space according to the present invention.
Figure 14 demonstrates (A) a rear perspective view in a closed water collection chamber of and (B) a rear perspective view outside a water tank of a drum comprising rollers attached to gear pulleys grouped together and driven by belts rotated by motors in the drum fin space according to the present invention.
Figure 15 demonstrates (A) a rear perspective view of a drum inside a closed water collection chamber having service covers at its rear cover sheet and (B) a rear perspective view outside a whole perforated cylindrical surface drum comprising rollers driven by motors that are attached respectively to each roller and are placed in the rear of said drum according to the present invention.
Figure 16 demonstrates (B) a rear perspective view of a drum in a rear side base opened water collection chamber wherein said drum comprises rollers attached to gear pulleys driven by a gear belt rotated by a (A) single motor and (C) two motors on a fixed chassis according to the present invention.
Figure 17 demonstrates side sectional view of an indented drum comprising rollers having cylindrical grindstone pieces and that are attached to gear pulleys driven by a gear belt rotated by a motor on a fixed chassis and coarse grindstones in-between said rollers according to the present invention.
Figure 18 demonstrates a simplified perspective view of a stone washing machine comprising rollers respectively connected to and driven by motors placed in the rear of a drum, a drum being placed in a half-water tank so that
the rear of said drum is outside, a particle separation and injection system on a circulation line according to the present invention.
Figure 19 demonstrates (A) a perspective view of a water tank comprising a water accumulation chamber, (B) a side sectional view of a water tank comprising a water accumulation chamber, (C) a perspective view of a water tank comprising a water storage tank and (D) a side sectional perspective view of a water tank comprising a water storage tank wherein said systems also comprises a pump circulation system according to the present invention.
Figure 20 demonstrates (A) a perspective view and (B) a side sectional perspective view of a water tank comprising service covers at the rear side of the tank together with a water accumulation chamber and (C-D) together with a water storage tank and all having a pump circulation system according to the present invention.
Figure 21 demonstrates (A) a perspective view and (B) a side sectional perspective view of a rear side opened half water tank comprising a water accumulation chamber (C) a perspective view and (D) a side sectional perspective view of a half water tank comprising a water storage tank having a circulation system having a circulation system according to the present invention.
Figure 22 demonstrates (A) a perspective view and (B) a side sectional perspective view of a water collection chamber around drum and a chamber around drum opening gap and a (C) side perspective view and (D) side sectional perspective view with water storage tank comprising a circulation system connected to drum holes water collection tank having a circulation system according to the present invention.
Figure 23 demonstrates (A) a perspective view and (B) a side sectional
perspective view of a drum opening water collection chamber comprising a circulation system connected to narrow water collection chamber of drum having drum holes in a narrow zone and a (C) side perspective view and (D) side sectional perspective view with water storage tank having a circulation system according to the present invention.
Figure 24 demonstrates a (A) front perspective view and (B) detailed view of a big size industrial washing machine having drain system comprising a circulation system connected to narrow water collection chamber of drum surround drum perforations in a narrow zone and water collection chamber placed around drum opening gap respectively separate circulation pump systems for each other and having direct heating gas combustion chamber and comprising light apparatus directly mounted on front drum base according to the present invention.
Figure 25 demonstrates (A) a perspective sectional view of the part of the ribbed drum of a big size industrial washing machine comprising discharge chamber surround perforated narrow zone of the drum draining through narrow water collection chamber and water collection chamber placed around drum opening gap and (B) a close-up sectional side view of the water collection chamber applied around drum opening to collect drain water from gap between drum mouth to pump water separately into the drum via water inlets over drum door (C) a close-up sectional side view of water inlets inject water into the drum from pump according to the present invention.
Figure 26 demonstrates (A) a perspective view of the narrow water collection chamber surrounding perforated narrow zone of the drum and water collection chamber applied around drum opening to collect drain water from gap together with gas flue outlet from and fan and both water collection system comprising pump to inject water into the drum and (B) a close-up
perspective view of water inlets placed over drum door as shown detailed according to the present invention.
Figure 27 demonstrates a (A) close-up sectional perspective sectional detailed view and (B) close-up sectional side view of the water collection chamber applied around drum opening to collect drain water from gap between drum mouth together with gas flue outlet from and fan and comprising circulation water inlets placed over drum door as shown detailed according to the present invention.
Figure 28 demonstrates a schematic view of a washing machine drum (A) comprising poly ribs on cylindrical inner surface and (B) a piece of textile has fallen and lay on the surface of the drum and from (A) to (C) show forming a tent from said textile over poly ribs leaving water passage gap under the tent according to the present invention.
Figure 29 demonstrates a side perspective view of a midsize industrial washing machine comprising a pump circulation system comprising a narrow water discharge chamber surround perforated narrow zone of the conical drum wherein the discharge outlets to drain water into the collection chamber can be operated by pneumatic piston valves according to the present invention.
Figure 30 demonstrates a perspective sectional view of a big size industrial washing machine comprising protrusive drum and a direct gas heating system to heat drum through protrusive outer surface of the drum according to the present invention.
Figure 31 demonstrates (A) a perspective sectional and (B) close-up rear side perspective view of a big size industrial stone washing machine drum (A) comprising cylindrical abrasive rollers applied over drum surface (B) 3 rollers
drive in groups by electric motors according to the present invention.
Figure 32 demonstrates (A) a perspective sectional view and (B) close-up sectional perspective view of a big size industrial stone washing machine comprising cylindrical abrasive rollers applied over drum surface and narrow water discharge chamber surround drum perforations in narrow zone and water collection chamber placed around water discharge chamber and having direct heating system with gas burner in combustion chamber and two rotatable weight balance system mounted at front and rear side of the cylindrical drum surface and light apparatus directly mounted on front drum base according to the present invention.
Figure 33 demonstrates (A) a sectional perspective view and (B, C, D) close- up sectional perspective view of a drum discharge chamber comprising pneumatic piston valves surround around the drum perforations in the narrow zone on the conical drum sheet and water collection chamber around water discharge chamber according to the present invention.
Figure 34 demonstrates (A) a general view and (B) a detailed perspective view of a machine comprising a water chamber in communication with a pump on the circulation line, a balance system, a water discharge tank controlled by a valve wrapped around the narrow band zone holes of the drum having a conical cylindrical sheet having a poly-rib formed by grate elements and (C) a second circulation system connected to a pump of the drum opening water chamber according to the present invention.
Figure 35 demonstrates a perspective view of different roller structures and shapes wherein said rollers are driven along with neighboring rollers by a central roller (A) with geared pulley and threaded belt (B) with the details of roller with a motor directly connected to the central roller and (C) with
different grindstone or brush parts of the rollers according to the present invention.
Figure 36 demonstrates (A) a perspective view of rollers having a round brush shape placed in-between fixed brushes mounted into roller housings inside the drum and (B) a perspective view of a three roller group wherein brush rollers are used, central roller is connected directly to a motor and a roller bearing is show in sectional view according to the present invention.
Figure 37 demonstrates (A) a perspective view from a sectional front sheet of an indented drum having rollers having buckled grindstone pieces and that are attached to gear pulleys in groups in-between said rollers and a (B) perspective view of mounting of buckled grindstone pieces rotating with neighboring rollers driven by a central roller having a geared pulley and threaded belt according to the present invention.
Figure 38 demonstrates (A) a sectional perspective view of a roller having cylindrical grindstone pieces at rear side and spherical grindstone pieces at front side that is rotated by a motor belt pulley system and (B) a detailed sectional perspective view of frontal bearing and bearing lock mechanism of a roller having spherical grindstone pieces and (C) a detailed sectional perspective view of rear ball bearing of a roller having cylindrical grindstone pieces according to the present invention.
Figure 39 demonstrates a perspective view of (A) the area of the drum which is isolated by a cover wherein motors rotating interlocking rollers via transfer gears and which are placed in drum fin spaces are placed and close-up view of the isolated space in wet area closed by an cover as shown (B) opened and (C) closed according to the present invention.
Figure 40 demonstrates (A) a perspective view of the mounting of rollers
having cylindrical grindstone pieces and fixed grindstone rods in roller bearings inside the drum and (B)a perspective view of the mounting of or rollers having cylindrical grindstone pieces onto a drum sheet shaped as roller bearing according to the present invention.
Figure 41 demonstrates (A) a perspective view of mounting of interlocking rollers side by side in a drum, (B) a perspective view of grindstone pieces of interlocking rollers and (C) a perspective view of interlocking rollers according to the present invention.
Figure 42 demonstrates (A) a perspective view of mounting of interlocking rollers side by side with movement transfer gears, (B) a perspective view of a gear system attached to a motor in the drum fin space and (C) a perspective view of grindstone pieces of interlocking rollers according to the present invention.
Figure 43 demonstrates a perspective view of (A) grindstone rods and (B) the mounting of brush rods in the manner to be affixed along with roller bearings molded between the cylindrical grindstones rollers placed in the drum according to the present invention.
Figure 44 demonstrates a perspective view of the mounting of (B) indented grindstone pieces placed on vibrated platforms (A) mounted on the drum surface via a spring mechanism with vibrators having electrical motors according to the present invention.
Figure 45 demonstrates a perspective view of (A) the mounting in the drum of and (B) roller housings of the drum wherein the discharge holes at the end of the water channel of molded roller housings that are wrapped below the cylindrical rollers that is inclined towards the holes correspond to the holes in the narrow zone of the conical cylindrical sheet drum according to the
present invention.
Figure 46 demonstrates a general perspective view of (A) a drum comprising a balance system and a water channel grate made up of grate elements wherein the holes in the narrow zone on the conic cylindrical sheet the drum top water barrier in two levels around said holes can be seen and (B) closed up small part of a water channel grate area, (C) application of a water channel grate to a drum sheet having lifting ribs and (D) the distribution of water channel grate having conical grate elements wherein said a water channel grate is made up of grate elements on the conical cylindrical sheet of the drum according to the present invention.
Figure 47 demonstrates a perspective view of the details of a drum lifter rib movable by a jack connected to an electric motor (A) highest position, (B) close to the drum surface during extraction stage and (C) in the washing position for more sensitive textile according to the present invention.
Figure 48 demonstrates (A) a schematic perspective sectional view of the movable lifter ribs on perforated drum, (B) sectional from the side and (C) detailed perspective view of a drum rib movable by a jack according to the present invention.
Figure 49 demonstrates (A) a schematic perspective view from sectional outer frame of a household washing machine comprising a poly ribbed drum and drum perforations shown at the rear corner of the drum from a sectional opening of water discharge chamber peripheral cover sheet and (B) an exploded perspective view of a circulation pump and line, a perforated drum in the back in a narrow zone, water tanks and motor-pulley parts of a household washing machine according to the present invention.
Figure 50 demonstrates (A) a schematic perspective view of a circulation
pump and line, a perforated drum in the back in a narrow zone and water tanks of a household washing machine and (B) a schematic perspective sectional side view of a circulation pump, circulation line, cover, water grate angled on the cylindrical sheet inside drum, water tanks and motor-pulley parts of a household washing machine according to the present invention.
Figure 51 demonstrates an exploded perspective view of (A) a two rotatable weight balance system mounted on front side base of a household washing machine drum and (B) rear side base of a household washing machine drum according to the present invention.
Figure 52 demonstrates a side sectional (A) front and (B) rear perspective view of a circulation pump, circulation line, cover, protrusive drum in the form of water grate angled on the cylindrical drum sheet inside drum and water collection chamber around drum perforations and water tank connected with chamber and two weight balancing system mounted at both side of the drum base of a household washing machine according to the present invention.
Figure 54 demonstrates (A) a side sectional perspective view of front part around drum door of a household washing machine and (B) a side sectional perspective detailed view of a rear part together with balance system and sectional view of the drum bearing and water collection chamber and water storage tank of a household washing machine and a side sectional detailed perspective close-up view of rear grate around drum perforations of a household washing machine drum according to the present invention.
Figure 55 demonstrates (A) a side sectional detailed perspective view of cover sheet wrapping around the water discharge hole inside a perforated drum volume at the rear corner and outside the drum sheet to cover said water discharge hole and water collection tank of a household washing
machine from two different angles and (B) a side sectional perspective view of a drum opening water collection tank, a water collection tank and the connection there between of a household washing machine from two different angles according to the present invention.
Figure 56 demonstrates a side sectional detailed rear perspective view of a rear balance system, balance weight rotation system connected to gears on balance motor and a water collection tank, a water storage tank and the connection there between of a household washing machine according to the present invention.
Figure 57 demonstrates a side sectional detailed front perspective view of a rear balance system, balance weight rotation system connected to gears on balance motor and a water collection tank, a water storage tank and the connection there between of a household washing machine according to the present invention.
Figure 58 demonstrates a side sectional detailed front perspective view of a rear balance system and the connection of the gears on the balance motors with the gears on the weight parts of a household washing machine according to the present invention.
Figure 59 demonstrates (A) a front sectional perspective view of a drum of a household washing machine comprising grate elements forming water channels extending towards the drum holes at the rear of the drum and placed at an angle with the drum axis and (B) a side sectional perspective view of a drum of a household washing machine comprising water channel grates made up of grate elements placed at an angle according to the present invention.
Figure 60 demonstrates a detailed perspective view of a three weight
threaded bearing balance system (A) from the front of the drum and (B) having a balance weight motor and the connected weight threaded bearing of according to the present invention.
Figure 61 demonstrates (A) a schematic back view and (B) a perspective view of motors directly connected to rollers and a two weight rear balance system according to the present invention.
Figure 62 demonstrates a schematic view of (A) opposing forces FI and F2 created by balance weights balancing each other and (B) and the opposing force created by FI and F2 created by balance weights balancing the Fx force creating an imbalance in the drum in a two weight balance system according to the present invention.
Figure 63 demonstrates (A) an schematic exploded view showing each balance weight system of the two rotatable balance weight separately system and (B) a front perspective view from a drum having a two weight front balance system according to the present invention.
Figure 64 demonstrates (A) a schematic perspective view showing assembled the two weight balance system and (B) a exploded perspective view showing moving system of a two weight balancing system having two weights and balance weight movement motors with chain gear and chain connected with balance weights and (C) a view of the connection details of and (D) a close up detailed perspective view of motor-gear-chain of a two weight front balance system according to the present invention.
Figure 65 demonstrates a perspective view of different sections (A, B, C) of a two weight front balance system according to the present invention.
Figure 66 demonstrates a sectional perspective view of a gear belt of the
gear connected to a motor driving the weight part, drive wheels carrying said weight part on the travelling path and a guide wheel ensuring that said weight remains in the guide channel of a two weight front balance system according to the present invention.
Figure 67 demonstrates (A) a top perspective view and (B) a bottom perspective view of additional weight parts of a two weight front balance system according to the present invention.
Figure 68 demonstrates an exploded view (A) and a sectional perspective view (B) of the mounting of gear belt of the gear connected to a motor driving the weight part on to the weight part, drive wheels for said weight part, a guide wheel ensuring that said weight remains in the guide channel and a guide wheel lock system of a two weight front balance system according to the present invention.
Figure 69 demonstrates(A) a side sectional perspective view of a midsize industrial washing machine drum comprising poly-ribs having a two-weights balance system applied around cylindrical drum surface at the front and rear side and drain system through drum perforations collect in a narrow zone and monitoring with pneumatic valves on water discharge chamber to drain via collection chamber and having gas burner in gas combustion chamber to heat drum and (B) close-up sectional perspective view of a pneumatic valve on water discharge chamber according to the present invention.
Figure 70 demonstrates an exploded side sectional perspective view of a mid size stone washing machine's drum having balance system to show balance weights moving system of the two weight balance system applied around cylindrical drum surface at the front and rear side on a drum comprising cylindrical abrasive rollers over the inner drum surface according to the
present invention.
Figure 71 demonstrates a perspective view of a complete two weight balance system and only moving systems of a two weight balance system comprising chain drive by geared electric motors to move balance weight according to the present invention.
Figure 72 demonstrates (A) a perspective view of moving systems of a two weight balance system having chain move on chain guide channel and geared electric motors to drive chain to move balance weights according to the present invention.
Figure 73 demonstrates a sectional perspective close-up view of the geared electric motor driving the balance weights on to the weight parts moving on weight guide path, drive wheels for said weight part, a guide wheel ensuring that said weight remains in the guide channel and a guide wheel lock system of a two weight balance system according to the present invention.
Figure 74 demonstrates a perspective view of (A) mounting of both weight parts along with motors having gears, (B) mounting of weight part closest to drum sheet along with motors having gears and (C) mounting of weight part farthest from drum sheet along with motors having gears in a two weight balance system mounted on the front of a household washing machine according to the present invention.
Figure 75 demonstrates a sectional perspective view of (A) mounting of both weight parts along with motors having gears and (B) metal weight embedded inside a plastic weight part of a two weight balance system mounted on the front of a household washing machine according to the present invention.
Figure 76 demonstrates (A) a perspective view of two rotatable liquid
container balance system comprise rotatable two counter balance container having balance liquid pump to pump liquid from one to other to create balance load mounted on roller stone washing machine drum and (B, C) perspective separate views of two rotatable liquid container balance system according to the present invention.
Figure 77 demonstrates perspective views of one rotatable liquid container and one counter balance weight to balance empty balance container system comprise an equilibrium liquid tank that has no effect on imbalance according to the present invention.
Figure 78 demonstrates (A) a perspective and (B) perspective close-up views of shaft and bed system of the drum mounted with sliding bed to sense movement of the drum by balance sensors according to the present invention.
Figure 79 demonstrates (A) a perspective view of boards wherein materials and equipment that need to be placed in a board on a drum with and without a cover and a close up detailed perspective view of a slip ring ensuring that required communications for electricity and fluid transfer to the drum are realized via drum shaft and rotating fluid connection element (B) from a sectional view of bearing-pulley parts on the shaft and (C) slip ring and hose channel on the shaft according to the present invention.
Figure 80 demonstrates a detailed perspective view of a slip ring ensuring that required communications for electricity and fluid transfer to the drum are realized via drum shaft and multiple rotating fluid connection elements connected to the hose channels opened on the shaft according to the present invention.
Figure 81 demonstrates (A) a perspective view of a rotating drum cover for
leak-proof covering of drum opening that is hinged to the drum and comprising a pneumatic lock system in a closed position and (B) a perspective view of rotatable circulation buffer on the fixed chassis security cover from the circulation inlet on the drum cover for leak-proof covering of drum opening that is hinged on the drum according to the present invention.
Figure 82 demonstrates a side sectional perspective view of a washing machine wherein the inside of the drum is covered by water channel grates showing the inlet of circulation line to the drum via cover of drum opening and rotatable circulation buffer on the security cover according to the present invention.
Figure 83 demonstrates (A) a close up detailed and (B) general perspective view of the open positions of drum cover of drum opening that is hinged on the drum and security cover hinged on the fixed chassis carrying the hinged cover rotatable buffer providing connection of circulation line to the drum at its center and (C) a side sectional detailed perspective view of a hinged cover rotatable buffer providing connection of circulation line to the drum cover hinged on the drum for covering drum opening via security cover hinged on the fixed chassis according to the present invention.
Figure 84 demonstrates a side sectional perspective view of a hinged cover rotatable buffer providing connection of circulation line to the drum cover hinged on the drum for covering drum opening via security cover hinged on the fixed chassis on a washing machine according to the present invention.
Figure 85 demonstrates (A) a side sectional perspective view and (B) a close up perspective view of a rotatable drum cover carried by security cover hinged on the fixed chassis via a rotatable bearing mechanism which covers the drum opening and is connected to circulation line according to the
present invention.
Detailed Description of the Present Invention
Explanation of the basic principles of the invention via Figures 1 - 9.
The figures illustrate a stone washing and spinning machine that is one of the important areas of application of the invention. As explained before one of the most important moving systems that are applied in the drum are rollers (201). Abrasive rollers (202) with grindstones are placed between lifter ribs (107) for stone washing. The rollers (201) can be rotated between bearings placed on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) of the drum sheet, at desired speeds via motors placed on drum rear circular base/shaft side (110) as in the front. A balance system (300) is mounted both on the rear along with the roller motors connected to moving parts (134) and on the front of the drum. The peripheral perforated narrow zone (510) is surrounded by a water chamber (500) on the sides, with its front and rear left uncovered. The front and rear sections of drum (104), which exist inside water tank/outer drum (101) in conventional machines, is removed from the tank by replacing the water tank in conventional machines with water chamber (500) that able to redesign using the system described in EP2229475. As described in this patent document, drum (104) has 10-20 times less number or size of holes compared to conventional drums, and said drum perforations/holes (105) prevented from being blocked by the materials by protruding structures placed on or next to said holes. Said drum perforations/holes (105) are positioned below rollers (201) that also serve as protruding structures within drum (104). Therefore, even though the number of holes is low, the discharge of water from drum
(104) is almost fixed at the desired flowrate. As drum perforations/holes
(105) are not blocked by the materials, draining water flow through
perforations in between the water barriers (122) on cylindrical perforated drum sheet (106) will flow through water chamber (500) to either the inlet of circulation pump (112) or to water storage chamber (504). Water, having flown from water chamber (500) to either the inlet of circulation pump (112) is pumped back into drum (104) in a controlled manner during the washing and rinsing cycles. The pumping capacity of said circulation pump (112) is higher than the flowrate of water exiting the drum, therefore water chamber (500) and water storage chamber (504) never overflows. As the front and rear of drum (104) are outside of the water chamber (500), these areas have no contact with water. Therefore different types of electric, pneumatic and mechanical systems other than motors directly connected to rollers (412), such as motor controlled balance systems (300) be mounted on the front and rear of drum (104), as can be seen from the figures. In the machine shown in Figure 6 in exploded view, it is possible to separate drum (104) and fixed chassis (111) where drum rotation motor (115) is located and water chamber (500) with pumping system together with machine front panel (119) where drum door (118) is located from each other. Therefore the weights of drum (104) and the bearing system for drum (104), as shown in Figure 7-A, are lightened.
Preferred embodiments of the present invention are described below.
1- The descriptions commence with water-free zones 100") and presence of water-free zones flOQj outside the drum via Figures 3-9, 29-34.
One of the objects of the invention is to provide dynamism and different functionalities to a drum (104) of a washing machine (50) wherein a cylindrical shape perforated drum (104) is made from a stainless sheet, and for some applications only some parts may be made from plastic. So inner drum (104) is very basic, important and indispensable part of the
conventional washing machine but also it is one of the simplest parts. Moving parts (200) drive with motors to move parts on the drum (130) by using energy such as electricity, pressurized air and steam, under control with electric, electronic, control systems (900) placed inside and/or outside drum (104) provide said drum (104), which is now more important part of a washing machine, with many new and useful functions that were previously unavailable. The present invention effectively overcomes the disadvantages of the drum (104) being placed in a water tank/outer drum (101) full of water.
The question that the invention seeks to answer is how to prevent the presence of water in the regions of the movement transfer system (401) moving these moving parts outside drum (251) when there is enough water in the drum (104) and when the water in the drum is drained at the end of the washing and rinsing cycles and also during high speed extraction it is inevitable that the water leaving the drum from perforations and passes into the water tank/outer drum (101). The first solution to come to mind will be isolation.
On the regional isolated area in movement system (142) or isolated unit in movement system (143) basis, isolation is possible, but due to their restrictions the preferred method is to prevent the ingress of water into the areas where movements systems are located without isolation. In other words, to render areas required for movement system outside the drum (104) are water-free zones (100).
Drum (104), at least a part of the drum (104) taken out of the water tank/outer drum (101) and especially clearing water from areas where systems that are dangerous to be placed and operated in water are located has paved the way for many new useful possibilities and applications on the
drum. Even though it is not necessary for the area where movement transfer system (401) is located to be free of water, it is preferable for the functionality and economy of the system.
In addition to being easier and more applicable than isolated areas in movement system (142) or isolated units in movement system (143), said method also makes it possible to use all kinds of mechanical, electric, electronic and control parts in movement systems (401) in the area between water chamber (500) for collecting water draining from the drum (104). In this manner, drum (104) is changed from a cylindrical perforated drum sheet (106) into a moving, dynamic and functional device, i.e. a machine by itself. It can be referred to as a machine, because even though the rotation of the drum stops, the systems on the drum can continue its operations which ensures that drum (104) remains functional.
2- Forming of water-free zones flOO ) in water chamber bv a circulation
pump (112) is explained below via Figures 1-3, 6, 8-11, 18-26.
The first step is to ensure that the limits and flow paths on water chamber (508) of water in water chamber (500) are determined, that the water remains in these areas and that the water level can be controlled. In other words, it is possible to turn areas on drum outer surface (104-s), where the presence of water is not required, into water-free zones (100).
To identify the water-free zones (100), means that there is no water inlet to the area which is partially constrained by the drum outer surface (104-s) which is referred to as water-free zones (100) of a part of the drum under all circumstances except in the case of an unintended fault, the system is out of control, despite all precautions and measures taken in the machine.
The areas that are always kept dry on drum outer surface (104-s) the drum
are water-free zones. (100).
Areas on drum outer surface (104-s) where water-free zone (100), i.e. the dry zone conditions cannot be obtained are areas where water drains from the drum. These areas can be determined as drum perforations/holes (105) part of drum inner surface (104-n) allowing water discharge from the drum and the gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108) that needs to be left gap around drum opening between drum and front panel (114) in-between drum (104) which is the rotating part and the fixed part unless additional precautions are taken.
In washing machines (50) known in the art, the water level in drum (104) is balanced out to the same level with the water level in water tank/outer drum (101) according to principles of communicating vessels. Water first fills up water tank/outer drum (101) and enters through perforations in to the drum (104) when water level reaches required quantities in the drum. In these washing machines, the main function of water tank/outer drum (101) is first to fill drum (104) with water and then discharge the water exiting the drum.
The task of the water reservoir (500) is to ensure the flow of the water leaving the drum from the shortest flow path on water chamber (508) to the circulation line (113) or the water chamber discharge line (511-d). When the definition of the outer drum is redefined as "the function of water chamber (500) is to ensure that water exiting the drum flows into circulation line (113) or water chamber discharge line (511-d) via the shortest flow path on water chamber (508), a big step will be taken in terms of providing to explain this system. When we defined in this way, the outer tank is no different from a sink or a bathtub. For example, similar to a sink or bathtub where the water from the tap flow out from the drain in everyday use and the drain can be
blocked to fill the sink with water and opening the drain after use so that the water can be drained.
Using this definition, there is no longer a need for an outer drum to be present outside of drum (104) of a washing machine (50). The function of outer drum, i.e. water chamber with the new shape (500), is not to fill the drum with water but to collect the water draining from the drum and direct it towards the water chamber drain outlet (503). Rather than a water tank/outer drum (101) wrap the drum completely, the water exiting drum (104) can be collected by water chamber(s) (500) placed only in areas where water discharge occurs.
It is possible to apply the systems proposed by the invention by turning areas outside those where the water exiting the drum flows into water chamber drain outlet (503) of water chamber (500) and areas where moving parts (200) are placed in water-free zones (100).
It is clear that in order to turn necessary areas on drum outer surface (104-s) into water-free zones (100) by simple water chamber barrier (511), there needs to be enough water in the chamber on the other side of chamber barriers to not pass through the barrier due to pressure. Going back to the sink example, in order to prevent water from overflowing, the sink needs to be sufficiently deep, the sides need to be steep and high and the water level in the sink needs to be below the overflow level. For this reason, water level outside drum (104) should not be high enough to reach the drum and water sensitive systems connected to said drum (300, 400, 900). In other words, while a sufficient amount of water is present in drum (104), the water level in water chamber (500) should under no circumstances be high enough to reach drum (104). Because the water in water chamber (500) can be kept constant at the desired level using the Eco-Drum system (61), the volume and depth
of water chamber (500) is irrelevant with respect to water consumption.
The systems according to the present invention prevent the water from passing into water-free zones (100) without need for using sealing elements such as gaskets or felts, even at the highest possible water level. Water build-up levels high enough to go over water chamber barrier (511) between areas containing water and water-free zones (100) and build-up of pressure enough to push water over should not be allowed. Structural water chamber barriers (511) are actually only barriers to direct water flow in order to keep the water in the desired area without overflowing.
To ensure that the areas required for the system outside the drum (104) are water-free zones (100), it was possible to implement the Eco-Drum system (61) as described in EP3252207 so that there was no water accumulated in the water chamber (500), outside the drum to reach the drum. According to the system explained in this document, the pumping flow rate is higher than draining flow from the drum (104) to the water chamber (500), will keep the water in the drum and keep at a desired level in the chamber that will prevent it from entering the water-free zones during the process requiring the presence of water in the drum. In other words to make sure that the water level stays low enough to prevent water from flowing into water-free zones using a circulation pump (112) having a pumping flowrate higher than the flowrate of the water flowing from drum (104) to water chamber (500), using the Eco-Drum system (61).
As long as the water exiting drum (104) is pumped back into said drum by a circulation pump (112), entry of water into water-free zones (100) will be prevented. However, depending on the treatment operation, it may be necessary to reduce the amount of water in the drum without discharging the water from the machine. In this case, circulation pump (112) will also need to
be stopped. When water in drum (104) has to be reduced or discharged as much as possible, there is a need for a storage space to store this water in the machine. This storage tank may be a water accumulation chamber (502) or a water storage chamber (504) connected to said water chamber (500). Water accumulation chamber (502) or water storage chamber (504) can be used to store water for a treatment operation of the machine as well as transferring water from one treatment operation to another. When a water accumulation chamber (502) or a water storage chamber (504) is present, the water level inside the drum can be changed in a controlled manner during the treatment operation. In addition, in case of a malfunction, all the water in the drum can be transferred to the storage space (502, 504) to prevent water from overflowing from water chamber (500).
Even if a water chamber capable of storing all the water when it is out of drum (104) is not present in the machine, reaching the water level and pressure allowing water to go over simple water chamber barriers (511) in water chamber (500) and into water-free zones (100) or overflow from the machine must be prevented. To achieve this, the water level in water chamber (500) must be continually monitored to ensure it stays below the desired limits and water must be discharged through a water chamber overflow line (511-o) if it goes above.
The logic here can be explained using an example from real life. If seawater filling a boat from a hole can be continuously pumped out of the boat using a pump having a flowrate higher than the inlet flowrate, then the boat will not sink. It the pump is stopped intermittently and the water level in the boat rises, if the pump is operated again before the water level becomes high enough to cause the boat to sink, the water can be discharged.
In order to achieve this, the water in water chamber (500) needs to be
pumped back into drum (104) at a flowrate higher than the drain rate of water from drum (104) to water chamber (500) under any circumstances as described in Eco-Drum system (61).
When the pumping capacity of circulation pump (112) is always greater than the drain rate of water flowing from drum (104) to water chamber (500), water chamber (500) and water accumulation chamber (502) can be completely emptied by collecting all the water in said water chamber (500) in drum (104). It should be noted that circulation pump (112) having a flowrate higher than the flowrate of the water exiting the drum is necessary not only to ensure water-free zones outside the drum remain dry but also to ensure the efficiency and sustainability of the treatment operation in the drum and also for water savings.
The capacity of the pump used to empty water chamber (500) can be reduced by reducing the drain flow rate of water from the drum to the water tank.
For this reason, placing drum perforations/holes (105) in drum (104) at locations where they won't be blocked by the laundry material and reducing their number and diameter will allow circulation pump (112) required to drain the water in water chamber (500) or control the water level to have reasonable capacity and size and economic energy consumption. Reducing the number and/or size of drum perforations/holes (105) will make it possible to limit the flowrate of water exiting the tank as desired. However, it is also important to ensure that the flowrate of water exiting the tank is constant. Therefore, blockage of drum perforations/holes (105) designed to control water permeability by materials being treated in the drum must be prevented. In this case, drum perforations/holes (105) must be positioned so that the materials cannot reach and block them completely. To achieve this, either
drum (104) must have a structure suited to preventing the materials from reaching drum perforations/holes (105), or drum perforations/holes (105) must be placed in the hollows between the protruding structures (261, 234, 240) placed on the surface of the drum or drum perforations/holes (105) must be placed in the effective area of the protrusions so that the materials cannot block most of the said drum perforations/holes (105). For drum (104) to have a structure suited to preventing the materials from reaching drum perforations/holes (105), the function of protruding structures (261, 234, 240) in drum (104) as described by the Poly-Rib system (60) must be fulfilled by other parts on drum (104) surface. For example, drum perforations/holes (105) positioned beneath or in the effective area of rollers (201) inside drum, fixed grindstone pieces (216) and similar parts can ensure that drum perforations/holes (105) are open to water flow.
3- The preparation of isolated areas in movement system in water
chamber according to the present invention is explained below via
Figure 39.
There are other methods to provide water-free zones (100) outside drum (104) needed to mount said moving parts (300-400) outside said drum. Moving on to more individual solutions than those described above, it is also possible to isolate desired areas outside drum (104) from a drum wet-outer surfaces (104-w) by suitable structural precautions such as water barriers(122) and using gaskets (530). It is possible to separate desired isolated areas in movement system (142) on drum (104) by an isolated areas in movement system (142) that can be opened as needed using sealing elements such as gaskets and felt.
Methods that are more separate than placing movement transfer systems (401) in isolated areas instead of water-free zones (100) can also be used. In
this case, some of isolated areas in movement system (142) applied against water entry can be applied by directly isolating the isolated units in movement system (143) instead of areal applications on the drum. Devices used within the system can be isolated for water individually or in groups or isolated units in movement system (143) that are operational in water and chemicals may be used.
To summarize, areas outside drum (104) that are defined as water-free zones (100) may be areas on drum outer surface (104-s) where contact with water is prevented using the technical or structural precautions presented by this invention, as well as isolated areas in movement system (142) for placing the devices outside the drum that are isolated against water entry or isolated units in movement system (143) of the devices mounted on the outside of the drum.
It is possible to apply isolated zones on a conventional machine for moving systems in the water tank on the drum. However, for this type of application, the main problem is to eliminate the malfunctions and service the maintenance because of the drum is completely closed by water tank. However, the application of the isolated areas in movement system (142) shall be a suitable solution for the installation of water sensitive parts of the moving system on the drum even mounted in the volume of the water chamber (500).
4- The preparation of water-free zones flOO ) on and around the drum shaft 103") and drum rear circular base/shaft side fllO ) of drum 104") according to the present invention is explained below via Figures 5-7, 10, 14-21.
When it becomes possible to form water-free zones outside drum (104), the first area to be considered will be drum shaft (103) and its surrounding drum
rear circular base/shaft side (110). As is known, in washing machines having a perforated drum (104) inside an outer drum, flow of water out from water tank/outer drum (101) is prevented by sealing elements such as felt or gasket placed between drum shaft (103) and the outer drum. When the need for said sealing system is eliminated, drum shaft (103), which is the point of connection between drum (104) and the outer drum, sealing system around shaft can be canceled. Shaft will become free and the simplest way to transfer energy or fluids to the drum. In conventional washing machines as known in the art, water tank/outer drum (101) and inner drum (104) need to move together, be a part of the same system, in short, be connected to each other due to the sealing elements used therein. Whereas if contact of water within the tank with the drum shaft is prevented using methods other than felt, there will be no need to use sealing elements around the drum shaft (103), inner drum (104) and water tank/outer drum (101) can be separated from each other. The separation of drum (104) and water tank/outer drum (101) allows for radical changes in washing machine design. When there is no need for drum shaft (103) felts, drum (104) can be removed from outer frame chassis (120) and moved along with drum chassis (529). Therefore water tank/outer drum (101) in the form of water chamber (500) and machine cover and drum door (118) connected to water tank/outer drum (101) become an independent chassis. This will especially provide ease or production and maintenance of large industrial washing machines (51).
Creating a water-free zones (100) starting from drum rear circular base/shaft side (110) where drum shaft (103) is connected to drum (104) towards the corner where drum rear circular base/shaft side (110) is connected to perforated cylindrical perforated drum sheet (106) will provide a suitable area to mount movement transfer systems (401) on drum outer surface (104-s).
When it is taken into account that there is constant water flow from drum perforations/holes (105) on perforated cylindrical perforated drum sheet (106) and the gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108), it becomes clear that the best place for placing moving parts (200) outside drum (104) and movement transfer systems (401) for providing movement thereto that will be mounted on the drum is drum rear circular base/shaft side (110). For this reason, it is preferable that drum rear sheet and drum shaft (103) and surrounding area are the first place to be cleared of water to provide water-free zones (100).
5- Isolation of isolated units in movement system (143~) or isolated areas in movement system (142) according to the present invention is explained below via Figures 10, 19, 20.
It is possible to use isolation precautions such as sealing, gaskets, chambers, covers and barriers to separate isolated areas in movement system (142) where motors, devices and equipment of said moving parts system (141) and parts belonging to movement transfer system that should not be in contact with water draining from the drum (104) are placed.
In an embodiment of the invention, if the area where movement transfer system (401) is placed is suitable, it may be preferable to use an isolated area in movement system (142) that is closed to water entry instead of a water-free zone (100). In particular, an isolated volume will be more preferable if the appropriate region in which the movable parts are to be located within the water chamber. It is possible to surround the all moving system, devices and parts in a fully isolated area using covers for isolated areas in movement system (142-w) with gaskets. However, it is very difficult to isolate and provide maintenance for the entirety of moving parts system (141) and parts. Whereas the water-free zones (100) system proposed by the
present invention makes it possible to place and operate under aqueous conditions even devices that are suitable for use at any place on a washing machine (50) with drum outside water chamber (500). It is obvious that the areas where moving parts system (141) is placed need to be water-free zones (100) for this to be possible. The present invention allows the placement of electrical drive electrical drive motor on drum (132) and/or electrical drive motor on fixed chassis (133).
In the present invention, some areas of drum (104) may be water-free zones (100) in a water chamber (500) or drum (104) may be taken mostly out of water chamber (500). In both cases, it won't be wrong to say that a section of the drum is a water-free zone (100). If drum rear circular base/shaft side (110) is a water-free zone (100) even though the entirety of the drum is in water chamber (500) as shown in Figures 10,19 and 20 as no water is present in this area of water chamber (500), it will be easy to reach and provide service to moving parts system (141) and movement transfer system (401) via the openings provided by water tank service doors (121) which are kept closed for security. A water tank having service doors to reach moving parts system (141) and movement transfer system (401) on the back of the drum, looks like a conventional water tank/outer drum (101) when said doors are closed.
6- Prevention of moving parts system (141) and movement transfer systems f401j from contacting water according to the present invention is explained below.
The most important reason why moving parts (200) are the subject of the present invention is that in conventional washing machines it was nearly impossible to apply mechanical, electric or electronic motor system (400) and movement transfer systems (401) placed water tank/outer drum (101) to a
drum (104) rotating in a water tank/outer drum (101) normally filled with water. The present invention allows the operation of movement transfer systems (401) needed to move moving parts system (141) inside/outside the drum in a controlled manner.
The elements that should not be operating in/contacting with the treatment water flowing from drum (104) to water tank/outer drum (101) from among motors, devices and equipment of moving parts system (141) and other parts belonging to movement transfer system (401) need to be placed in said water-free zones (100).
In the systems disclosed by the present invention, a substantial part of drum (104) is taken out of water tank/outer drum (101). This eliminates the possibility of getting affected by water. As there is no closed volume surrounding drum (104), it is not possible for water to find a way to flow into areas of said drum.
Despite this, the preferred embodiment may entail keeping drum (104) in the conventional water tank/outer drum (101) by preventing water access to drum front circular base/opening side (109) and drum rear circular base/shaft side (110) without changing the structures of drum (104) and water tank/outer drum (101). In this case, the water level in water tank/outer drum (101) can be controlled by the Eco-Drum system (61) described in EP3252207. Therefore, water is conserved and the water in water tank/outer drum (101) is prevented from reaching drum front circular base/opening side (109) and drum rear circular base/shaft side (110). As shown in Figures 10, 19 and 20 even though drum (104) is immersed completely in water tank/outer drum (101), it will be possible to mount and operate mechanical, electrical and pneumatic movement transfer systems (401) on drum front circular base/opening side (109) and drum rear circular base/shaft side (110).
7- Moving parts inside drum f250T moving parts outside drum G251T and the techniques of driving said parts using a movement production motor system G400T movement transfer systems (401) and electrical, electronic, control systems (900) according to the present invention is explained below via
Figures 3-9, 11-18, 31, 32, 36-45.
Mounting moving parts (200) on a perforated drum (104), which rotates horizontally or at an angle with the horizontal axis and is placed inside a water tank/outer drum (101) with drum shaft bearing (102) on closed circular base side and loaded and unloaded from the opening on other circular base, or both circular bases with drum shaft bearing (102), load and unload from the opening on cylindrical surface to assist the functioning of said drum is not a method that is known and used currently. Household washing machines (57), commercial washing machines (56) and industrial washing machines (51) that operate within a water tank/outer drum (101) have drums (104) made of only metal and plastic. These drums do not have moving parts or devices consuming energy, such as electricity, pressurized air or fluids, mounted thereon. However, today it is possible to obtain mechanical, pneumatic, electric, etc. devices that can operate under all manner of conditions. Current technology allows the production of such devices, even if they have not been made before. Mounting of isolated units in movement system (143) on drum will allow use of movement transfer systems (401) and electrical, electronic, control systems (900) on the drum along with multiple moving parts (200) as disclosed by the present invention in washing machines (50). Even though it is possible to apply isolated units in movement system (143) produced to be resistant to effects of water and chemicals in accordance with IP codes and international standards onto available washing machines without changing them; that has not been realized so far. Because isolated units in movement system (143) having the aforementioned
functions have higher production costs and are harder to maintain when mounted on drum (104) covered completely by water tank/outer drum (101), it can be seen that it would be more advantageous to create water-free zones (100) on drum (104) without needing to use special isolation precautions.
One of the aims of the present invention is to add dynamism to the rotation motion of drum (104) by adding moving parts (200) driven by a movement transfer system (401) comprising a motor outside or both inside and outside said drum, moving parts inside of the drum (250) that are placed inside the drum (104) add processing dynamism to the machine's intended use and increase the performance of the operation and provide savings.
Moving parts (200) mounted inside (250) and/or outside (251) drum (104) so that they can move in a controlled manner will increase the efficiency of the machine and therefore provide savings in resources such as water, energy, chemicals and time.
A function of the invention is providing controlled movement of said moving parts (200) by motors connected to moving parts (134) or via movement transfer systems (401).
Said moving parts outside drum (251) may be moved to rotate, oscillate or vibrate. As rotation is the easiest among these to apply and has the highest efficiency, rollers (201) providing rotational motion will be the most commonly utilized moving parts.
Rollers will be able to realize the dynamism claimed by the system by rotating the full rotations in the cylindrical structure of the drum (104) without any limitation. The most important advantage of rollers (201) driven directly by motors connected to moving parts (134) is that it allows rollers (201) to be rotated at desired speeds by controlling the speed of said motors connected
to moving parts (134). Rollers (201) can be completely stopped when necessary and can be rotated at very high rotation speeds within the limits of motors connected to moving parts (134) and roller bearings (205) when necessary. For the moving parts (200) on drum to move in the desired way in a controlled manner, motor system (400), mechanical movement transfer system (401), electric and electronic control systems (900) need to be present on drum (104).
The present invention proposes methods for operating movement transfer systems (401) required to move moving parts inside/outside drum (250, 251) in a controlled manner even in conditions where water is present.
The system proposed by the present invention discloses methods for smooth operation of necessary equipment mounted on drum (104), referred to as "movement transfer system (401)" and comprising motors, pump, valves, pistons connected to drum (104) to provide controlled movement of moving parts (200) and electricity, pressurized air and steam system to use with them, movement transfer systems (401) such as pulleys, gears, belts, chains, etc. and related equipment such as sensors, control systems, electrical and electronic systems, cables, hoses and other connection equipment and auxiliary devices and electric system panels on drum (901) where these devices are placed.
8- The moving parts inside of the drum f250 ) which increase the physical effect within the drum (104) presented in accordance with the present invention will be described below via Figures 3-9, 11-18, 31, 32, 36-45.
All of the treatments done in drum (104) require physical effect and dynamism in varying degrees. This is the reason for the rotation of the drum. Increasing the movement within drum (104) will increase the efficiency and
decrease the operation time of wet and dry treatment operations such as washing, dyeing, stoning, polishing and brushing.
The main function of moving parts inside of the drum (250) is to increase the physical effect provided by the rotation of the drum. For example, in a front- load washing machine (50) with drum the rubbing effect obtained by the friction between the materials and dropping materials from the top of the drum during the rotation of the drum will be increased by placement of brush rollers (203) in the drum. In addition, it also becomes possible to obtain physical effects that cannot be obtained only by the rotation of drum (104). For example, while it is not possible to impart a stoning effect to the material only by the rotation of drum (104) without adding abrasive materials into the drum of a stone washing machine, addition of moving abrasive parts in the drum will make this possible.
In this way, moving parts (200) added into drum (104) perform functions such as, mixing, shuffling, rubbing, fluffing, stoning and brushing the materials undergoing treatment in the drum.
The physical effect that until today had been produced only by the rotation of drum (104) will increase significantly by the movement of parts suitable for the treatment in drum (104). Compared to treatments using pumice stone or similar abrasive materials in an industrial stone washing machines (54) providing abrasion on textile surfaces, stoning treatments performed by rotating grindstones/abrasive rollers (202) inside drum (104) will take a much shorter time. In this way one stone washing machine according to the invention will be able to perform the task of two or three conventional stone washing machines in the same time period.
Another importance of placing the rollers drive directly by the motors in
controlled manner into the drum is that the rollers can be rotated at the desired speed from very slow up to very high speed.
9- Water tanks according to the present invention, namely, water chamber (500), water chamber surrounding partially perforated cylindrical drum surface . water chamber surrounding around whole perforated
cylindrical drum surface are explained below via Figures 3-9, 11-18, 31, 32, 36-45.
Water tank/outer drum (101) placed outside drum (104) in currently available horizontal washing machines serve the purpose of collecting water draining from the drum (104) as well as filling water into said drum. In order to limit water consumption, the distance between water tank/outer drum (101) and drum (104) is kept as small as possible. It is also important that the volume of water tank/outer drum (101) below drum (104) bottom level is as small as possible in terms of water consumption. On the other hand, as the water level in water tank/outer drum (101) is controllable using the Eco-Drum system (61) described in EP3252207, the system of the present invention proposes a large storage volume under drum (104) where a certain amount of water may be collected, and all the water in the washing machine may be collected without coming into contact with drum (104) when necessary. As the water volume under drum (104) will be controlled by the system and can be drained by the pump, its size is irrelevant to the amount of water consumption. When the Eco-Drum system (61) is applied, on the section of drum (104) where drum perforations/holes (105) are located will become wet. If the perforated area is restricted by water barriers (122, 511); the overflow of water being discharged from drum (104) from this area can be prevented. In this embodiment, the areas outside water barriers (122) will be water-free zones (100). Additionally, it is not necessary for a structure that
will only be used to collect water exiting drum (104) to fully envelop said drum (104). A water chamber (500) surrounding drum (104) only in the manner to collect water exiting said drum (104) as around perforated surface and around drum entrance. Until today, the main reason for the closed volume outside the drum to be referred to as water tank/outer drum (101) was that it was filled with water. However, in the system proposed by the present invention, the volume surrounding the drum should never be filled with water. Because these volumes are always empty and only serve the purpose of directing the water exiting the drum towards the discharge outlet, it is more appropriate to refer to said volumes as water chamber (500) instead of water tank/outer drum (101) to avoid confusion.
As water exits drum (104) from drum perforations/holes (105) and the gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108), it is possible to collect water exiting the drum by placing water chambers (500) at these areas if desired.
10- A water storage chamber ('504’) in communication with a water accumulation chamber ('502’) positioned in a water chamber according
to the present invention is explained below via Figures 3-8, 10, 14-23.
In contrast to conventional washing machines (50), it will be beneficial for a system according to the present invention to comprise a water accumulation chamber (502) below the water chamber (500) which has the capacity to store partially or all the water in the drum (104) when necessary.
This storage volume may be in the form of a water accumulation chamber (502) directly inside water chamber (500) or it may be a separate volume as water storage chamber (504) in communication with a water chamber (500) with a water chamber-water storage chamber connection (507) serving the
function of collecting and storing water from drum (104) when necessary.
It must be ensured that the water draining from the drum (104) flows directly to water accumulation chamber (502) or water storage chamber (504) without entering water-free zones (100) in water chamber (500). If water chamber (500) needs to not have water within in order to keep the whole required water in drum (104) constant, the water entering the water tank is continuously pumped back into said drum by circulation pump (112) as described with Eco-Drum system (61).
If the areas where movement transfer system (401) in water chamber (500) and required devices thereof are placed is desired to be kept water-free, then they need to be placed above the maximum water level that water accumulation chamber (502) can reach.
11- Methods of controlling the water level in water chamber fSOQj according to the present invention are explained below.
While the main functions of water accumulation chamber (502) and water storage chamber (504) are to keep water from the drum so that water chamber (500) does not overflow in case of an expected malfunction and by controlling water level in the water chamber (500) also be used to adjust the water level in the drum with circulation pump (112) control. They can also be used to change the amount of water in drum (104) and temporarily store the water required at a different stage of the treatment operation when necessary. Even if water accumulation chamber (502) is filled with all the water that can be used by the machine, it should be able to prevent water level from reaching up to overflow level.
One of the important aspects of the invention is defining the physical conditions, dimensions and depth of the boundaries of flow path on water
chamber (508) on water chamber (500). The water chamber (500), which provides the appropriate size and conditions, allows the water draining from the drum to reach the water chamber drain outlet (503) by preventing it from flowing out of the flow path on water chamber (508) between the water chamber barriers (511).
Water flow paths/water ways are structures facilitating flow of water between two locations, wherein water does not go beyond their boundaries even though they are at least partially open. While pipes are closed systems, water channels are open from the top. Even though water ways are open, when they are designed and controlled carefully they can transfer water from one location to another. Water channels are water ways with defined boundaries. This is the basic principle applied on the outside of drum (104). While until today, water tanks/outer drums (101) wherein drums (104) rotate were closed systems, water chambers (500) proposed by the invention form of flow paths on water chamber (508) directing water exiting from drum (104) to the discharge outlet.
12- The placement of a portion of drum (104) outside water chamber (500) and solution for the problem about steam that coming out from the machine according to the present invention are explained below via Figures 1-9, 11, 14, 16-18, 24, 29, 32-34.
In front-load washing machines (50) having a perforated drum (104) that is rotates inside a water tank/outer drum (101). The system proposed by the invention wherein a portion of the drum starting from drum rear circular base/shaft side (110) is a water-free zone (100) adds a new dimension to washing machine design. There is no need for water-free zones (100) to be inside water tank/outer drum (101). In this case, water-free zones (100) can be taken out of water tank/outer drum (101). Looking at it this way, it would
not be correct to talk about the existence of a water tank/outer drum (101). For this reason, it would be more correct to define the structure outside of drum (104) that collects water exiting said drum (104) as a water chamber (500) rather than a water tank/outer drum (101). In other words, it is possible to refer to the structure that is usually referred to as water tank/outer drum (101) in cases where water reaches ever part thereof, as water chamber (500) when drum (104) becomes visible from the outside.
As it is necessary for there to be water exiting drum (104) and collection of said water by a water chamber (500), it is sufficient to place water chamber (500) around the areas where water exists drum (104) in order to collect said water.
Placement of mechanical, electric, electronic devices and all auxiliary parts and equipment belonging thereto of movement transfer system (401) on drum (104) and/or moving parts system (141) outside drum in areas outside water chamber (500) will make it easier to provide periodic maintenance or repair services in case of malfunction.
Drums (104) of conventional washing machines are generally parts that don't require a lot of maintenance. However, addition of moving mechanisms and electric and electronic movement transfer systems (401) to drum (104) will require more frequent maintenance and parts replacements. Therefore, it will be advantageous to provide service to areas easily reachable from the outside rather than areas inside a water tank/outer drum (101).
Creating water-free zones (100) within water chamber (500) and preventing water entry to areas where moving parts (200) of moving parts system (141) outside drum and movement transfer system (401) are placed do not protect these areas from the effects of steam. As washing machines can provide
services at temperatures above the boiling point of water when necessary, it is not possible to prevent steam from exiting the areas confining the water by water chamber barrier (511) and entering water-free zones (100). In other words steam easily goes out not only from water chamber (500) but also from the washing machine. Existing steam from water chamber (500) contacting with the water-free zones (100) may also contain chemicals. When steam condenses on the parts constituting movement transfer system (401), it is expected that it causes corrosive effects to said parts as well as many other problems. In this case, the steam coming out of the water chamber must be aspirate by a fan and removed from the machine properly. Solutions for this application are known from various examples in the art.
13- The case where water chamber fSOCD is a chamber surrounding whole wet parts of the drum G505 i.e. front and sides surfaces according to the present invention is explained below via Figures 8, 9, 22-27, 29.
The water drain from the drum is from the drum inlet opening gap around drum opening between drum and front panel (114), except the drum perforations/holes (105) in the cylindrical perforated drum sheet (106). The structure of the drum entrance/inlet opening (108) is different in household washing machines (57) and industrial washing machines (51). Household drum door (617) closing household drum entrance/inlet opening (608) of household washing machines is on household frame frontal sheet (618) of household outer frame (616) and there is also a flexible household drum door bellows (614) between the door and the outer drum to prevent water from leaking out of the outer drum. On the other hand, industrial washing machines do not have a door bellows and instead drum door (118) is connected to machine front panel (119) which is also the front sheet of the drum. In both types of washing machines, the water leaving drum opening
(108, 608) reaches outer drum via the space between the outer drum and drum (104, 604).
As water exits drum (104) from around drum entrance/inlet opening (108) and from drum perforations/holes (105), the fluid communication between flow path on water chamber (508) and water-free zones (100) must be completely severed while the transfer of water from said drum opening and said drum holes is directed. Solutions other than the known method of forming a flow path on water chamber (508) in known conventional water tank/outer drum (101) by taking precautions may be suggested for directing the water exiting drum (104) from around drum entrance/inlet opening (108) and from drum perforations/holes (105) to water chamber (500). As the water in water chamber (500) will not under any circumstances be collected outside of water accumulation chamber (502) placed at the bottom of said water chamber (500), presence of water chamber barrier (511) for preventing water from leaving water flow path on water chamber (508) wherein water flows from drum (104) to water accumulation chamber (502) will facilitate formation of water-free zones (100).
Considering that movement transfer system (401) is concentrated on drum rear circular base/shaft side (110), taking this area out of water chamber (500) is the safest way to cut out fluid communication of water from the chamber with said movement transfer system (401).
When water chamber (500) for collecting the water leaving drum (104) is designed in a way to leave drum rear circular base/shaft side (110) outside, it will be a water chamber close whole wet parts of the drum surrounding drum front circular base/opening side (109) and perforated cylindrical perforated drum sheet (106) as exemplified in Figures In terms of design and appearance, said water chamber resembles a customary half water
tank/outer drum (101) without a rear sheet. So from now on this water chamber surrounding whole wet parts of the drum will be referred to as a half water chamber (505)
Said half water chamber (505) must contain water chamber barrier (511) systems designed to prevent water flowing from drum (104) to water chamber (505) at the edge portion at drum rear circular base/shaft side (110) from leaving half water chamber (505).
As said half water chamber (505) is ended at the edge portion where perforated cylindrical perforated drum sheet (106) and drum rear circular base/shaft side (110) meet, the rear of the drum is outside the tank.
14- Water chamber around drum opening gap at around the drum gap
around drum opening between drum and front panel (114) around drum entrance/inlet opening 108") according to the present invention is explained below via Figures 5, 6, 8B, 22-27, 34A, 34C, 50, 52, 54A, 55B.
If a moving parts system (141) outside drum is present on drum front circular base/opening side (109), it would be advantageous for this section to be a water-free zone (100) as well. As balance system (300), which is one of the systems proposed by the invention, will be mounted on the front sheet or cylindrical surface at the front part of the drum, in drums having a balance system, drum front circular base/opening side (109) must have a water-free zone (100). It is possible to create the conditions for a water-free zone (100) on drum front circular base/opening side (109) in half water chamber (505) surrounding the gap around drum opening between drum and front panel (114) where drum entrance/inlet opening (108) and drum perforations/holes (105) are. However, as difficulty in providing service and the effects of steam will cause problems for the aforementioned reasons, taking drum front
circular base/opening side (109) also out of water chamber (500) will be a good solution. Especially in cases where a balance system (300) is mounted on the front of drum (104), it would be very advantageous for drum front circular base/opening side (109) to be easily accessible for the smooth operation of the system and for providing maintenance and repair services. The system applied to drum rear circular base/shaft side (110) can be applied to different sections of drum (104). In this way, other sections of drum (104) can be taken out of water chamber (500). In other words, water chamber (500) may be in the form of water chamber surrounding only perforated cylindrical drum surface (501) applied only to necessary areas on drum (104) to collect water exiting said drum (104). To achieve this, a water chamber around drum opening gap (506) formed to surround drum gap around drum opening between drum and front panel (114) around drum entrance/inlet opening (108) can collect the water exiting from said drum opening and directing it to water chamber surrounding partially perforated cylindrical drum surface (501) or a water accumulation chamber (502) via a water chamber- water storage chamber connection (507) pipe connected below.
Dividing water chamber (500) into a water chamber around drum opening gap (506) for collecting water exiting from drum opening gap around drum opening between drum and front panel (114) and water chamber surrounding partially perforated cylindrical drum surface (501) for collecting water exiting drum perforations/holes (105) provides a practical solution to the problem of taking drum front circular base/opening side (109) out of water chamber (500) like drum rear circular base/shaft side (110). In this way, when the water chamber (500) is divided into two sections (501, 506), the area left between will be a water-free zone.
Using water chambers (500) mounted only onto areas where water exits the
drum instead of a water tank surrounding the entire drum will both make it easier to provide service to the outside of the drum and save on materials and labor for producing said water tank and make the washing machine lighter.
As exemplified in Figures 5, 6, 8, 22-27 water chamber around drum opening gap (506) positioned to surround drum opening gap around drum opening between drum and front panel (114) contains a water chamber- water storage chamber connection (507) below for transferring the water exiting drum (104) to a water collection or storage tank.
In conventional industrial washing machines (51), drum door (118) connected to water tank/outer drum (101) must be connected directly to the front sheet, namely machine front panel (119) of the machine along with water chamber around drum opening gap (506). In conventional washing machines, said machine front panel (119) also covers the front of water tank/outer drum (101). In the new system, the front sheet/machine front panel (119) is directly connected to fixed chassis (111) of the machine. In this way, communication of drum door (118) and water chamber around drum opening gap (506) with drum-perforated area-water chambers (500) for collecting water exiting drum holes will be completely severed. And in industrial washing machines (51), drum door (118) will be directly connected to outer frame chassis (120), in other words fixed chassis (111) of the machine.
As exemplified in Figures 50, 52, 54A, 55B because household drum door (617) is on household outer frame (616) in household washing machines (57) there is a household drum door bellows (614) at the household drum entrance/inlet opening (608) covering the area between the drum and household drum door (617). However, as there is no need for the drum opening water chamber to be in the same system as the drum in the system
proposed by the invention, household drum opening water chamber (615) may be on household outer frame (616), i.e. on the fixed chassis system. In this case there will be no need for bellows and it will be possible to connect household drum door (617) to household drum opening water chamber (615) in household washing machines (57) as with industrial washing machines (51).
If the machine to which a system as exemplified in Figures 34A, 34C is applied is an industrial washing machine (51), it is possible for the exiting water to be pumped directly back into the drum by a drum opening water collection chamber circulation pump (528) connected to the household drum opening water chamber (615) outlet instead of connecting water chamber or other tanks.
As is known, in free standing washing machines, water tank/outer drum (101) is connected to fixed chassis by spring and suspension systems and water tank/outer drum (101) moves freely due to the imbalance during the spin cycle. In the case where a balance system (300) is also present in the washing machine according to the present invention, said machine can be a hard mounted machine. This means that no connection element can perform an elastic movement beyond stretching within the bounds of material tolerance in the machine including the chassis. In this case, even though drum (104), water chamber (500), outer frame of the machine (117) and drum door (118) are separately mounted to fixed chassis (111), they cannot move with respect to each other and so it will be possible to decrease the gap around drum opening between drum and front panel (114) between drum entrance/inlet opening (108) and drum door (118) and water chamber around drum opening gap (506) or drum (104) and water chamber (500) compared to free standing machines wherein all said parts are on the same
chassis. As limiting the distance between drum (104) and drum door (118) will significantly decrease water leaking with the help of additional barrier systems, a small drum opening water collection chamber circulation pump (528) connected to water chamber around drum opening gap (506) will be able to pump the water exiting from drum opening gap around drum opening between drum and front panel (114) back into the drum.
15- Water chamber surrounding partially perforated cylindrical drum surface surrounding the portion of the drum where drum holes are located according to the present invention is explained below via Figures 5 and 22. 1-4, 6, 8, 9, 19-26 32-34, 45, 46.
When a water chamber surrounding only perforated cylindrical drum surface (501) is placed in the area where drum perforations/holes (105) are located, the water exiting from said drum holes can be directed to circulation pump (112) pumping the water directly back to the drum or a water storage chamber (504) via a water chamber drain outlet (503). With this design, water tank/outer drum (101) that consisted of one piece until today will be divided into two or, necessary, more sections referred to as water chamber surrounding partially perforated cylindrical drum surface (501) as exemplified in Figures 5 and 22. Because a smaller water chamber surrounding partially perforated cylindrical drum surface (501) will be more practical and economic, it will be advantageous to use an embodiment comprising drum perforations in peripheral zone (509) placed in a peripheral perforated narrow zone (510) in this system. As exemplified in Figures 1-4, 8, 9, 23-26 and 32-34, peripheral perforated narrow zone (510) can be placed on one or more positions on the drum. In other words, having drum perforations in peripheral zone (509) only in the area(s) surrounded by water chamber surrounding partially perforated cylindrical drum surface (501) will be
advantageous is many respects. In this manner, the cylindrical sheet of the drum will be a cylindrical drum sheet peripheral perforated narrow zone (510) wherein said drum perforations in peripheral zone (509) are placed in peripheral perforated narrow zone (510) will have the appearance of a cylindrical sheet without holes. Water chamber surrounding partially perforated cylindrical drum surface (501) for water exiting from drum holes can be placed around the middle, front or rear of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510). In this case, as drum perforations in peripheral zone (509) will be only in this area, it must be ensured that the water in the drum flows towards this area. Having a drum sheet that is a Conical drum sheet perforated in the narrow belt zone (512) with a conical structure to ensure that said drum sheet is sloping towards the area where the holes are located will assist in the flow of water towards the area where the holes are located.
If drum holes in peripheral band zone (509) are distributed on the conical or cylindrical surface in groups in multiple peripheral perforated narrow zone (510), it will be required to utilize multiple drum-perforated area-water chambers (500).
A flow path on water chamber (508) may be formed by structural obstacles and barriers to prevent water from overflowing outside from between water chambers surrounding drum opening and drum holes and the drum. As exemplified in Figures 6, 9, 19-23, 25 and 26 overflow of the water flowing from drum (104) to water chambers surrounding around partially perforated cylindrical drum surface (501) from said water chamber limits can be blocked by a water chamber barrier (511) placed on water chamber surrounding partially perforated cylindrical drum surface (501) and corresponding external water barriers (122) placed on the drum. The function
of the barriers on water chamber surrounding partially perforated cylindrical drum surface (501) is to prevent water at the bottom of the tank from overflowing into water-free zones (100) of water chamber surrounding partially perforated cylindrical drum surface (501) and overflowing out of water chamber surrounding partially perforated cylindrical drum surface (501). The function of external water barrier (122) placed on the drum is preventing water exiting the drum from overflowing past water chamber barrier (511) while being flung by the rotation of drum (104) during the spin cycle and wetting every surface of flow path on water chamber (508) in water chamber (500). Water barriers may be positioned in single lines opposite each other and side by side or they may have a multiple cascading structure in the form of successively positioned sets as exemplified in Figure 45, 46.
16- The connection of water chambers to fixed chassis (111) is
explained below via Figures 1-6, 8, 22, 23, 29.
Especially in conventional washing machines (50) having sealing elements between drum shaft (103) and water tank/outer drum (101) to prevent water leaking from drum shaft (103) require water tank/outer drum (101) to move with drum (104), therefore the two parts must be mounted onto the fixed chassis together as a single unit. This is especially imperative for structures having a freestanding drum-water tank chassis. In the system proposed by the invention, due to the possibility of creating water-free zones (100), there will be no need for a sealing element, which is the main reason for the connection between drum shaft (103) and water chamber (500). Therefore regardless of whether drum chassis (529) has a flexible or fixed structure, water chambers (500) can be detached from drum (104) and mounted on fixed chassis (111). Because the drum, the water chamber, half water
chamber or water accumulation chamber may be mounted on the fix chassis separately, they will become independent systems. In this way, it will be possible to separate these two fundamental parts of the washing machine from each other as shown in Figures 1-6.
In the system wherein water leaving drum (104) through drum perforations in peripheral zone (509) in the rear section of said drum (104) is collected by a water chamber surrounding partially perforated cylindrical drum surface (501) and directed towards a water chamber drain outlet (503), said water chamber surrounding partially perforated cylindrical drum surface (501) can be centered by drum shaft bearing (102) on drum shaft (103) and fixed in place by a connection to fixed chassis (111). Whereas in conventional washing machines, water tank/outer drum (101) is connected to the frame and also serves to carry drum (104). In embodiments where an outer drum according to the disclosure of the present invention is not present, drum (104) will be carried by drum shaft bearing (102) fixed on the fixed chassis (111). In this way, it will also be possible to take water chamber (500) out of drum shaft bearing (102) system. One of the important results of the proposed system is the separation of the drum and the tank system completely.
Especially considering that in a washing machine having balance system (300) proposed by the present invention drum (104) does not oscillate, connecting water chamber (500) to fixed chassis (111) will have many advantages. Figures 5, 8, 22, 23 and 29 show water chambers (500) connected to machine front panel (119) via tank-front panel connection (522) or to front chassis (11) simultaneously carrying the drum via fixed tank-drum chassis connection (523) at the same time.
Mounting water chambers (500) on fixed chassis (111) of the washing
machine, as separate parts independent from the drum system will make both the water tank/outer drum (101) system and the drum (104) system much lighter and make it possible for the main chassis of the washing machine to be much lighter as well.
An important point to consider is that, unlike freestanding conventional washing machines, drum (104) does not oscillate or vibrate on the springs and suspensions during the spin cycle. A drum (104) rotating under fixed chassis conditions will allow the space tolerance between parts to be kept at the minimum. On the other hand, if there is enough tolerance left between drum (104) and said water chambers (500), this will cease to be a problem and it will be possible to apply structures such as water-free zones (100) and water chambers (500) to said free mounted washing machines.
17- Use of a discharge system to prevent steam/aas leaking from the water chambers according to the present invention is explained below via Figures 24A, 26A, 27A.
It has been mentioned above that by taking water-free zones (100) out of water tank/outer drum (101) or water chamber (500) devices placed in these areas (400-900) are protected from negative pressure effects caused by the steam generated due to the high water temperature in the drum. Also some of the washing processes need to inject harmful gas into the drum. We have to avoid also uncontrolled gas leakage from water chambers. However, as structural barriers preventing water drain or leakage do not prevent steam or gas leakage, steam and gas will continue to leak out of drum (104) and water chambers (500) having water-free zones (100).
With additional measures to be taken it is possible to prevent steam and gas leaking out from of water chambers (500) and entering into water-free zones
(100) also means surroundings from wet zones through water chambers (500).
The hot air, steam and also gas exiting from drum perforations/holes (105) or drum entrance opening will go into water chamber (500). In machines where water tank/outer drum (101) is completely closed off, steam is discharged via a ventilation flue at the top of water tank/outer drum (101). It is possible to place a similar steam/gas flue outlet from water chamber (513) on the top section of water chambers (500). Water chamber (500) surrounding drum (104) being open to the atmosphere around the periphery of drum (104) does not impose of all steam outflow occurring from said steam/gas flue outlet from water chamber (513).
In order to prevent steam or gas from leaking out of drum wet-outer surfaces (104-w) where it is formed, a steam/gas flue fan (514) having a suitable flowrate to provide negative air pressure in drum wet-outer surfaces (104-w) must be used. Placing said steam/gas flue fan (514) so that the inlet is at the ventilation flue at the top of water chamber (500) will aid in collecting the hot water at steam that naturally moves upwards.
Air with steam or gas can be directed outside by the steam/gas flue fan (514) via suitable discharge and steam/gas flue chimney systems (515). If there are no discharge means in the system for air with steam, the air steam mixture or is passed through a condenser, and steam is separated from air by condensing.
This method will prevent steam from entering water-free zones (100) within water chamber (500) and from leaking out of water chamber (500).
The gasket at the outside of the chamber (530), which is mounted on the circular outer surface of the water chamber (500), so as to cover the gap
between the circular outer surface of the drum and the circular outer surface of the chamber, adheres to both circular elements mounted at the same alignment and provides sealing with negative pressure created by the suction of steam/gas flue fan (514) in the reservoir.
18- The features of the drum and drum holes in narrow band forming a peripheral perforated narrow zone f51C0 according to the present invention is explained below via Figures 2, 3B, 4, 8, 9, 28, 30-34, 45,46.
Making the area where drum holes are placed narrower and placing said drum holes in a peripheral perforated narrow band zone (510) on cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) in order to make use of the advantages of the invention by making water chamber (500) as small as possible will be an advantageous embodiment for making water chamber (500) narrower and creating water-free zones (100) that are as wide as possible on the surface of drum (104).
Placing drum perforations in peripheral band zone (509) within the boundaries forming peripheral perforated narrow band zone (510) in the rotation direction of and peripherally surrounding the drum and also within the areas where water exit from cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) is possible will make it possible to limit the size of, narrowing the width of and decreasing the volume of water chambers (500). The narrower the limits of the area where peripheral perforated narrow zone (510) where drum holes are located are, the narrower the water chamber (500) can be. If drum perforations in peripheral zone (509) are located close to the rear sheet of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510), this will provide an advantage for application of solutions for speeding up water exit from drum (104) and sizing and mounting solutions for the water chamber.
19- The rotation axis of the drum having an angle with the horizontal axis and the conical structure of the perforated drum according to the present invention are explained below via Figures 8, 11, 29, 34, 45, 46, 49, 50,
52-59.
In conventional washing machines, drum perforations/holes (105) are distributed homogeneously throughout cylindrical perforated drum sheet (106). This is necessary because drum outer surface (104-s) is essentially horizontal and flat. Otherwise, water discharge from drum (104) during wash and spin cycles would be inefficient and take a long time. The laundries, which is spread over the perforated drum surface during draining and spin extraction stage, causes most of the drum holes to close, blocking water outflow. On the other hand if drum perforations in peripheral zone (509) for water to exit drum (104) are only placed in one area at the rear of drum (104), the time needed for all the water that needs to exit drum (104) will cause the draining and extraction get much longer. It will be necessary for water to flow as fast as possible over the surface of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) in the area from the front of drum (104) to the rear where no holes are located. If drum perforations in peripheral zone (509) are located at the rear side of drum (104), placing drum (104) in an inclined way so that drum front circular base/opening side (109) is up and drum rear circular base/shaft side (110) is down will speed up the water flow towards the rear of drum (104). In this way, the water will flow towards the rear of drum (104) during discharge and exit through drum perforations in peripheral zone (509) located in the rear into water chamber (500) and will flow through water chamber-water storage chamber connection (507) and reach water storage chamber (504).
If the rotation axis of drum (104) is positioned to make an angle with the
horizontal axis enough to facilitate water flow from the surface of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) towards drum perforations in peripheral zone (509), water will flow from all over drum (104) towards peripheral perforated narrow band zone (510).
While it is possible for the drum to be positioned to make an angle with the horizontal axis so that water can flow towards peripheral perforated narrow band zone (510) where drum perforations in peripheral zone (509) are located, it is also possible for the drum to be a conical drum sheet perforated in the narrow belt zone (512) so that the flow direction of water is towards where drum perforations in peripheral zone (509) are located. Both of these options will ensure that flow of water within drum (104) is towards where drum perforations in peripheral zone (509) are located.
20- The formation of water channels/Polv-Channels within drum fl04j
according to the present invention are explained below via Figures 2, 24, 25, 27, 28, 30, 34, 46, 49, 50, 52-56, 69, 82, 83, 85.
While drum (104) having a conical shape or being positioned to make an angle with the horizontal axis is a functional solution when said drum (104) is empty, it will lose its functionality once drum (104) is filled with materials obstructing the water flow. Despite the angle created for flow, water will have to flow between the materials blocking the flow path on the drum inner surface (104-n). The barrier formed by materials strewn on the surface of cylindrical drum sheet perforated in the peripheral perforated narrow zone (510) will slow down the flow of water, especially during the spin cycle as the compressed materials are jammed against the drum sheet.
Because the barriers formed by the compressed materials on the drum inner surface (104-n) slow down the flow of water through the drum to the
perforated zone, the draining and extraction times are longer. The aim is to ensure that, even when drum (104) is filled with materials having high density and low water permeability, water flows towards peripheral perforated narrow band zone (510) where drum perforations in peripheral zone (509) are located and exits drum (104) via drum holes.
It is possible to position the drum holes in a narrow band zone so that water is discharged in a timely manner using the system described in EP2229475. Said system allows the number of drum holes to be reduced 10 to 20-fold without causing a decrease in the flowrate efficiency of water discharge. While the exit area of water is very limited in the system described in EP2229475, said system also aims to prevent said holes from being blocked by the materials being treated in drum (104) and ensure a constant but limited outflow of water. Therefore, the discharge flowrate can be suitable to the capacity of the pump used to pump water back into drum (104) and said pump can be used at a high efficiency. Said system regulates water discharge from drum holes. On the other hand, a problem that needs to be solved is ensuring that water flows from non-perforated regions of drum (104) towards where drum perforations in peripheral zone (509) are located at a constant flowrate that is suitable to the discharge flowrate.
A solution to this problem is forming water channels/Poly-Channels (524) on the conical drum sheet perforated in the narrow belt zone (512). Water will flow through water channels/Poly-Channels (524) without coming across any obstacles in drum (104) according to the system described in EP2229475, as explained above. This system preferably comprises a water channel grate (526) forming water channels along the drum inner surface (104-n) of cylindrical or conical (512) drum which are parallel to or make an angle with the rotation axis of drum (104) using Poly-Ribs/protrusions/sheet bar/grate
bars (525) made of metal or plastic protrusions. Said water channels/Poly- Channels (524) are comprised of water channel grates (526) placed on drum outer surface (104-s) or plastic or metal conically molded roller housing (240) parts. Water flows towards the area where drum perforations in peripheral zone (509) though said water channels/Poly-Channels (524). In a conical drum sheet perforated in the narrow belt zone (512), flowrate increases with degree of the conicity of the conical drum sheet perforated in the narrow belt zone (512). Figures 34 and 46 show water channel grates (526) and water channels/Poly-Channels (524) formed by them in a conical drum.
In the embodiment as exemplified in Figure 46D, water channels/Poly- Channels (524) are shown which are side by side positioning of the sheet bar pieces suitable for lattice or the like-shaped grating, both as applied in the drum and on the conical sheet of the drum will keep the materials in the drum on water channel grate (526) and away from conical drum sheet perforated in the narrow belt zone (512) so that water channels/Poly- Channels (524) can facilitate flow of water across the length of the cylindrical surface of the drum without coming across any obstacles. As is known, water channel grates (526) also known as trash screens are structures that allow passing of fluids such as gases and liquids between the two volumes they are separating but prevent passing of materials that are desired to keep on one side. In order to achieve this, water channel grates (526) may have the structure of bars or cages of different shapes and sparsity. It is possible to use any structure that fits the general description of a water channel grate (526) and that makes it possible to keep the materials being treated away from the sheet of perforated drum and allows the flow of water on the surface of the drum beneath said materials. In a drum comprising water channels/Poly-Channels (524), water can flow through said water channels/Poly-Channels (524) towards drum perforations in peripheral zone
(509) without encountering any obstacles. Water flow channels (524) are created by Poly-Ribs/protrusions/sheet bar/grate bars (525) placed on the surface of the drum (104) to flow the water through drum perforations/holes (105) located in a region of the drum. The shape and dimensions of the Poly- Ribs/protrusions/sheet bar/grate bars (525) have to be suitable to form water channels/Poly-Channels (524) having enough water passageway volume to allow water to flow towards drum perforations/holes (105) on the surface of the drum. It would be right to call the volume where the materials are at the top of the Poly-Ribs/protrusions/sheet bar/grate bars (525) forming the water channels/Poly-Channels (524) as washing material drum also means real drum. The volume below water channel grates (526) extending to conical drum sheet perforated in the narrow belt zone (512) can be referred to as water flow area. Basically there is a kind of effluent system consisting of Poly- Canals under the grids. For example, water flowing from the water grids placed on the roadside to the sewer system under the road and flowing under the streets can be given.
The problem will be practically solved when water channels/Poly-Channels (524) are formed in adequate depth and width so that the material treated within the drum will not reach and/or approach the cylindrical surface of the drum to prevent water flow to reach the cylindrical surface of the drum sheet (511) and flow through the drum perforations in peripheral zone (509) and drain out without any obstacles
Poly water channels/Poly-Channels (524) may have any structure forming indents preventing entry of materials and allowing flow of water on conical drum sheet perforated in the narrow belt zone (512) from the area without holes towards the area where drum perforations in peripheral zone (509) are located. This can be achieved by placing Poly-Ribs/protrusions/sheet
bar/grate bars (525) on the surface of drum (104) or directly shaping cylindrical perforated drum sheet (106) to form water channels/Poly-Channels (524) or placing parts or covers in accordance with water channels system to conform to the Poly-Canal definition on the surface of drum (104).
As the system described in EP2229475 aims to prevent drum perforations/holes (105) from getting completely blocked by the washing material, the relationship between the Poly-Ribs/protrusions/sheet bar/grate bars (525), drum inner surface (104-n) and drum holes described in existing system forming water channels/Poly-Channels (524) may be different than said protrusions. The textiles being laundered form a tent-like structure across Poly-Ribs/protrusions/sheet bar/grate bars (525) placed on the drum sheet to prevent to reach drum inner surface (104-n) and to block drum perforations/holes (105) completely. The goal is that said water flow ways and drum holes are below this tent on the protrusions (531). In this case, the height of Poly-Ribs/protrusions/sheet bar/grate bars (525) and the space between the protrusions must be designed with the elasticity of the textile so that the textile forming the tent on the protrusions (531) does not block the drum holes when it stretches towards the bottom of Poly- Ribs/protrusions/sheet bar/grate bars (525). If the protrusions are close enough and high enough so that even if the textile stretches it cannot reach the drum inner surface (104-n), then the placement of drum perforations/holes (105) between the protrusions is not important. However, if the textile can stretch far enough between Poly-Ribs/protrusions/sheet bar/grate bars (525) to reach the drum sheet, then preferably drum holes have to be positioned close to the protrusions to accelerate the water discharge. In fact, if drum perforations/holes (105) are positioned beneath Poly-Ribs/protrusions/sheet bar/grate bars (525), they cannot be blocked by the textiles. The 2 mm height Poly-Ribs/protrusions/sheet bar/grate bars
(525) will allow for the desired result, provided that both drum perforations/holes (105) remain unblocked to ensure water flow through the peripheral non-perforated zones (510-n) of the drum to peripheral perforated narrow zone (510) if said protrusions have the proper shape and density.
In conclusion, while it is not important whether or not the materials reach the surface of the drum in the Poly-Rib system (60), it is undesirable in the Poly- Canal system because if the materials stretch enough to reach the drum inner surface (104-n), they will restrain water flow in water channels reducing drain flow rate and increasing process time. For this reason, it is preferable that the protrusions of the Poly-Canal system are higher and more densely placed than those of the Poly-Rib system (60) to maintain efficient water drainage.
There is no difference between a cylindrical drum with drum holes in located in a peripheral perforated narrow zone (510) and no Poly- Ribs/protrusions/sheet bar/grate bars (525) and a conical tank with Poly- Ribs/protrusions/sheet bar/grate bars (525) and water channels/Poly- Channels (524) in terms of the application of the present invention except for the water discharge and extraction periods being longer than desired. Any type of protruding structures designed to prevent holes from being blocked and ease water flow within the drum will benefit the efficiency of water discharge and the extraction cycle.
21- Water channel grates (526) on drum inner surface (104-n) according to the present invention are explained below via Figures 2, 24, 25, 27, 28,
30, 34, 46, 49, 50, 52-56, 69, 82, 83, 85.
Water channel grates (526) having the form of grates made up of Poly- Ribs/protrusions/sheet bar/grate bars (525) placed side by side to create a channel system is an ideal solution of the invention. In this way, two areas
are created in drum (104), the area above the water channel grates (526) Poly-Ribs/protrusions/sheet bar/grate bars (525) where the materials are located and the area below said water channel grates (526) where only water is located. So, the water coming out of the materials on Poly- Ribs/protrusions/sheet bar/grate bars (525) can flow freely from the non- perforated cylindrical area of drum (104) towards the holes and exit drum (104) via drum perforations in peripheral zone (509). There are two imaginary drums, the first one is called "new inner drum" which contains laundries over Poly-Ribs/protrusions/sheet bar/grate bars (525) for washing process and the second one is called "new outer drum" which is under Poly- Ribs/protrusions/sheet bar/grate bars (525) surrounding the new inner drum which drains water and both placed in the same rotatable main drum.
Said water channel grate bars (526) can be parallel to the conical drum sheet perforated in the narrow belt zone (512) or be in the form of angularly cut water channel grate/sheet bars (527) in order to provide a volume and a flowrate that increases towards the holes. Angularly cut water channel sheet/grate bars (527) are exemplified in Figures 46C and 46D. Angularly cut water channel sheet/grate bars (527) cut in this manner are lower in peripheral non-perforated zones (510-n) and higher in peripheral perforated narrow zone (510). This means that as water approaches peripheral perforated narrow zone (510) on cylindrical perforated drum sheet (106), the amount of water to pass through water channels/Poly-Channels (524) will increase. When the drum sheet is a conical drum sheet perforated in the narrow belt zone (512) having a conical shape towards the perforated area, if the angle between the narrow sides of angularly cut water channel sheet/grate bars (527) causing the difference in heights is equal to the angle of conicity, the material section above the grates will have a cylindrical shape.
Water channel grates (526) formed by Poly-Ribs/protrusions/sheet bar/grate bars (525) such as bars and rods having quadrangular, rectangular or triangular cross sections having enough height and placed densely enough to prevent materials being treated inside the drum to reach the conical drum sheet perforated in the narrow belt zone (512) will allow formation of water channels/Poly-Channels (524).
The distances between grate elements constituting the grates are mostly determined by the features of the materials to be treated. While it is suitable to have a distance between 15 and 25 mm for water channel grates applied to household or industrial textile washing machines, in an industrial sock dyeing machine, this distance must be between 5 and 10 mm. In contrast, in a carpet and mat washing machine having a drum diameter between 1800 and 2000 mm, it is acceptable for this distance to be between 20 and 40 mm. Likewise, the heights of the grate elements change according to the size of the channels, i.e. the depth of drum (104). As the depth of drum (104) increases, so must the depth of the channel. The depth and width of Poly- Canals and the shape of Poly-Ribs/protrusions/sheet bar/grate bars (525) forming said Poly-Canals (524) should be chosen according to the type of treatment and the type of material to be treated. Especially for industrial machines, the materials to be treated can range from very thick, large and hard materials such as dust mats with rubber bottoms to small and delicate materials such as elastic socks. For this reason, it is important to take the physical properties of the materials to be treated into account when designing Poly-Canals and Poly-Grates.
Water channel grates (526) can be made from plastic or metal and may be an integral part of drum (104), or be reversibly mountable onto drum (104).
22-The tents on the protrusions (531) and water channels/Polv-Channels
(524) on both sides of the protrusions on drum inner surface rO of the
drum to accelerate drainage rate according to the present invention are explained below via Figure 28.
Water channels/Poly-Channels (524) formed such that the washing material cannot enter between Poly-Ribs/protrusions/sheet bar/grate bars (525) as described above is the ideal embodiment of the invention described. When the invention is applied in this way, the water entering the channel (524) will reach drum perforations/holes (105) without any obstacles and will come out of the drum (104) as soon as possible. But it may be undesirable for a variety of reasons to implement a sufficient amount of Poly-Ribs/protrusions/sheet bar/grate bars (525) placed side-by-side to form water channels/Poly- Channels (524). During the rotation of the drum, the material transported upward falls in the drum. The material that falls on Poly- Ribs/protrusions/sheet bar/grate bars (525) will set up tents on the protrusions (531) on the protrusions. In this case, the material can reach the drum inner surface (104-n) between Poly-Ribs/protrusions/sheet bar/grate bars (525). The presence of Poly-Ribs/protrusions/sheet bar/grate bars (525) in the shape and size that will create space in between protrusions and the drum inner surface (104-n) to provide water flow in the drum (104) under the material is sufficient for the application of the system. For this purpose, Poly- Ribs/protrusions/sheet bar/grate bars (525) placed on the surface of the drum create tents on the protrusions (531) to be formed in sizes that allow water flow on the drum inner surface (104-n). Therefore, water channels/Poly-Channels (524) similar to those between the protrusions can occur on both sides of Poly-Ribs/protrusions/sheet bar/grate bars (525). It is also possible to provide the maximum efficiency expected from the invention if also the drum holes are located close to the protrusions and within the tent on the protrusions (531). When the drain drum perforations/holes (105) are
placed away from Poly-Ribs/protrusions/sheet bar/grate bars (525), the draining time of the water from the drum (104) will increase.
As a result, it is sufficient that Poly-Ribs/protrusions/sheet bar/grate bars (525) are in shape and size to accelerate water flow through the drum inner surface (104-n) and to increase the drainage rate from the drum (104) through the remaining space under the tent on the protrusions (531) created by washing materials under, around or between the protrusions to provide further advantages of the invention.
22- Conical drum sheet perforated in the narrow belt zone according to
the present invention are explained below via Figures 8, 11, 29, 34, 45,
46.
Positioning drum (104) having drum perforations in peripheral zone (509) in a peripheral perforated narrow band zone (510) at the rear of drum (104) with its front side up and its rear side down and having water channel grates (526) forming water channels/Poly-Channels (524) on cylindrical drum sheet
(511) will enable water to exit quickly during discharge. However, positioning drum in this manner is only partially helpful for ensuring water exits said drum quickly during high speed spin cycles.
In these cases, having a conical drum sheet perforated in the narrow belt zone (512) whose diameter gets larger towards the perforated area will make water exit the drum quicker during high speed spin cycles. It is clear that to provide a conical drum structure the cylindrical drum sheet must be conical
(512). It will be beneficial to examine the positioning of drum perforations in peripheral zone (509) at the rear side of drum (104), drum (104) having an incline to facilitate water flow towards the holes, drum having a conical structure (512) and application of water channel grates (526) forming water
channels/Poly-Channels (524) in drum (104) in terms of household washing machines (57). One feature of household washing machines (57) is that they are generally produced using mass production techniques. While they are defined as household-type, these washing machines produced in large scale production facilities using automated systems can also be used for applications other than household-type. These machines have a drum capacity between 30-40 and 250-300 L. In machines having high capacity, household drum water channel grates (622) used may be fixed and detachable and made of plastic and metal. Due to production techniques, it will be preferable for household drum water channel grates (622) forming the household drum water channel/Poly-Canals (621) within the drum to be made of plastic in household washing machines (57). Figures 69-80 show household drum water channel grates (622) in the form of household drum water channel/Poly-Canals (621) made of household drum water channel grate bars/Poly-Ribs (623) inside the drum; however, that particular embodiment of the household washing machine does not comprise household drum lifter ribs (607). Household drum water channel grates (622) inside the drum will also fulfill the function of carrying the materials during the rotation of the drum. It is possible to use drum lifter ribs (107) in-between the water channel grates (526) as shown in Figure 63B. One of the most pressing goals of producers of washing machines is to increase the size of household drum (604) to be placed in a household outer frame (616) having standardized dimensions. In some countries, the volumes allowable for washing machines are very limited. Especially as houses become smaller, the volumes allocated for washing machines also decrease. In Europe, the width and depth of a household outer frame (616) of a household washing machine (57) must not exceed 600 mm in order to fit in the allocated spaces in the kitchens and bathrooms. Setting aside 20 mm for the frame and spaces, the outer drum to
be placed inside household outer frame (616) must have a diameter below 560 mm. Even if the washing machine contains a system wherein water tank/outer drum (101) does not oscillate, the diameter of household drum (604) will be around 520 mm. If the machine has a free oscillation body, the diameter of water tank/outer drum (101) will be around 520 mm and the diameter of household drum (604) will be around 480-485 mm. Using the balance system (300) proposed by the present invention and other features of the invention makes it possible to increase the diameter of household drum (604). The diameter of a household drum (604) having the highest volumetric capacity possible may be around 560 mm, taking into account the required distance between household outer frame (616) and household drum (604) and other tolerances. This measurement means that no place is set aside for a water chamber (500) to be placed around household drum (604). When inclined household drum (604) is placed so that the rear section is downwards of the horizontal axis and household water chamber (611) is placed behind household drum (604) in the corner where household drum rear circular base sheet (610) and cylindrical household drum sheet (606) meet, it will be possible to collect the water exiting from household drum holes/perforations (605) at the back of household drum (604) by a water chamber placed behind the drum. With this design, it will become possible use a cylinder having the highest diameter possible to fit in rectangular box as a drum.
23- Discharging water from drum via drum discharge chamber
and drum discharge chamber water discharge valve (519) to create completely closed drum according to the present invention is explained below yia_Figures 25, 29, 32-34, 69, 81, 82, 85.
When water is discharged from drum (104) through drum perforations in
peripheral zone (509) on a peripheral perforated narrow band zone (510) an important embodiment is made possible. The aim of trying to collect a large portion of the water draining drum (104) back inside the drum by pumping said water back into the drum using a circulation pump (112) having a greater flowrate capacity than the drain flowrate of water from the drum is to save water and chemicals in the water by using them only in the drum. In fact, drum (104) could simultaneously be used as a water tank/outer drum (101) and the outlet of the water therein could be opened and closed as desired, and the problem will be solved at the source. In other words, when drum (104) is simultaneously used as a water tank/outer drum (101), there will be no need for water to be present outside the drum. The present invention makes this possible. As exemplified in Figures 36 and 37, when a drum discharge chamber (517) completely surrounding the where drum perforations in peripheral zone (509) on a peripheral perforated narrow band zone (510) on drum outer surface (104-s) on drum (104) and covering and sealing said holes, the water exiting from said drum perforations in peripheral zone (509) will enter and collect in said drum discharge chamber (517). Said drum discharge chamber (517) will cover the areas where the holes are located by creating a small volume on the conical drum sheet perforated in the narrow belt zone (512). Water exiting drum perforations in peripheral zone (509) will flow to drum discharge chamber (517). When the outlet from drum discharge chamber (517) is closed, drum water will be collected in the drum. However, as the volume of the discharge chamber is markedly smaller than water chamber (500) and the circulation system, the amount of water present in drum discharge chamber (517) during washing will not affect the targeted water saving values. In case water outflow from drum opening gap around drum opening between drum and front panel (114) in between drum and front panel is prevented by fully covering drum entrance/inlet opening
(108) with a rotatable door (533, 542) or pumping the water exiting from drum opening gap around drum opening between drum and front panel (114) back into the drum using a drum opening water collection chamber circulation pump (528) having a suitable capacity, it will be possible to confine the water inside drum (104) during washing. The solution provided for connecting drum (104) and water chamber (500) by mounting moving parts outside drum (251) on drum (104) is opening a drum discharge chamber water valve opening (518) in the drum to allow water outflow from drum (104). For this, one or more drum discharge chamber water discharge valves (519) need to be placed around drum discharge chamber (517). Figure 37A shows drum discharge chamber water discharge valves (519) of drum discharge chamber
(517) for collecting drum water in the drum in closed position. Said drum discharge chamber water discharge valves (519) mounted on drum discharge chamber (517) can be opened and closed using an electric motor or a pneumatic piston of drum discharge chamber discharge valve (520) of drum discharge chamber discharge valve (519). Said pneumatic piston of drum discharge chamber discharge valve (520) of drum discharge chamber discharge valve (519) used for opening and closing the valve may be placed in a suitable position such as the spaces of drum lifter ribs (107). When the water in the drum needs to be discharged, drum discharge chamber water valve door (521) covering drum discharge chamber water valve opening
(518) providing water outlet from drum discharge chamber (517) is closed by pneumatic piston of drum discharge chamber discharge valve (520) as shown in Figure 37B, 37C and 37D. Drum water passing drum perforations in peripheral zone (509) on drum (104) through to drum discharge chamber (517) flows to water chamber (500) via drum discharge chamber water valve opening (518) that has been opened. For example, Figure 36 shows four drum discharge chamber water discharge valves (519) mounted on drum
discharge chamber (517). Water will pass through drum discharge chamber water discharge valves (519) to water chamber (500) due to the centrifugal force created during the spin cycle. Even though there is no need to take special precautions for drum (104) discharging water by rotating, when drum (104) rotation needs to be stopped while water discharge is going on it will be necessary to stop the drum at a position where one of the open drum discharge chamber water discharge valves (519) is at the bottom.
In this way, as the drum becomes a fully closed system during washing operations, the highest water savings can be reached.
24- The rotatable door for drum opening (533, 542) according to the present invention are explained below via Figures 81-85.
Determining the location of drum entrance/inlet opening (108) and drum perforations/holes (105) when determining the water flow lines from drum (104) to water chamber (500) was explained above. In current washing machines, the flow of water from drum entrance/inlet opening (108) to water tank/outer drum (101) is via the gap around drum opening between drum and front panel (114) between water tank/outer drum (101) which is stationary when the drum is rotated or household drum door (617) on household outer frame (616) outside of the outer drum and drum entrance/inlet opening (108). Due to the flow of water, it is necessary to make a flow path on water chamber (508) to prevent water from entering moving parts outside drum (251). For this reason, a flow path on water chamber (508) must be formed or a water chamber around drum opening gap (506) must be placed. On the other hand, if the drum opening is covered by a hinged drum door (533) as exemplified in Figure 81A, there will be no water leakage from drum entrance/inlet opening (108) and no need for a water chamber around drum opening gap (506). The door rotates along with
the drum and is connected to said drum by a hinged drum door hinge (535). In the system proposed by the invention, one of the advantages of having all kinds of sensors, pneumatic, electric, electronic units and control systems (900) mounted on drum (104) is allowing drum entrance/inlet opening (108) to be covered by a hinged drum door (533) in a secure and controlled manner. Hinged drum door (533) is locked by electric or pneumatic hinged drum door lock (536) systems mounted on drum (104). When said locks secure the door on the opening flange, the door is fixed onto the drum by hinged drum door gasket (538) in a leak-proof manner.
In this embodiment, any technical means necessary for the door, including locking of the drum door, controlling of the locks and the position of the door and automatic opening of the door. What is important to consider is that for the door to be opened, drum (104) needs to be at the same position every time.
A second point to consider is that as hinged drum door (533) rotates along with drum (104), there is a need for a second fixed chassis drum safety door (540) for providing security on the outer frame of the machine as exemplified in Figure 81-83.
Rotating drum door can be fully closed; however, in embodiments where water inlet into drum is through the drum opening, rotating drum door must contain a hinged drum door water inlet hole (534). In this embodiment, the water connection providing water inlet through hinged drum door water inlet hole (534) is also placed on fixed chassis drum safety door (540) corresponding to the rotation axis of the drum. When fixed chassis drum safety door (540) carrying the water inlet line is closed, water inlet pipe/injector passes through the hinged drum door water inlet hole (534) and is positioned to provide water to the drum. Hinged drum door rotatable buffer
(539) of water inlet circulation line (113) on the safety door in contact with the drum is designed to be rotatable. There is a hinged drum door rotatable buffer gasket (537) elastically contacting to the rotatable drum door at the place where a hinged drum door rotatable buffer (539) having ball bearings and sealing felts and the drum are in contact for providing water sealing. The rotatable drum door can be opened upwards as shown in Figure 83, or towards the left or the right depending on the positioning of the drum. When the rotatable drum door covers the drum opening, there needs to be a locking system in order to provide sealing of the gasket between the door and the drum opening flange. The sealing of the rotatable door can be ensured by locks that are manually closed by the machine operator without closing the safety door, or by a system operating using a fully automatic motor or pneumatic system. Figure 81B shows rotatable door being locked by a drum door lock hinged to the drum having a piston operated by two pneumatic systems to move parts on the drum (131) positioned at drum front circular base/opening side (109).
This embodiment brings about many advantages. Because water will exit the drum only from the drum holes when drum opening is closed onto the drum by hinged drum door (533), when said drum perforations in peripheral zone (509) are in a peripheral perforated narrow band zone (510) at drum rear circular base/shaft side (110), a narrow water chamber (500) positioned to surround said drum perforations in peripheral zone (509) will solve the water tank problem. It will be possible to place mechanical, electric, electronic and even pneumatic systems capable of solving problems such as locking, opening and closing and providing lock safety for the door rotating along with the drum, on the periphery of the drum opening to rotate along with the drum.
There are solutions other than mounting a door onto the drum to cover drum entrance/inlet opening (108) to prevent water flow. As exemplified in Figures 84 and 85, a from rotary door carried by a door with a bearing (542) connected to a bearing for rotatable door on fixed door (541) on the rotation axis of the drum can be applied to a fixed chassis drum safety door (540). So, when the door needs to be opened, the mechanism locking from rotary door carried by a door with a bearing (542) onto the drum is opened and rotatable door and bearing for rotatable door on fixed door (541) is carried by a fixed chassis drum safety door (540) connected thereto as shown in Figure 85. Also using a balance system proposed by the invention in the machine wherein the system proposed by the invention is applied will make the drum rotatable around a fixed axis, therefore it is possible to use an openable rotatable door carried by a door on the chassis to cover the drum opening.
25- The fresh or circulation liquid and/or gas inlet to drum (104) from water entrance to drum through drum shaft (103-c) or around drum door is explained below via Figure 80.
In the past, pumping the water exiting drum (104) pumping water back into drum (104) via drum door (118) directly, after heating or after filtration was seen as the most practical solution. In the embodiment where drum (104) is covered by an inner drum door (533) hinged to drum front circular base/opening side (109), an additional option for water inlet besides from rotary door carried by a door with a bearing (542) may be water inlet (532) from water entrance to drum through drum shaft (103-c) or water inlet around drum door(532-a/b). Connecting the rotatable water inlet system on drum shaft (103) and circulation pump (112) line to drum (104) will simplify drum door (118) design and allow for a shorter pump line. When rotatable
fluid connection element (912) providing water inlet (532) to drum (104) from water entrance to drum through drum shaft (103-c) is placed at the end of drum shaft (103) on its rotation axis as shown in Figure 80, it will be necessary to connect said rotatable fluid connection element (912) to drum (104) by a hose/pipe embedded in drum shaft (903). On the other hand, if said rotatable fluid connection element (912) is positioned to wrap around drum shaft (103) at the corner where drum shaft (103) and drum rear circular base/shaft side (110) meet, water inlet into drum will be realized from drum rear circular base/shaft side (110) without need for additional pipes.
Fresh or circulated water inlet (532) placed around drum door (532-a/b) is more suitable than both water inlet (532) from door and shaft. Water inlet (532) for fresh water, water inlet (532-a) for circulation water connected by water collection chamber placed around perforated drum surface and water inlet (532-b) for the drum entrance gap water collection chamber is mounted around or over the drum door. Similar as explained water entrances (532), gas inlets to inject gas into the drum are also possible to place around drum door through drum entrance opening.
26- The angle of the water channel grates (526) on drum inner surface (104- nj with the drum rotation axis according to the present invention is explained below via Figures 49-59.
As the oscillations and vibrations generated by household drum (604) are dampened via water tank/outer drum (101) using additional weights, springs and suspension connections, drum stretched with respect to water tank/outer drum (101) and in order for household drum (604) to not contact the outer drum during stretching, there needs to be a gap between the drum and water tank/outer drum (101) taking into account the stretching tolerances
between the two. Due to the oscillations and vibrations generated in the outer drum by household drum (604), a space large enough to prevent outer drum from hitting household outer frame (616) needs to exist between said outer drum and said household outer frame (616). The drum capacities of household washing machines (57), for which the dimensions of household outer frame (616) are standardized, can have a maximum value of 60-65 L. Whereas in a machine where oscillation tolerances are minimized, it is possible for the drum to have a capacity of 90-100 L even if household drum (604) is placed inside a water tank/outer drum (101) and it is possible for the drum to have a capacity of 110-120 L for a washing machine having a water chamber (500) instead of a water tank/outer drum (101). This indicates that for household machines having a frame width of 600 mm where the invention is utilized has double the capacity of conventional household machines. The first step to achieve this is to prevent the oscillation of household drum (604) during the spin extraction cycle.
While it is possible to produce conical drum sheet perforated in the narrow belt zone (512) for household washing machines (57) using available production techniques, having a conical household drum (604) will require some compromise from the volume of the drum. Theoretically, the outside dimensions of household drum (604) must be limited by the limits of household outer frame (616) in order to place a drum having the largest volume without changing the dimensions of said household outer frame (616). Household drum (604) having a diameter at the limits of household outer frame (616) means that there is no space available for a household water chamber (611) outside the drum. In this case, the only solution is for the outer dimensions of household water chamber (611) to not be larger than the diameter of household drum (604). Draining the water from household drum (604) into a household water chamber (611) having the same diameter
as said drum can only be realized using specific solutions. For example, in Figures 49-59, household drum holes/perforations (605) of cylindrical household washing machines cylindrical household drum sheet (606) are placed at the corner of household drum rear circular base sheet (610). Drum sheet forms a water discharge recess in household drum sheet around perforated area (601) through inside of the cylindrical household drum sheet (606) around household drum holes/perforations (605) area; in this way a water discharge chamber (619) outside cylindrical household drum sheet (606) inside household drum (604) is formed. Water exits the drum in the same level with household drum rear circular base sheet (610) and in a way as to not go beyond the diameter of cylindrical household drum sheet (606). For the water exiting from the holes to continue flowing past household drum rear circular base sheet (610), water discharge chamber outside household washing machines drum sheet but inside water discharge chamber (619) is surrounded by a household water discharge chamber peripheral cover sheet (620) having the same diameter as the cylindrical drum sheet to cover the rear corner of the drum as shown Figures 55A, 56 and 57. Said household washing machines household water discharge chamber peripheral cover sheet (620) is circular and has the same diameter as cylindrical household drum sheet (606) and is mounted there onto in a leak-proof manner. While the water in the area defined as water discharge chamber (619) outside cylindrical household drum sheet (606) but inside the household drum (604) that is surrounded by household water discharge chamber peripheral cover sheet (620) has exited the drum sheet, it has not completely left the volume of household drum (604). Figures 55A, 56-58 show the water discharge chamber (619) obtained by shaping of the cylindrical household drum sheet (606). Said water discharge chamber volume may be formed by different techniques and auxiliary plastic parts placed inside the drum. This way, the
water discharged from household drum (604) will flow through household drum water channel/Poly-Canals (621) formed by household drum water channel grates (622) in the household washing machines drum and reach household drum holes/perforations (605) on the cylindrical household drum sheet (606), wherefrom it will flow into the water discharge chamber (619). The water entering water discharge chamber (619) will flow on circular household water discharge chamber peripheral cover sheet (620) and into household water chamber (611). Since the household drum (604) is inclined towards backwards, the water outlet from the household drum entrance opening gap (627) will be less than the horizontal drum condition. When a household drum (604) comprising household drum water channel grates (622) forming household drum water channel/Poly-Canals (621) inside said household drum (604) is placed at an incline so that water will flow towards the rear, exit of water from household drum (604). However as high speed rotation of the drum will decrease the effect of the incline on the flow of water, a different solution is needed to increase the flow of water during the extraction cycle. Placing the household drum water channel grate bars/Poly- Ribs (623) forming household drum water channel/Poly-Canals (621) on the cylindrical household drum sheet (606) at an angle with the axis of rotation will speed up the flow and exit of water during the extraction. During extraction household drum (604) rotates at the same direction. The sweeping effect created by protrusions placed at an angle inside the helical structure created by household drum water channel grate bars/Poly-Ribs (623) placed at an angle determined according to the direction of rotation of household drum (604) during the spin extraction cycle will direct the water towards the rear of the drum and out of said household drum (604). The water will flow out from the rear corner of the drum and into household washing machines water chamber (611) wherefrom the water will flow into household water
collection/storage tank (625) via household washing machines water chamber-storage tank connection (624). As household drums (604) of household washing machines are inclined towards the rear, there will be considerably less water flow from the drum opening compared to horizontal drums. Despite this, water flowing from the drum opening will flow into an elastic household water collection/storage tank (625) via household drum opening water collection chamber-water collection/storage tank connection (626). A household washing machines circulation pump attached to the outlet of household water collection/storage tank (625) pumps the water coming to the tank during the washing cycle directs the water towards discharge when needed. While in Figures 49-52, the measurements of the exemplary household washing machine are close to the measurements of the application of the invention, the positioning and measurements of household circulation pump (612) and household circulation pipeline (613) are shown schematically to provide clarity. The measurements and proportions of the parts in the drawings are given only as examples.
While in industrial washing machines, the circulation system is connected to the drum via the drum cover, in household washing machines (57) it is acceptable for it to be connected to the drum opening water chamber and be placed within the bounds of the outer frame.
27- Moving parts inside drum f250 ) according to the present invention are explained below, via Figures 4-18, 31, 32, 35-45, 47, 48.
The conditions and solutions for the operation of movement transfer system (401) placed outside of the drum to provide movement to moving parts inside drum (250) or moving parts outside drum (251) were discussed above. The conditions that need to be satisfied in order for movement transfer system (401) to be mounted outside drum (104) in a water-filled environment to
operate within water in a water tank/outer drum (101) or water chamber (500) and the conditions for creating water-free zones (100) on drum outer surface (104-s) for movement transfer system (401) so that they don't have to operate under water were disclosed above. It is clear that moving parts inside drum (250) and all types of related parts that will also be mounted inside the drum need to satisfy the conditions of operating under water. The parts that are dangerous or not possible to operate under water are isolated against water using known techniques, or placed in water-free zones (100) formed by methods proposed by the invention. The object of mounting a movement transfer system (401) outside drum in water-free zones (100) is to ensure the operation of moving parts inside and outside the drum that are aiding in the operation of the machine.
A preferred result of the invention is mounting moving parts inside the drum (250) that are driven by a movement transfer system (401) which is mounted outside the drum in order to create a physical effect and enhance the physical effect imparted by the movement of the drum on the materials being treated in the drum.
28- Rollers f201j inside the drum fl04j according to the present invention are explained below, via Figures 4-18, 31, 32, 35-43, 45.
Moving parts inside drum (250) to change the physical effect provided inside the drum are rotating parts whose rotation speeds can be adjusted according to the treatment operation. There are obvious technical advantages and practical application areas provided by choosing the rotating parts to be rollers (201) that are placed lengthwise inside the drum. Because rollers (201) which are placed onto cylindrical perforated drum sheet (106) side by side covering the inside of the drum can be rotated at desired speeds or not at all as required, the provide the dynamism that is the object of the
invention.
As such, one of the best examples of the application and results of the "moving parts inside the drum" system is choosing moving parts inside drum (250) as cylindrical or eccentrically-profiled rollers (201) rotating around an individual axis.
Rollers (201) placed in-between roller bearings (205) located at drum drum rear circular base/shaft side (110) on the drum shaft (103) side and at drum front circular base/opening side (109) on the drum door (118) side, parallel to the rotation axis of the drum can be rotated in the desired direction or oscillate within predetermined angular limits, at the desired speed for the desired length of time by movement transfer system (401) mounted on the front or rear circular base surface of the drum to create or enhance the physical effect required by the ongoing treatment operation within the drum. Rollers (201) do not need to be rotating in the same direction all the time. In cases where it is unfavorable for rollers (201) to rotate in only one direction due to technical reasons, they can periodically change direction. If the direction of rotation of the rollers is in the opposite to the direction of rotation of the drum, it will be possible to increase the mechanical effect desired in the drum. In fact, in cases where it is dangerous for rollers (201) to rotate fully, it is possible to configure rollers (201) to continually change direction and oscillate within predetermined angular limits.
29- Eccentric rollers inside the drum according to the present invention
are explained below.
The advantages of using rollers (201) as moving parts inside drum (250) were disclosed above. However, moving parts do not have to be in the form of rotating parts.
It is also possible for moving parts inside drum (250) to be in the form of parts that vibrate or oscillate by moving axially, freely or eccentrically in horizontal and/or vertical direction depending on the application. A mechanism mounted inside the drum can be driven to vibrate or oscillate by a system from outside of the drum.
30- A brushing machine and brush rollers (203) inside drum according to the present invention is explained below, via Figures 35, 36
A good example for fully rotating moving parts are abrasive rollers (202) placed inside the drums of industrial stone washing machines (54). However, if brush rollers (203) are used as rotating parts inside drum as shown in Figures 35 and 36, new treatment operation applications that were not possible to achieve with conventional washing machines will become available. Round brush rollers (203) will provide different stoning effects on the materials that are not possible to obtain by abrasive stones.
The surface of the cylindrical rollers (201) generally referred to as brushes may be covered by bristles protrusions of different materials, shapes and sizes. Said protrusions can be of different hardnesses in various shapes and lengths ranging from the size of the steel bristles that can be measured by microns up to the size of the plastic bristles 3-5 mm in diameter.
In a preferred embodiment of the invention, rollers (201) inside drum can be in the form of brushes made from materials used for producing brushes, such as fibers, steel, plastic etc., having different shapes, hardness and thickness to brush the materials in the drum in order to clean, wear down, felt, shine and/or shape them. The definition of brush used here is meant to be a general definition and indicates parts having protrusions made of any type of flexible or semi-flexible material on their surfaces.
Round brush rollers (203) shown in Figure 36B can be used for creating surface effects such as felting and wearing down on textile products, as well as for cleaning rubber mats or similar hard and semi-hard materials by brushing during washing. For example, Figure 36A shows round brush rollers (203) mounted side by side in the drum. Fixed brushes between rollers (208) having a semi-cylindrical shape are mounted between the rotating rollers in the manner that the brush protrusions of the fixed brush go in- between the brushes of the brush round rollers. The purpose of said fixed brushes between rollers (208) is to prevent the materials from getting tangled with the brush rollers. For example, both the rotating and fixed brushes shown in Figure 35 and 36 are made from flexible-hard plastic material. When these brushes are used in a washing machine, they will speed up the effects of the chemicals and shorten the washing time. They also provide rubbing effect to the materials and allow the desired cleaning result to be obtained much more quickly.
Aside from being round, the brushes may be egg-shaped, indented or elliptical. Brush rollers having eccentric surfaces will impart a stronger physical effect to the materials. Even if the brush rollers have indented surfaces, the indentations of the fixed brushes will be placed in-between the indentations of the brush rollers to prevent the materials from getting tangled.
If the indentations of brush rollers that are mounted side by side pass in- between each other, there will be no need to use fixed brushes.
31- An industrial washing f51Vdyeina machine according to the present
invention is explained below, via Figure 36A
One of the most important advantages of this system is that the speed of
each moving part can be adjusted depending on the treatment operation. While the rollers (201) providing rubbing may rotate slowly during the washing of delicate materials, brush rollers (203) with steel fibers used to stone wash jeans may rotate at high speed.
Brush rollers (203) will be especially useful for washing heavily stained and dirty materials such as work uniforms and table cloths. Using brushes having a special surface structure along with chemicals will provide faster and more effective cleaning.
Another feature of rollers (201) is that said rollers can be mounted to and dismounted from roller bearings (205). Therefore, the changes required by different types of treatments can be realized quickly.
When the rotation axis of rollers (201) is offset from the central axis of the cylinder, the rotation of said roller (201) will be eccentric. Rotation of eccentric rollers (204) will provide a beating effect to the materials in addition to the friction effect. The same effect may be obtained by elliptical rollers as well. In conclusion, when eccentric rollers (204) whose surfaces rotate eccentrically are used in washing machines, they will provide a rubbing effect on the laundry.
32- An industrial stone washing machine f54j according to the present invention is explained below, via Figures 4-11, 17, 31, 32, 37, 38, 40-45.
Stone washing treatments constitute a significant portion of treatments performed in industrial washing machines (51). And industrial stone washing machines (54) are the most widely sold type of industrial washing machines.
In drums with protrusions where Poly-Rib system (60) described in EP2229475 is applied, efficiency of stone washing using pumice stone
increases significantly. The protrusions placed on the surface of drum (104) increase the mechanical effect, therefore the stone washing process is shortened and consumption of pumice stones decreases because even if pumice stones crumble, they remain within drum (104). However, there are some difficulties in applying the Eco-Drum system (61) which is described in the same patent document and which is necessary for the application of these inventions. As is known, pumice stone and pumice sand have abrasive properties. It is possible to prevent presence of water in areas of drum (104) outside of water chamber (500) with the circulation pump system described by the Eco-Drum system (61). Because they can be carried along with water, pumice stones small enough to pass through drum perforations/holes (105) and pumice sand will need to be pumped back into drum (104) using the same circulation line. In this case, the pumice stone passing through the pump will cause abrasions in the pump, pump housing and pump propeller. In addition pumice stones tend to aggregate and sediment in areas where water flow is weak. The solution to these problems is proposed by the system described in 23rd article "Discharging water from drum via drum discharge chamber water discharge valve (519)". Water discharge valves controlling water discharge from drum (104) can be kept closed throughout the stone washing treatment process to keep pumice stones and pumice sand in the drum (104) for the duration of the treatment. This way, the abrasive effects of pumice stones are limited to within drum (104) which increases efficiency, and also water is saved. While preventing water outlet from drum (104) during the treatment solves some problems associated with using pumice stones, other the disadvantages of can be summarized as: the problems associated with obtaining, transporting, storing, loading and disposal of pumice stone and environmental issues caused by waste water containing sand; and health issues caused by dust and debris buildup in the facility.
Thanks to the invention, the process of stone washing, which is carried out in underdeveloped countries where labor health is not too much care and labor is cheap, will get rid of all these problems. The present invention eliminates these downsides of stone-washing. Another disadvantage of stone-washing using conventional mechanic abrasive materials is that the abrasive materials also wear down the drum inner surface (104-n) they come in contact with and in time render some of the parts unusable. Abrasive materials used in the drum will render the drum sheet unusable in 2 to 3 years. The present invention eliminates this problem. If the surfaces of the moving parts in drum (250) contain the required abrasiveness, it will be possible impart the desired stoning effect to the textiles being treated.
33- Abrasive moving parts inside drum ( 250) according to the present invention are explained below.
Moving parts inside drum (250), which can be controlled in a controlled manner in the desired speed, with abrasive characteristics, make the systems described by the present invention optimized for stone washing applications.
The desired abrasion effect on the textile can be achieved even if there are no additional abrasive materials inside the drum by covering the surface of moving abrasive parts (260) mounted on drum inner surface (104-n) with abrasive materials, mechanically or chemically treating the material constituting the surface of said moving abrasive parts (260) to impart abrasive character or choosing an abrasive material such as grindstone as surface material for said moving abrasive parts (260). Mechanical abraders such as pumice stone, added to drum (104) along with textiles will provide abrading and wearing down of textiles by the friction created by the textiles rubbing against each other with the rotation of the drum. In the case where moving parts inside drum (250) are abrasive, abrasion by friction will take
place between the textiles and said moving parts inside drum (250). In addition to the abrasive effect of the abrasive surface of moving abrasive parts (260), the movement speed of these parts is very important. In some cases, increasing the movement speed is more effective, while in some cases it may be the opposite. It is therefore one of the most important features of the present invention that the speed of movement of the abrasive moving parts (260) can be controlled as desired.
34- Rollers having grindstone pieces mounted thereon according
to the present invention are explained below, via Figures 4-11, 17, 31, 32,
35, 37, 38, 40-43, 45
One of the most important embodiments of the invention is having moving abrasive parts (260) mounted on drum inner surface (104-n) be in the form of abrasive rollers (202).
It is also advantageous for the material constituting the surface of abrasive rollers (202) to be grindstone pieces (207).
When the surface of roller (201) is covered by an abrasive material to obtain abrasive rollers (202), both the material undergoing treatment and the abrasive material will be worn down in time. The sharp corners of abrasive hard parts (265) used as abrasive agent that are attached to the surface by adhesives will get rounded out and lose its abrasive quality. While this problem can be ameliorated by applying multiple layers of covering, having a new and sharp part coming out from under an abrasive hard part (265) that has broken off as in the case of grindstone is not comparable to the number of cycles.
Conventionally, stone-washing of denim jeans is done in multiple steps. The first step is stone-washing with abrasive materials to impart a base design
onto the jeans. Afterwards, the pants are dry-treated to impart the desired shapes there onto. One of these treatments is an application where fold marks are created on desired sections of the pants. This treatment application may entail creation of lines or marks on the jeans using laser technology or small grindstones rotating at high speeds. Abrasive grindstone rollers (206) rotating inside the drum will have the same effect on the jeans.
One of the most important embodiments of the moving parts inside drum (250) system is abrasive grindstone rollers (206). Figures 4-11, 17, 31, 32, 35, 37, 38, 40-43, 45 show different examples of abrasive rollers (202) mounted on drums (104) of industrial stone washing machines (54). It is preferable for abrasive rollers (202) to have a grindstone surface; however, it is not required. It is also possible to use abrasive rollers (202) produced by methods to obtain abrasive materials known in the art, such as covering by an abrasive material other than grindstone, being in the form of an abrasive brush and shaping metal to have an abrasive surface. Either way, using abrasive rollers (202) mounted inside the drum that can rotate at hundreds, even thousands of revolutions per minute for providing fast and homogeneous stone-washing of textiles without need for pumice stone will solve a very important problem in the textile industry. The rotation of the rollers (201) in a few hundred revolutions per minute can be achieved in many ways, but it is possible to turn them in thousands of revolutions per minute by driving only with motors connected to moving parts (134). Rollers (201) may be produced from solid grindstone as abrasive grindstone rollers (206). Cylindrical abrasive grindstone rollers (206) having support materials added during the production stage to make them more durable may be mounted in the drum. Rollers (201) do not have to be produced from solid grindstone. Rollers (201) may comprise cylindrical (210) or spherical/buckled (211) grindstone pieces (207) mounted on a mechanical structure.
Spherical/buckled grindstone pieces (211) may be preferred in order to prevent formation of different levels of abrasion at the folds of the textiles contacting the rollers and to impart different designs to the textile. Spherical/buckled grindstone pieces (211) may be preferred even though treatment time increases because abrasion in desired shapes can be obtained. Figure 40 shows cylindrical abrasive grindstone rollers (206), rollers comprising cylindrical grindstone pieces (210), rollers comprising spherical/buckled grindstone pieces (211) and abrasive rollers (202) covered by protrusions such as brush rollers (203) for use as abrasion agent. Figure 35 also exemplifies different abrasive pieces that can be used on the rollers.
Mounting cylindrical abrasive rollers (202) that are bed housing from two ends by roller bearings (205) and that can rotate around its axis at desired speeds into the drums of stone-washing machines will speed up the stone washing process and provide many advantages to the textile industry. Factors such as the number of rollers (201) inside the drum, the degree of abrasiveness of the abrasive material on the surface of the rollers and the rotation speed of the rollers, diameter and surface profile of the rollers and also many other applications on rollers provide a wide variety of options that allow for customization of the treatment based on the type of material being treated, the stone-washing effect desired and the target quality of the end product. An embodiment of an industrial stone washing machine (54) comprising abrasive grindstone roller (206), abrasive and felting brush rollers (203), fixed grindstone pieces (216) mounted on drum inner surface (104-n) along with smooth or indented abrasive sheets (264) covering the drum surface will provide the user with many options with which to customize treatment formulas compared to treatments performed using pumice stone only. In addition to all these options that can be used instead of pumice stones for stone washing, any mechanical or chemical stone washing,
abrading and otherwise modify known in the art may be used with the systems proposed by the present invention.
Abrasive grindstone rollers (206) can rotate at desired speeds independently of the rotation of drum (104), therefore their speed can be adjusted based on the type of material, density and distribution of desired effect on the material and the planned duration of stone washing treatment. Independent abrasive grindstone rollers (206) may comprise grindstones having different physical properties and each abrasive grindstone roller (206) may be rotted in different directions and speeds. There will be no need to remove pumice stones after stone washing and the washing operation necessary after stone washing treatment can be done in the same machine after rollers are stopped. In fact, if the machine has a spin cycle, it can be used after chemical washing and rinsing cycles.
An exemplary embodiment of a stone washing machine of the invention as shown in detail in Figure 37B comprises abrasive rollers (202) comprising cornered grindstone carriers (212) serving as a shaft between roller frontal bearing (205-f) and roller rear bearing (205-r) having abrasive grindstone rollers (206) of measurement and shape suitable for said grindstone carriers (212) mounted there onto or covered by grindstone pieces mounted side by side to cover the surface of said shaft. The reason why grindstone carriers (212) carrying and realizing the rotation of the grindstones have a cornered structure is to facilitate the rotation of the grindstones. Quadrangular grindstone carriers (212-4) and hexagonal grindstone carriers (212-6) are preferable due their suitability for grindstone production methods and their ability to function as a wedge. On the other hand only one or two flat surfaces which are placed mutually and parallel to one another on a 2 flat surface on circular shaft carrier (212-2) will provide the same result. If the
carriers are round, the grindstone pieces can be attached to the cylindrical surface with a strong adhesive. However, it should be understood that any known techniques for facilitating the rotation of grindstones along with said carriers may be utilized.
While it is possible for the grindstone mounted onto said carriers through the central hole therein to be a single piece, it is preferable that they be in multiple parts. As the different sections of grindstones covering the drum inner surface (104-n) from rear to front will be worn down at different rates, the whole part will need to be replaced based on the most worn down section. However, if pieces of grindstone are used, it is possible to only change the most worn down grindstones. As abrasive grindstone rollers (206) are made of long single pieces, they are not durable against bending and have high risk of breaking which requires them to be produced using special techniques. Additionally, a single piece of grindstone will be harder to mount that multiple grindstone pieces (207). For these and similar reasons, it is preferable to use multiple grindstone pieces (207) to form abrasive grindstone rollers (206).
35- The features and montage of the rollers according to the present invention are explained below.
Grindstone carriers (212) may be circular shaft with one or two flat surface carrier (212-2) or quadrangular grindstone carriers (212-4) as shown in Figures 35A and 37C or hexagonal grindstone carriers (212-6) as shown in Figure 43C, as well as any polygonal shape acting as a wedge for the holes in the grindstones.
Moving parts inside drum (250) in the form of rollers (201) are reversibly mounted on roller bearings (205) located at drum rear circular base/shaft side
(110) on the drum shaft (103) side and at drum front circular base/opening side (109) on the opening side in the drum, parallel to the drum axis where they can rotate or oscillate around the axis of said bearings.
It is advantageous for the rollers to be mounted and dismounted by a practical mechanism. Therefore, it is possible to use any mechanism known in the art for practically mounting and dismounting rollers from two roller bearings (205).
Roller frontal bearing shafts (213) providing the connection between roller bearings (205) located at drum rear circular base/shaft side (110) drum front circular base/opening side (109) can be mounted into roller bearings (205) through in roller frontal bearing shaft housing (214) and rotatable lock abrasive grindstone rollers (206) between the bearings.
Grindstone pieces (207) on roller may be cylindrical, spherical, buckled, conical and eccentric or indented.
36- Fixed grindstone pieces located inside the drum according to the
present invention are explained below, via Figures 37, 43A
Abrasive character can be imparted to the drum inner surface (104-n) by methods other than covering said drum with abrasive sheets (264). One such method is covering the drum with fixed grindstone pieces (216). As shown in Figures 37, covering the area of the drum in-between abrasive grindstone rollers (206) with fixed grindstone pieces (216) instead of abrasive sheets (264) will have different advantages. Fixed grindstone pieces (216) having an indented structure possess a larger abrasive surface area to come in contact with the textile than abrasive sheets (264). Also, it is possible to only change the parts that have been too worn down to function.
It was explained above that while it is possible to use a machine wherein the drum only comprises fixed grindstone pieces (216) mounted thereon for stone-washing, it would not be very efficient. However, mounting fixed grindstone pieces (216) onto the drum inner surface (104-n) in a drum comprising a circulation system with abrasive particles and/or abrasive rollers (202) will aid the stone washing treatment process.
Stone washing treatment in the drum may be performed dry or generally with the addition of water and chemicals. Abrasive rollers (202) may be placed on the cylindrical surface of the drum side by side in the manner that no space is left between them. This way the whole area of cylindrical perforated drum sheet (106) will be moving and abrasive and it will be possible to decrease the time needed for the stone washing treatment by adjusting the speed of the rollers. In order for abrasive rollers (202) to wear down the surface of the material, there needs to be friction between said material and rollers. If abrasive rollers (202) placed side by side are all rotated in the same direction, the materials sitting thereon would be carried by the rollers in the direction of rotation. In this case, wearing down of materials decreases significantly. This problem may be solved by rotating abrasive rollers (202) placed side by side in opposite directions. Because abrasive rollers (202) placed side by side and rotating towards each other will move in a way to trap the textile between them, they may cause harm to the textile. Placement of abrasive rollers (202) side by side in the manner that no space is left between them will also cause movement transfer system (401) placed outside the drum to drive said rollers, such as gears, racks and pinions, timing belt pulleys, poly-V belt pulleys, smooth belt pulleys and V belt pulleys, to have a crowded mechanical structure. In order to free up space in movement transfer system (401) and to prevent the materials to be dragged on the rollers, material holding parts (218) are mounted in-between the rollers. Said material holding parts (218)
may be made of any indented material but are preferably made of abrasive materials such as fixed grindstone pieces (216) or fixed brushes between rollers (208).
Fixed grindstone pieces (216) placed between abrasive rollers (202) will function to wear down the materials being treated as well as prevent said materials from being dragged and rolled by the rollers and aid said materials in rotating along with the drum.
As shown in Figure 43A, fixed grindstone pieces (216) placed between abrasive rollers (202) may be of different sizes depending on the space between said abrasive rollers (202). When abrasive rollers are placed close together, only a fixed grindstone rod (217) or fixed brush between rollers (208) can fit between them. But when abrasive rollers are placed farther apart, larger fixed grindstone pieces (216) can fit there between. Like the grindstones on the abrasive rollers, fixed grindstone pieces (216) are mounted to be replaceable. If they are large in size, it would be advantageous for them to have coarse protrusive surface structure of fixed grindstone (219).
37- Indented grindstone part structures of recessed protruding threaded rollers (209) according to the present invention are explained below via
Figures 41, 42.
Abrasive grindstone rollers (206) comprising abrasive grindstone pieces are mounted onto cylindrical perforated drum sheet (106) side by side with no space in-between. When they are placed in this manner, it will not be possible for the materials being treated inside drum (104) to get caught between two rollers (201). However, in this embodiment grindstone pieces (207) will need to be replaced often. While it is not possible for the material
to enter the space between two rollers when grindstone pieces (207) are replaced, as grindstone pieces (207) are worn down, their diameters will get smaller and the space between rollers will increase enough that the material can enter, which will cause problems. In order to solve this problem, said rollers must have the indented structure of grindstones of recessed protruding threaded rollers (209-s) as shown in Figure 41, 42. When each grindstones of recessed protruding threaded rollers (209-s) of recessed protruding threaded rollers (209) is comprised of two cylindrical sections referred to as tab of recessed protruding threaded roller (209-p) and recess of recessed protruding threaded roller (209-r); and these tabs and recesses are arranged on grindstone carrier (212) part of roller such that they form a male-female connecting structure, the rollers will have the appearance of being interlocked. In this way, drum inner surface (104-n) has a fully moving abrasive surface and the indented surface structure increases the overall abrasiveness. Recessed protruding threaded rollers (209) placed side by side with no space in-between as shown in Figure 39C are driven in groups by a electrical drive motor on drum (132) mounted on drum (104) via main gear of group of gears connected to motor (414) on the motor and via gears connecting to rollers and each other (418) connected thereto, wherein said gears connecting to rollers and each other (418) are mounted onto each recessed protruding threaded roller (209) in the manner to rotate every roller in the group. Gears connecting to rollers and each other (418) providing movement to recessed protruding threaded rollers (209) placed side by side rotate the rollers that are beside and in connection with each other in opposite directions. By having the rollers that are side by side rotate in opposite directions, the problem of the material being dragged in the drum caused by the rollers all rotating in the same direction is solved. It is obvious that the indented cylindrical grindstone pieces forming recessed protruding
threaded rollers (209) will have a much longer critical wearing down period compared to cylindrical grindstone pieces (207).
The textile need not be wet for stone washing treatment. However, as the weight of the textile will increase when it is wet, the contact-friction force between the textile and fixed grindstone pieces (216) and moving abrasive parts (260) will increase and therefore the wearing down effect will increase. The harder the materials press down on moving abrasive parts (260) especially, the more the abrasiveness will increase. For this reason, wet stone washing is more efficient than dry stone washing. By that logic, as the total load inside drum (104) increases, the amount of contact the material has with the abrasive surface decreases while the wearing down effect on the material will increase. However, when the amount of water increases above optimum level, the excess water will cause the weight of the textile to decrease due to buoyancy and in addition will serve as a buffer zone between the textile and the abrasive surface when the textile is carried up by drum (104) and dropped down onto said abrasive surface and decrease the wearing down effect caused by the friction between textile and abrasive surface with force of dropping. Placing water channels (220) in large fixed grindstone pieces (216) so that excess water can be discharged during impact of textile to decrease the buffer effect of water will provide faster and stronger contact between the textile and the abrasive surface and therefore increases the wearing down effect. While wetting the material that is desired to be stone washed, i.e. worn down, and even presence of a small amount of water in drum (104) along with the textile is beneficial for the efficiency of stone washing, excess water will have an adverse effect on the efficiency of the treatment. Therefore, the presence of water accumulation chamber (502) is very important. The amount of water in drum (104) may be adjusted using said water accumulation chamber (502) and therefore the wearing down of
the material can be controlled.
After the stone washing treatment, the textile will need to be washed with the addition of chemicals. It is beneficial for the stone washing and chemical washing treatments to be completed in the same machine, one after the other without delay. When it is determined that the desired effect on the textile has been achieved during the stone washing treatment, moving abrasive parts (260) are stopped and the amount of water within drum (104) is increased to decrease the abrasiveness of the drum inner surface (104-n) so that chemical washing treatment can proceed without changing the stoning effect on the textile. The ability to continue washing operation in the same machine as the stone washing operation will be advantageous in terms of cost, manpower and time.
38- The moving parts inside drum that accelerate the movement of
treatment materials, water, chemicals or dyestuffs in the drum are explained below.
It is mainly intended to create a physical and mechanical effect to accelerate the chemical treatment of the material to be treated in the drum of the washing machine (50). This is what is desired to be done in many applications such as bleaching, washing, dyeing, abrasion, cleaning and softening. To date, said physical and mechanical effects can only be achieved by the rotation of the drum (104) or by water sprayed from the drum door (118) into the drum. With the present invention, many and more effective applications have been created to increase the physical and mechanical effects. It will be possible to agitate and move the material being treated with moving parts (200) to be placed inside the drum (104). The proper rotation speed of the rollers (201) with protrusions on protruding parts in rollers (227) on the surface will allow the material to move, mix, agitate, rub and animate.
Many times, by moving the treated material creates an effect to accelerate the process but sometimes on the contrary, enables to decrease the process speed to be controlled in a controlled manner. Since the abrasive rollers (202) rotate very speedily, if they contact with the material at the same point they cause non-homogeneous wear on the contact surface. In this case, it is necessary to prevent the abrasive rollers (202) and treated materials being kept constant for more than a moment time in the same position. The addition of protruding parts in rollers (228) between the abrasive cylindrical grindstone pieces (207) in the abrasive rollers (202) will solve the problem as the material will be displaced during the rotation by contacting with said protrusions. These protruding parts in rollers (228) can be mounted on the same roller (201) with the abrasive pieces, or as separate rollers which provide movement between the said abrasive rolls. In some washing processes, increasing the movement of water in the drum rather than increasing the movement of the washed material may be more beneficial for the chemical process. Especially in direct chemical interaction processes such as dyeing, bleaching, and softening, it will be more efficient to spray, agitate, inject and atomize water powerfully towards to washing material. When water is powered to hit the treated material strongly, the water-borne chemicals penetrate into the material. For this purpose, when the propeller parts in rollers (229) placed inside the drum (104) rotate at high speed, pushing the water towards to the treatment material at high speed will provide unprecedented chemical interaction. Material agitator protruding parts in rollers (228), abrasive surface roller grindstone pieces (207), abrasive brush roller (203) parts, water sprayer propeller parts in rollers (229) can be applied in separate rollers or together with the same roller (201) when required.
39- Eccentric oscillating parts f221j and moving vibrating parts f222j
according to the present invention are explained below via Figure 44
It is possible for movable abrasive parts (260) on drum inner surface (104-n) are mounted to said drum inner surface (104-n) surface via motors connected to moving parts (134) or movement transfer system (401) or mechanisms that are connected to a drive source on the rotating rollers and that oscillate eccentrically.
Moving parts inside drum (250) may be in the form of vibrating parts (222) vibrating on a linear plane. The movement of grindstones mounted on drum inner surface (104-n) instead of fixed grindstone pieces (216) will contribute to the dynamism desired to be created inside drum (104).
In this way, vibrating parts (226-260) having abrasive feature placed between abrasive rollers (202) will contribute to the stone washing treatment process. It is known that eccentric movements are not as efficient as rotating systems in terms of mechanism and energy consumption. In spite of this, providing different abrasive movements inside drum (104) will provide many options to achieve the desired effect on the material.
If the surfaces of said vibrating parts (222) are abrasive, they will also function to wear down the material like the abrasive rollers that are rotating axially. Using vibrating parts (222) in the form of grindstones attached to vibrating part platforms (224) mounted onto drum (104) via vibrating part connection springs (223) instead of grindstones affixed onto drum (104) of industrial stone washing machine (54) and having said platforms be in connection with a vibrating part vibrator (225) placed outside drum (104) in order to vibrate, is an efficient method. When indented grindstones mounted in this manner are activated by vibrating part vibrator (225), they will provide much more active abrasion than their fixed counterparts. Said vibrating parts
(222) can be used along with abrasive rollers in the drum or by themselves without any additional moving part.
40- Demountabilitv of moving parts inside drum f25C0 according to the present invention is explained below
Figure 38 shows a detailed side sectional view of a roller comprising abrasive grindstone pieces. A roller (201) mounted in drum (104) comprises two roller bearings (205) connected to frontal and rear sheets respectively, a grindstone carrier (212) reversibly mountable between said two roller bearings (205), roller frontal bearing shafts (213) connecting said grindstone carrier (212) and said roller bearings (205), a roller frontal bearing lock system (215) facilitating connection of at least one roller frontal bearing shaft
(213) to grindstone carrier (212) and roller shaft locks (226) for locking grindstone carrier (212) in place in corresponding roller bearing (205). In order to remove a roller frontal bearing shaft (213) from said roller bearing (205) on drum, said roller frontal bearing shaft (213) of grindstone carrier (212) should be able to be pulled into roller frontal bearing shaft housing
(214). Roller frontal bearing shaft (213) should comprise a mechanism placed in roller frontal bearing shaft housing (214), said mechanism facilitating compression of roller frontal bearing lock system (215) ensuring roller frontal bearing shaft (213) remains within roller frontal bearing shaft housing (214) and therefore ensuring that roller frontal bearing shaft (213) enters into roller frontal bearing shaft housing (214). For example, said shaft can be gradually removed from said bearing and inserted into said housing using a tool having a suitable diameter to be inserted into roller shaft pulling bore as shown in Figure 47.
It will be possible to use the same drum for different purposes by changing the roller grindstone pieces (207) within with those having different functions
or different degrees of effect for the same function. In addition, as they will get worn out faster than other parts of drum (104) due to their physical activity, they will be easily replaceable when needed. The same machine can be used as a stone-washing machine using abrasive grindstone rollers (206) and fixed grindstone rod (217) pieces on roller or a washing machine using brush rollers (203) and semi-circular fixed brushes between rollers (208).
Quick dismounting and mounting of rollers (201) is important in terms of time conservation. Regardless of whether the rollers are made of brushes, grindstones or other materials, it will be advantageous both in terms of production and application for rollers to comprise pieces placed side by side. Grindstone pieces (207), brush rollers (203), eccentric, helical, indented plastic rubbing or mixing pieces perforated in the middle in the axis of rotation corresponding to the profile of the carrier part are placed side by side on said carrier part. Roller bearings (205) ensuring that said rollers (201) rotate around their axis may be made by a variety of methods from a variety of materials depending on the rotation speed of the roller. For example, a plastic roller frontal bearing (205-f) to be inserted to the housing on drum front circular base/opening side (109) and a stainless roller rear bearing (205- r) to be inserted to the housing on drum rear circular base/shaft side (110) are exemplified in Figures 47 and 48. Sealing elements such as roller shaft seal ring (232) need to be used at the ball bearing to prevent water from drum (104) from entering the area where roller ball bearings (231) are located. In case there is water leakage in spite of this, it will be useful to have a roller bearing water discharge hole (233). Roller rear bearing (205-r) comprises a roller rear bearing shaft (230) having an end in the drum and one end out of the drum. Rotating rollers (201) within drum (104) are connected to shaft-roller connection (230-f) of roller rear bearing shaft (230). This end of the shaft comprises a shaft-roller cornered lock structure (230-fl)
or shaft-roller wedged lock structure (230-f2) for rotatably connecting and locking a roller (201) or similar part. Movement transfer system (401) mounted outside and to the rear of the drum is connected to shaft-movement system connection (230-r) at the end of said shaft sticking out of the drum.
41- The structural features and protrusions on cylindrical drum surface
protrusive surface structure of drum (266) according to the present invention are explained below via Figures 3, 4, 12A, 17, 37, 44A
In order to increase the activity obtained from moving abrasive parts (260) mounted on drum inner surface (104-n) in drum (104), especially for stone washing machines, it will be necessary to increase the area of the moving part, to mount more moving abrasive parts (260) on drum inner surface (104-n), and in order to do that, increase the surface are of drum (104) where moving parts inside drum (250) are mountable. As exemplified in Figures adding structures such as protrusions on cylindrical drum surface (261) and/or recess between protrusions on cylindrical drum surface (262) will increase drum inner surface (104-n) area in contact with the material and the surface area of the moving parts that can be mounted thereon in addition to providing the necessary protuberant structure of the Poly-Rib systems (60) described by EP2229475. The protuberant structure of drum inner surface (104-n) will prevent drum perforations/holes (105) from being blocked by the materials, so there will be no unexpected significant changes to water discharge from drum (104). Water discharge having a limited flowrate will not overflow and will flow through water chamber (500) to water storage chamber (504) or drum opening water collection chamber circulation pump (528). The advantages of mounting additional abrasive parts in-between abrasive grindstone rollers (206) mounted on drum inner surface (104-n) in an exemplary stone-washing machine were explained previously. Said
additional abrasive parts can be fixed grindstone parts (216) or vibrating parts (222) wherein grindstones can move in a vibrating motion. In such an embodiment, the advantage of increasing drum inner surface (104-n) by indentations is making space for moving parts and additional parts to be used with them.
This way, protrusions on cylindrical drum surface (261) will ensure that the textile is spread evenly across drum inner surface (104-n), that the textile moves along with drum (104) and that water discharge is controlled and will also result in an increase in the contact surface area between moving abrasive parts (260) and/or fixed grindstones on inner drum surface (216) due to increase in surface area thereof.
42- Water channels (220) on the protrusive surface of the grindstones (219) according to the present invention are explained below via Figure 43C
Stone-washing is a treatment done in the presence of water. Increasing the weight of the textile by wetting will increase the friction between the textile and the abrasive material and lead to an increase in efficiency. However, there is always some excess amount of water in the drum, although it is not required. When the textile falls on a fixed grindstone part having a flat surface, the water between the textile and the grindstone surface will act as a buffer and reduce the friction between them, causing a decrease in wearing down of the textile.
Therefore, in order to prevent water from acting as a buffer during the contact of textiles and fixed grindstones reducing the wearing down effect of the grindstone, it would be advantageous to use grindstones having a protrusive surface structure of fixed grindstone (219), namely using grindstones comprising water channels (220) through which excess water can
be drained from the surface of the grindstone.
Having water channels (220) on the grindstones will also increase their textile gripping ability. Therefore, fixed grindstone pieces (216) or vibrating grindstone parts (222) placed in-between abrasive rollers (202) will prevent the textile from being dragged by said abrasive rollers (202) and ensure that the effect of friction is fully realized.
The structure described has a similar function to water channels on surface of the tires of vehicles. Similar to how the road grip of a tire decreases as the tire gets worn down and the risk of the vehicle slipping on a wet road increases; the grip of grindstones will decrease as they are worn down.
43- Water channels (220) on the protrusive grindstones surface forming water channels/Polv-Channels (524) on the drum according to the present invention are explained below via Figure 43C
The amount of drum perforations/holes (105) was lowered in order to control water discharge and limit discharge flowrate based on the capacity of circulation pump (112) as described in detail by the Poly-Rib system (60) and Eco-Drum system (61). Drum perforations/holes (105) having reduced number and water permeability are positioned in the recesses between the protrusions of drum inner surface (104-n) so that water can reach drum perforations without coming across any obstacles. Drum perforations/holes (105) are placed in a corresponding position to the holes in the recesses between protrusions of fixed grindstone pieces (216) on the surface of drum (104). Drum perforations in peripheral zone (509) in drum (104) being located only in a designated region of the drum and methods to ensure that water from other regions of the drum can flow to said holes without coming up against any obstacles was explained above. As shown in Figure 43C,
when fixed grindstone pieces (216) having water channels (220) are placed side by side on the drum so that said water channels (220) are connected to each other they will form water channels/Poly-Channels (524) on the drum surface. Water channels/Poly-Channels (524) on the drum surface were previously disclosed to be formed by water channel grates (526); however, they are also possible to be formed by water channels (220) on grindstone pieces. When grindstones having water channels (220) are placed side by side in such a way that said water channels (220) correspond to each other, they will form water channels/Poly-Channels (524) covering drum (104) from one end to another.
44- Roller side bumper prevent material entrance (244) and molded roller housing structures to prevent tangling around rollers according to the
present invention are explained below via Figures 36 A, 40A, 43, 45.
A drum (104) comprising moving parts inside drum (250) may be defined as a dynamic drum. An obvious application for a dynamic drum is in industrial washing machines (51). Generally, materials of textile type are treated in industrial washing machines (52). The first issue that needs to be addressed when textiles are physically and/or chemically treated like washing, dyeing, stoning, bleaching, coating, softening in a drum (104) comprising cylindrical rotating parts, such as rollers (201) is the textiles getting tangled up in said rollers (201). Rollers such as abrasive rollers (202) and brush rollers (203) mounted side by side on cylindrical perforated drum sheet (106) will move the textiles under them towards said cylindrical perforated drum sheet (106). It was explained above that recessed protruding threaded rollers (209) comprising indented surfaces that can engage with each other can be used to solve this problem. However, in embodiments where rollers are cylindrical and buckled and mounted apart from each other, it is unavoidable that the
rollers gets tangled with the material and gets stuck. To prevent this, the sided of the rollers must be covered to block the textiles from going under the rollers. In order to prevent the materials from getting tangled with rollers (201) or getting under rollers (201), part of the rotating parts must be covered in a way to not permit entry for any material being treated in drum (104), especially textiles. This is possible by a variety of methods.
The simplest way to prevent the materials from entering under the rollers (201) is to place roller side bumper prevent material entrance (244) on the drum inner surface (104-n) to cover the sides of the rollers as shown in Figures. This method is also the most practical and feasible solution in that it allows the roller side bumper prevent material entrance (244) to be approached in a desired manner to the rollers (201). However, roller side bumper prevent material entrance (244) method will cause increased water consumption problem due to space remaining beneath the rollers (201) and also will cause residual pollution problems caused by material particles that will accumulate under the rollers.
Better example to solve this problem is, molded roller housings (234) having a cylindrical housing suitable for the diameter of the roller and preferably made of plastic, aluminum or a similar material may be placed under the rollers as shown in Figures. Molded roller housings (234) are molded to fit against cylindrical perforated drum sheet (106) at the bottom and against the surface of the roller at the top and placed under the rollers, spaced apart just enough that no materials can enter there between. Another advantage of this embodiment is that molded roller housings (234) comprise molded roller housing water discharge holes (235) required for water discharge from drum (104). Molded roller housing water discharge holes (235) are positioned within molded roller housings (234), in order for rollers (201) to prevent the
materials from reaching the holes. Rollers passing close by molded roller housing water discharge holes (235) will ensure that said holes remain clear and open. Another function of molded roller housings (234) is serving as fixed part housing in molded roller housing (236) for fixed parts such as fixed grindstone pieces (216) or fixed brushes between rollers (208) when they are placed between the rollers. As said molded roller housings (234) are reversibly mounted like rollers (201) and fixed grindstones on inner drum surface (216), they are exchangeable for different purposes. The materials being dragged by the rotation of roller (201) can also be prevented by using specially shaped molded roller housings (234) without having to use additional blocking parts. Said molded roller housings (234) are placed side by side in an interlocking manner so that molded roller housing water discharge holes (235) correspond to drum perforations/holes (105) on cylindrical perforated drum sheet (106). Molded roller housing lock system (237) provides interlocking of molded roller housings (234). Molded roller housings (234) are screwed on drum (104) via molded roller housing-drum connection (238) or another method and mounted by locking each other and the fixed parts between the rollers in place.
The number and diameter of molded roller housing water discharge holes (235) of molded roller housings (234) are important to keep the flowrate of water exiting drum (104) under control. As said molded roller housing water discharge holes (235) are covered by rollers, the material being treated inside drum (104) can never block water flow therethrough. Having molded roller housing water discharge holes (235) always open will ensure that the maximum flowrate of water exiting drum (104) will remain constant depending on the rotation speed of drum (104) as explained with Poly-Rib system (60) in EP2229475. It is important to know the maximum flowrate of water exiting drum (104) in order to determine the operating conditions of
circulation pump (112).
Other types of buffers from different materials may be used in place of molded roller housings (234) to prevent the materials being treated to get tangles in the rollers. Even simply placing a shaped sheet roller (239) under the roller to serve as roller housing will prevent textiles from going under the roller. Moreover, fixed grindstones (243) mounted next to the abrasive roller will block the material without needing a special buffer. Said molded roller housings (234) or barriers/buffers must be selected according to the physical features of the material, such as thickness and touch. If the textile is jeans, as the fabric is thick denim, a few mm of distance between the buffer and housing will be sufficient. However, for thinner materials, such as socks, it will be necessary for the barriers to cover the area around the roller completely, such as fixed brushes between rollers (208) the ends of which contact the roller.
45- The direction of water flow towards molded roller housing water discharge holes f235j in molded roller housings f234j according to the present invention are explained below via Figure 45
Methods used to ensure that water in drum (104) flows towards the holes without coming against any obstacles in cases where drum perforations/holes (105) are located at a certain region of drum (104) in a peripheral perforated narrow zone (510) on cylindrical perforated drum sheet (106) were disclosed previously. Methods used with drums having rollers may be added to previously disclosed methods of inclined placement of the drum, using a conical drum, having water channel grates (526) on perforated cylindrical perforated drum sheet (106), using water channels on the grindstones. In the cases where the drum has a conical structure, rollers (201) and molded roller housings (234) can be placed in a parallel manner to the conical structure of
the drum so that the water can flow to the area of roller housings where discharge holes are located. While having a conical drum sheet perforated in the narrow belt zone (512) is not as easy as a cylindrical perforated drum sheet (106), it is possible. However, placing the rollers at an angle with drum front circular base/opening side (109) and drum rear circular base/shaft side (110) will be difficult. To provide ease of applicability, rollers (201) may be placed in a cylindrical structure even in a conical drum sheet perforated in the narrow belt zone (512). In this case, the space between rollers (201) and the conical structure of the drum will increase towards the area where the discharge holes are located. The space can be covered by roller housings. In a drum (104) having a conical drum sheet perforated in the narrow belt zone (512), conically molded roller housings (240) must be used as roller housings. Having a conically molded roller housing water channel (241) extending towards the discharge holes parallel to conical drum sheet perforated in the narrow belt zone (512) will provide water flow within the roller housings. For example, Figure 45B shows a conically molded roller housing water channel (241) extending towards area of the base of the roller housing where drum perforations in peripheral zone (509) are located.
46- Drum sheet in the form of roller housing (242) according to the present invention are explained below via Figure 40B
Another method of preventing the materials from being tangled in the rollers is shaping cylindrical perforated drum sheet (106) to form drum sheet in the form of roller housing (242) for said rollers, as shown in Figure 51. It is possible to form cylindrical indentations on cylindrical perforated drum sheet (106) using a press and place the rollers therein.
47- The electrical drive motor on drum and moving systems G200 )
according to the present invention are explained below via Figures 3, 5-8,
13-15, 16, 17, 18, 31, 42B
One of the most important gains of the invention is, of course, that it makes it possible to mount the electrical drive motor on drum (132) directly on the drum (104). Electrical drive motors on drum (132) that provide movement for moving systems (200) on the drum can work with electricity or pressure air.
It is clear that in order to provide movement to moving parts placed inside and/or outside the drum (200, 250), movement acquired from a drive source, namely a motor, must be transferred to said parts. Related systems may be exemplified by the following three embodiments.
Every washing machine comprises a drum rotation motor (115) for rotating drum (104) and it is possible to use said drum rotation motor (115) to drive moving parts inside drum (250) as said parts are rotated while drum (104) is rotated. As can be seen, this embodiment does not require an additional motor, however, using the same drum rotation motor (115) for drum (104) and moving parts inside drum (250) means that the rotation speed of moving parts inside drum (250) is determined by that of drum (104) and rotation of moving parts inside drum (250) is stopped when drum (104) stops. In addition, the left-right rotation direction of drum (104) will determine the rotation direction of moving parts inside drum (250). Therefore, it is evident that the exemplary embodiment will not provide the expected benefits from the system of the invention.
The second embodiment comprises at least one electrical drive motor on fixed chassis (133) mounted on fixed chassis (111) outside drum (104) to drive moving parts (200) as shown in Figures 12B, 16, 17. In this case movement is transferred from the motor via a movement transfer part such as belt (402) and a movement transfer system such as pulley on drum (104).
The advantage of this embodiment is that moving parts (200) may be moved independent of the rotation or speed of drum (104). With this application, it will be possible to achieve movement for moving parts independently of the drum motor. Despite this, it is possible to accept that there is a lot of limitations in the application, although it is possible to transfer the movement that achieved from a motor mounted outside the drum.
The third and most practical embodiment involves mounting a drum movement system motor to move parts on the drum (130) directly onto drum (104). There are many advantages to having moving parts be driven in groups (132) or individually (133) by electrical drive motors mounted on the drum as shown in Figures 3, 5-8, 13-15, 18, 31, 42B. First of all, each group or part can be controlled individually and their speeds and rotation directions can be determined separately. In this embodiment, if the areas where motors are mounted on drum (104) are outside water chamber (500), it will be easy to control the system and provide maintenance service thereto. If motors are mounted inside water chamber (500), they should be water proof.
48- Motors connected to moving parts (Ί34 ) according to the present invention are explained below via Figures 3, 5-8, 12-18, 31, 35B, 36B, 39, 42 B,
Driving the moving parts (200) of machines wherein drum (104) comprises electrical systems using electrical drive motors on drum (132) will have many advantages.
Electrical drive motors connected to moving parts (134) mounted on drum (104) may be directly connected to moving parts (200) or may applied in groups or regionally (413). Connecting an independent motor directly
connected to roller (412) directly to each moving part will simplify the system and make it easier to control. There are many advantages of having an independent motor directly connected to roller (412) regardless of whether a motor operating in a water-free zone (100) inside water chamber (500) is used or the motor is taken completely out of water tank/outer drum (101). When each roller is driven by an independent motor directly connected to roller (412) such as an AC, DC, universal or servo motor, their speeds and directions can be controlled separately as desired. This embodiment allows rollers (201) to have different features. It will be possible to apply rollers (202) comprised of grindstone pieces (207) and to apply brush rollers (203) having different featured brushes or brush type protrusions in the drum and to control them at different rotation speeds and directions.
In cases where a large number of motors to move parts on the drum (130) need to be used inside or outside drum (104), using separate motors may increase the overall costs. In this case, one roller is directly connected to the motor while the two adjacent rollers are connected to the main roller by a movement transfer part such as belt (402) and pulley (401) system or gear/chain system, forming a three roller system driven by one motor driving multiple movable parts (413) as exemplified in Figure 35B, 36B, 37B. Similarly, the number of rollers in a group connected to a motor may be increased. As the size of the motor will have to increase along with the number of rollers connected thereto, it may not be possible to mount these motors on the rear of the drum as with smaller motors. In this case, it is possible to place motors driving multiple moving parts (413) connected to many moving parts and having a larger size in drum lifter ribs (107) for rotating the material being treated along with drum (104) and to drivably connect moving parts (200) located in the area from said drum rib to the next drum rib to said motor via a movement transfer system as exemplified in
Figure 13, 14.
One of the embodiments shown in Figure 13 comprises 42 rollers operated by 3 motors divided into groups. Thus, 14 rollers are driven by a separate motor. The biggest benefit of this application is that it allows the desired group to be rotated in the desired condition according to the position of the drum. It may not be appropriate to activate the abrasive rollers when in contact with the textile. If the abrasive surface begins to rotate in contact with the garment, it will cause more damage than high-speed rotation conditions. In this case, during drum rotation the roller group passing through the top of the drum, which is not in contact with the textile, starts to rotate first. With the rotation of the drum, said group will reach the targeted rotation speed before the textile contact.
Industrial type drums generally comprise three or four drum lifter ribs (107). As drum lifter ribs (107) are located in the area where discharge holes on cylindrical perforated drum sheet (106) are located, and the water chamber (500) sides of drum lifter ribs (107) are generally open, in drums (104) where drum holes are not located in a peripheral perforated narrow zone (510) the area where the motor is mounted will be wet. In such a case, an isolated area in movement system (142) system must be used for the motor. For example, Figures 39 show a case where the water chamber (500) sides of drum lifter ribs (107) are sealed to be waterproof. When the opening left for mounting the motor is covered by a leak-proof cover, the area will be completely isolated. For example, a motor driving multiple movable parts (413) placed in the rib space may be connected to the adjacent geared pulleys for transferring movement to rollers (415) on two sides as shown in Figure 13. If connected in this manner, the belt will zig zag between the pulleys which will increase the contact surface of the belt with the pulley and
the pressure exerted on the pulley by the belt. The back side of the belt moves along a idler pulleys (417) that is moving on the shaft via idler pulley bearings (416) to prevent said belt from affecting the rotation of the following pulley while rotating a pulley. The motor rotates half of the rollers on both sides while the other half are rotated by a motor placed in the other drum rib space. Therefore, rotating adjacent rollers in opposite directions, the advantages of which were explained above, will be possible.
When rollers in drum (104) are placed close together, or in a protruding threaded roller (209) as explained above, roller rear bearing shafts (230) will be too close together to be able to connect a motor directly or via a pulley/belt system. The present invention provides a different solution to drive such types of rollers. First, all rollers are connected together by a gear connecting rollers to each other (418). When the first one of the rollers in the area between one drum lifter rib (107) to next that are connected together by a gear connecting rollers to each other (418) is connected to the motor in said drum lifter rib (107) via a gear connected to motor (414), said electrical drive motor on drum (132) connected to multiple moving parts (413) will be able to drive all the rollers. Another advantage of this system is that adjacent rollers will rotate in opposite directions due to their way of connection. Therefore the problem of recessed protruding threaded rollers (209) dragging the material thereon in their common rotation direction will be solved by itself. Gears mounted on the rollers may be made of metal or plastic. If drum rear circular base/shaft side (110) is located outside water chamber (500), maintenance can be easily provided to the gears. Also, it will be possible to provide lubrication to the gears using a variety of methods, including spraying, by completely closing off the area where said gears are located.
Another advantage of the embodiments of the invention is that lubrication
systems are applicable on drum (104). As is known, moving systems, especially systems moving at high speeds may require lubrication. A lubrication station mounted on drum (104) may provide automatic and controlled lubrication to required locations via distribution lines.
Movement transfer system outside drum (401) comprising belts, pulleys, bearings, gears and similar mechanical systems are in a position that is easy to reach and also provide maintenance and repairs, and that has no contact with water so they will be long-lasting and require less maintenance.
49- Closed-loop belts according to the present invention are explained below via Figures 12, 16, 17.
It is important to ensure that movable parts operate when necessary, in a controlled manner, at the necessary speed and for the necessary period of time. To achieve this, movable parts need to be driven by an electrical drive motor on fixed chassis (133). In this way, while the movement of the movable parts moved using the rotation of drum (104) depends on the rotation speed of drum (104), the speed of the movable parts drive by movable belts for drum peripheral rotation pulley (411) driven by a motor can be adjusted as needed. For example, in the case where rollers (201) mounted inside drum (104) are rotated by such an electrical drive motor on fixed chassis (133) as shown in Figures said rollers (201) can be rotated at the desired speeds and it will also be possible to synchronize the speed of the motor with the rotation speed of drum (104), thereby making the rollers motionless relative to the drum and rendering then nonfunctional. The pulleys may be driven by one or multiple movable belts for drum peripheral rotation pulley (411) and pulleys placed side by side as shown in Figure 16B may be used. This increases the contact surface between drum peripheral rotation pulley (403) and movable belt for drum peripheral rotation pulley (411) and
reduces the chance of the belt slipping on the pulley.
It was mentioned above that all the pulleys rotating in the same direction may have the effect of reducing the efficacy of the treatment. Having rollers (201) that are mounted side by side rotate in opposite directions will allow the desired effect to be obtained from treatments based on friction such as stone-washing and brushing. As an electrical drive motor on fixed chassis (133) and movable belt for drum peripheral rotation pulley (411) system can needed to rotate adjacent pulleys in opposite directions, as shown in Figure 12B. Therefore pulleys can be rotated in the same direction at different speeds and in opposite directions at desired speeds. Driving movable parts by a belt-pulley system as explained above may be preferable due to its cost efficiency. Driving the movable parts of machines wherein drum (104) comprises electrical systems using electrical drive motors on drum (132) will have many advantages.
Waterproof electrical drive motors on drum (132) may be mounted on a drum (104) rotating in a water tank/outer drum (101). It is not mandatory to place electrical drive motors on drum (132) to be mounted outside drum (104) to rotate abrasive rollers (202) comprised of grindstone pieces (207) in water- free zones (100) of the drum. When waterproof motors directly connected to roller (412) are directly connected to said abrasive rollers (202) and electricity is provided with the necessary precautions, abrasive rollers (202) inside drum (104) can be rotated at desired speeds. Unless it is necessary to do otherwise, it is advantageous to provide conditions wherein electrical drive motors on drum (132) on the drum and the equipment thereof do not come in contact with water to provide ease of maintenance services, application and material choices.
Therefore it would be beneficial for the motor to be mounted on a water-free
zone (100) of the drum, or for the motor to be taken completely out of water tank/outer drum (101). Electrical drive electrical drive motor on drum (132) mounted on drum (104) may be motors connected to moving parts (134) or may be applied in groups or regionally (413). Connecting an independent motor directly connected to roller (412) directly to each movable part will simplify the system and make it easier to control. There are many advantages of having an independent motor directly connected to roller (412) regardless of whether a waterproof motor mounted inside water tank/outer drum (101) is used, a motor operating in a water-free zone (100) inside water chamber (500) is used or the motor is taken completely out of water tank/outer drum (101). When each roller is driven by an independent motor directly connected to roller (412) such as an AC, DC servo or step motor, their speeds and directions can be controlled separately as desired. This embodiment allows rollers (201) used in drum (104) to have different features. It will be possible to use abrasive rollers (202) comprised of grindstone pieces (207) and brush rollers (203) having different brush or similar type of protrusions in the drum and to control them at different rotation speeds and directions.
In cases where a large number of motors to move parts on the drum (130) need to be used inside or outside drum (104), using separate motors may increase the overall costs. In this case, one roller is directly connected to the motor while the two adjacent rollers are connected to the main roller by a movement transfer part such as belt (402) and pulley (401) system or gear/chain system, forming a three roller system driven by one motor directly connected to roller (412-3) as exemplified in Figure 35B. Similarly, the number of rollers in a group connected to a motor may be increased. As the size of the motor will have to increase along with the number of rollers connected thereto, it may not be possible to mount these motors on the rear of the drum as with smaller motors. In this case, it is possible to place motors
driving multiple movable parts (413) connected to many movable parts and having a larger size in drum lifter ribs (107) for rotating the material being treated along with drum (104) and to drivably connect movable parts (200) located in the area from said drum rib to the next drum rib to said motor via a movement transfer system as exemplified in Figure 13. Industrial type drums generally comprise three or four drum lifter ribs (107). As drum lifter ribs (107) are located in the area where discharge holes on cylindrical perforated drum sheet (106) are located, and the water chamber (500) sides of drum lifter ribs (107) are generally open, in drums (104) where drum holes are not located in a peripheral narrow belt the area where the motor is mounted will be wet. In such a case, unless a waterproof motor is used, an isolated areas in movement system (142) must be used. For example, Figures 39 show a case where the water chamber (500) sides of drum lifter ribs (107) are sealed to be waterproof. When the opening left for mounting the motor is covered by a leak-proof cover, the area will be completely isolated. For example, a motor driving multiple movable parts (413) placed on a rib may be connected to the adjacent geared pulleys for transferring movement to rollers (415) on two sides as shown in Figure 13. If connected in this manner, the belt will zig zag between the pulleys which will increase the number of gears in contact with the pulley and the pressure exerted on the pulley by the belt. The non-geared side of the belt moves along an idler pulley (417) that is movable on the shaft via idler pulley bearings (416) to prevent said belt from affecting the rotation of the following pulley while rotating a pulley. The motor rotates half of the rollers on both sides while the other half are rotated by a motor placed in the other drum rib space. Therefore, rotating adjacent rollers in opposite directions, the advantages of which were explained above, will be possible.
When rollers in drum (104) are placed close together, or in an interlocking
manner as explained above, roller rear bearing shafts (230) will be too close together to be able to connect a motor directly or via a pulley/belt system. The present invention provides a different solution to drive such types of rollers. First, all rollers are connected together by a gear connecting rollers to each other (418). When the first one of the rollers in the area between one drum lifter ribs (107) to next that are connected together by a gear connecting rollers to each other (418) is connected to the motor in said drum lifter ribs (107) via a gear connected to motor, said motor driving multiple movable parts (413) will be able to drive all the rollers. Another advantage of this system is that adjacent rollers will rotate in opposite directions due to their way of connection. Therefore the problem of interlocking rollers (209) dragging the material thereon in their common rotation direction will be solved by itself. Gears mounted on the rollers may be made of metal or plastic. If drum rear circular base/shaft side (110) is located outside water chamber (500), maintenance can be easily provided to the gears. Also, it will be possible to provide lubrication to the gears using a variety of methods, including spraying, by completely closing off the area where said gears are located.
Another advantage of the embodiments of the invention is that lubrication systems are applicable on drum (104). As is known, moving systems, especially systems moving at high speeds may require lubrication. A lubrication station mounted on drum (104) may provide automatic and controlled lubrication to required locations via distribution lines.
50- The balance system and moving parts providing balance during the spin cycle according to the present invention are explained below via Figures 1, 2, 5-9, 18, 32, 34, 51-78.
One of the most important aspects of the invention is the balance system.
One of the main issues of washing machines (50) performing high speed spin extraction cycles is that when drum (104) enters the high spin extraction, the material that is unbalanced distributed therein causes oscillations at low spin speeds and vibrations at high spin speeds. For as long as machines having extraction cycles have been around, possible solutions to this problem have been investigated, however, so far no system that can fully solve this problem have been developed. Actually, "dynamic balance system" technique has been known and used for many years in "dynamic balance machines" wherein measurements are taken for allowing addition of balance weights to eliminate balance problems. The vibration problems caused by the unbalanced weight distribution are eliminated by means of the balance weights added to the parts. The parts can be rotated smoothly without vibration at high rotational speeds even that are in very large sizes and tons of weight after balancing. However, this technique has so far not been applied to drum (104) of a washing machine. This reason for that may be that said drum (104) is placed in a water tank/outer drum (101) filled with water. It is clear that in order for the dynamic balance system to be applied to the drum; electrically controlled moving mechanical systems must be mounted outside said drum. Water tank/outer drum (101) of conventional washing machines contain water with solid particles and abrasive chemicals which is not suitable for the operation of mechanical systems. The present invention has made it possible to directly mount a dynamic balance system onto the drum by providing electrical connections and water-free zones (100) on the drum whereby balance weight movement motors (306), moving system and parts together with control systems can be mounted onto said drum. Actually, it is possible to mount a balance system inside a water tank/outer drum (101) by water proof it against water. For example, if drum front circular base/opening side (109) is still in water tank/outer drum (101)
while drum rear circular base/shaft side (110) has been taken out of water tank/outer drum (101), water will continue to flow out of drum door opening gap around drum opening between drum and front panel (114). In this case, a balance system (300) mounted to drum front circular base/opening side (109) can be sealed off. Balance weight movement motors (306) to be used with balance system (300) may be produced to be waterproof or may be placed in an isolated area in movement system (142). Another difficulty in applying balance systems to washing machines having a conventional water tank/outer drum (101) and drum (104) system was the mechanical moving interaction between said water tank/outer drum (101) and drum (104). The different construction stretches between the rotating drum (104) and the stationary water tank/outer drum (101) made it difficult to accurately measure the unbalance load to be compensated, which is necessary for the "dynamic balance system" to determine the unbalanced load distribution. In conventional washer-extractor machines, the inner and outer drum must be combined in one body. The rotating drum (104) is mounted with the drum shaft (103) located from one side of drum rear circular base/shaft side (110), to water tank/outer drum (101) via drum bearing system (102) located on the outer drum frame. Fixing the drum (104) by just one side causes the drum to stretch in the water tank/outer drum (101) under the influence of unbalanced load forces. In order to determine the unbalanced load distribution inside the rotating drum, measurements are made from the non rotating outer drum. Uncontrolled stretching of the drum affects the accuracy of the measurement from the outer drum. Separating drum (104) from water tank/outer drum (101) eliminates this problem and makes it possible to measure unbalance conditions directly from inner drum and apply the dynamic balance technique directly to the system. The system proposed by the invention provides water-free zones (100) where balance system (300)
can be mounted, which have made it much simpler to use said system. Thanks to mounting motor to move parts on the drum (130) driven moving parts outside drum (251) together with electricity connection, electric and electronic control systems (900) which can be placed in rear and frontal sections of the drum, made it possible to apply dynamic balancing techniques on the washer extractor machine. By application Poly-Rib (60) and Eco-Drum (61) systems to create water-free zones (100) at the outside of drum (104) even drum is still be inside of the water tank/outer drum (101) or taking necessary sections of the drum out of water tank/outer drum (101) or rendering water tank/outer drum (101) nonfunctional and reducing its size to a negligible amount as a water chamber (500), the drum has become a mechanical and electric device/machine in its own right. The drum proposed by the invention can be defined as a mechanism, device or system that is capable of operating independent from the machine.
So it is possible to move balance weights at a position to create counter force against unbalance force occurred by unbalanced weight distribution on the drum. The balancing system applied to the drum is essentially a controlled movement of at least one counterweight to compensate for imbalance.
Connecting an electrical drive electrical drive motor on drum (132) controlled by electric, electronic, control systems (900) will make it possible to apply best known methods of providing balance to the drum. In this way, the drum of washing machine (50) with drum will become a "dynamic balance machine" by itself. While current dynamic balance machines determine the position and magnitude of the imbalance and provide information on the position and magnitude of weight needed to be added/removed to balance said imbalance and leave the rest up to the operator, the present invention provides a system where correction of the imbalance is performed by said
balance system during the spin extraction cycle. The most common dynamic balancing machines are tire balancing machines. The tires of all vehicles have balance problems occurred during production and this problem must be eliminated by dynamic balancing machines. By rotating the tire placed on the balancing machine at high speed, the position and magnitude of the imbalance are determined by the sensors. The master assembles a lead piece which creates the same magnitude of force against the detected imbalance. Thus, the tire does not cause vibration during high spin speed on the vehicle at high speeds.
It will be possible to move balance weights (301) having different structures and properties placed on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) in different ways in a controlled manner to restore the balance and maintain the balance by changing the positions of balance weights (301) during the spin cycle. In this way, no more need to add extra weight and shock absorbers together with springs used to suppress the imbalance motion and also no more need to apply redistribution when it is understood that the unbalanced distribution cannot be handled. The machine comprising the balance system proposed by the invention will save the energy normally spent on the oscillations and vibrations of drum (104), water tank/outer drum (101) and weight connected thereto.
While it is possible to apply the balance system proposed by the invention only on drum front circular base/opening side (109) or drum rear circular base/shaft side (110), it would be advantageous to apply two independently operating balance systems (300) on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) respectively in order provide total balance to the drum and eliminate imbalance during the spin cycle. While balancing drum (104) on one side only will partially fix the
imbalance issues, it may not be sufficient enough to completely discard sphng/suspension/shock absorber/weight systems used in conventional washing machines.
It is clear that different application methods can be found for providing a counterweight to balance the unbalanced load distribution by changing the positions or creating the mass of balance weights (301) at both drum front circular base/opening side (109) and drum rear circular base/shaft side (110). Balance weights (301) normally placed on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) or on the front and rear of cylindrical perforated drum sheet (106) to balance each other out will be moved by balance weight movement motor (306) in order to balance the imbalance in drum (104). Therefore, at last one balance weight (301) each must be present on either side of drum (104).
The mechanical balance system (300) described by the present invention comprises essentially of a balance control system (300-C) and at last one balance weight system (301-W) placed on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110). Balance system (300) may comprise one or two balance weights (301) on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110). In cases where there are balance systems (300) on both drum front circular base/opening side (109) and drum rear circular base/shaft side (110), it will be understood that four balance weights (301) are present. Each balance system (300) comprises at least one balance weight (301), balance weight handling and rotation structure (308) whereby said balance weight (301) is carried and rotated, a balance weight movement motor (306) to provide rotation and a movement transfer system for transferring this rotation motion. Each balance system (300) is capable to rotate around the rotation
axis at least one balance weight (301) to a position to provide balance of the drum. Said balance weight movement motor (306) may be an electrical, pneumatic or other type of motor. In order to explain the basic principles of the balance system described above, four examples will be given.
Balance systems (300) comprising moving balance weights (301) may be mounted on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) as well as any two positions on the drum shaft (103) system. On a washing machine (50), one balance system (300) may be placed in front of or behind drum pulley (116) mounted on drum shaft (103) before drum shaft bearing (102) and another balance weight (301) may be placed on any position on drum shaft (103) or drum (104) on the opposite side of drum shaft bearings.
All balancing system examples given in the descriptions and figures are for horizontal, front-loading and rear-shaft-bedding drums of washer-extractor machines. However, it should be noted that the explained balancing system as described will be applied to the horizontal side loading washer-extractor machine with two shaft on both side or to the vertical top-loading drums mounted via shaft-bedding on the lower side of the washer-extractors machines or the centrifuge type spin machines used only for extraction.
51- The movement of balance weights according to the present
invention is explained below via Figures 1, 2, 5-9, 18, 32, 34, 51-76.
In the exemplary balancing system (300), the two balance weights (301) on each side of the drum (104) are mounted on balance weight handling and rotation structure (308) so that the two balance weights are positioned in the home position to compensate each other mutually. Except from the balancing process, their masses are good to create equal centrifugal force when they
are mutually positioned against each other. Therefore, there is no imbalance effect created by these weights in all other washing processes. The two balance weights (301) have their own movement systems with a balance weight handling and rotation structure (308) driven by separate balance weight movement motor (306) so that they can move independently around their own path. Said balance system may be positioned on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110) or on the front and/or on the rear of cylindrical perforated drum sheet (106) so that the axis of rotation of drum (104) is also the axis of rotation of balance weights (301).
Frontal balance system (300-f) at drum front circular base/opening side (109) is mounted around drum cylinder at front side as shown Figure 32 or at drum front circular base, around drum entrance/inlet opening (108) as shown Figure 63. Rear balance system (300-r) at drum rear circular base/shaft side (110) is mounted around drum cylinder at rear side as shown Figure 1, 69 or at drum rear circular base, around drum shaft (103) as shown Figure 61.
Figure 70 shows an exploded view of balancing systems mounted around drum cylinder and Figure 8 shows an exploded view of balancing systems mounted on drum circular base surfaces. Figures 64-68 provide detailed images of the balance system from different angles.
Each balance weight system comprises a balance weight handling and rotation structure (308) to rotate each balance weight (301) 360° around drum (104) rotation axis independent of the others. Balance weight handling and rotation structure (308) comprises weight bearings for balance weight bearing system (302-S) and a weight guide path (307) in the form of a rail or channel for guiding the movement of said weights on said bearings. Balance weights (301) are positioned on balance weight bearing system (302-S) to be
rotatable 360°. A sliding or rotating balance weight handling and rotation structure (308), such as a sled, wheel or pulley will ensure that a balance weight (301) moving along a suitable path will move to rotate on drum front circular base/opening side (109) and drum rear circular base/shaft side (110). It is clear that in order to keep the weight within said weight guide path (307), the system must comprise a weight-guide path lock system (309) for locking said weight into weight guide path (307). To ensure that the weights are moved and positioned in a controlled and precise manner, said weights must be connected to gear connected to motor (310) driven by a gear chain/belt (311) transmitting movement from balance weight movement motor (306). Weight position detection sensors (312-p) of the system will monitor the positions of the weights and transmit this information to the balance control system (300-C). Weight position detection sensor (312-p) may be an "n-coder" connected to balance weight movement motor (306) or any gear connected with gear chain/belt (311) or any other sensor capable of monitoring the positions of balance weights for 2-weights balance system (302). When water tank/outer drum (101) is separated from drum (104) and directly mounted to the fixed chassis, drum (104) and systems rotating along with said drum (104) will be connected to a drum bearing chassis (313) that is connected to fixed chassis (111) via a drum shaft (103) and drum shaft bearing (102) system.
Balance sensor (312-b) may be positioned between said drum bearing chassis (313) and fixed chassis (111), so that the control system can determine the position and magnitude of the imbalance in drum (104). In cases where drum chassis (529) is connected to fixed chassis (111) in a moving or fixed manner depending on balance sensors (312-b). If drum chassis (529) is connected to fixed chassis (111) in a moving manner balance sensors (312-b) are sensors measuring the movement and if drum chassis (529) is connected to fixed
chassis (111) in a fixed manner balance sensors (312-b) are sensors measuring the force caused by the load imbalance in drum. If drum chassis is movably mounted, said connection may be realized by flexible wedges, steel springs or airbags and said balance sensors may be proximity sensors or the like. In cases where drum chassis (529) is connected to fixed chassis (111) in a not moving manner, balance sensors (312-b) may be sensors measuring the force created by unbalance in drum or the stress imparted on fixed chassis (111) by said load. When the bearing systems where the weights move are such that the centers of gravity of the weights are on circles having different diameters as exemplified in Figure 62, the weights create a centrifugal force, even when they are chosen to be of equal mass. They need not be of equal mass but they must be producing equal centrifugal forces (FI=F2) when placed opposite each other 180° apart, as shown in Figure 62A. Information coming from balance sensors is analyzed by the control system to determine the angle and magnitude of the imbalance force (Fx) in drum (104) after the distribution of materials within. Then, balance weight movement motors (306) controlling balance weights for 2-weights balance system (302) will move said balance weights (301) together, keeping the 180° angle between them constant to preserve their balance position, to the position where the direction of the centrifugal force created by balance weights (301) is perpendicular to the imbalance force of the unbalanced load. Therefore, the imbalance force will fall in the middle balance weights (301). In this case, as balance weights (301) still balance each other out, the only force causing imbalance on drum (104) will be the force created by the unbalanced load that is perpendicular to the balanced centrifugal forces of balance weights (301). In order to restore the balance, balance weight movement motors (306) move balance weights (301) at equal angles to create a balancing force against the unbalance force created by the
unbalanced load, as shown in Figure 87B. Balance weights for 2-weights balance system (302) will be moved towards each other until they create a force equal to the unbalance force (Fx) against the unbalanced load and until the vector average of the force created by said balance weights is equal to the magnitude of the imbalance force. The highest unbalance force will be created at the beginning of the spin cycle. While the increase of the rotation speed of drum (104) will cause the centrifugal force to increase, as water will be discharged, the force will also decrease. For this reason, if a counterbalance force to balance the unbalance force after uneven distribution of load can be created at the beginning, the adjustments needed as drum gains speed will be comparatively very small. In fact, at a certain point in the spin cycle, balance weights (301) will have to move in the opposite direction to compensate for the unbalanced load losing more water.
52- Traveling, carrying and guiding apparatus according to the present invention are explained below via Figures 1, 2, 5-9, 18, 32, 34, 51-78.
The systems applied to industrial washing machines (51) and household washing machines (57) will differ in terms of scale. While plastic molded parts are suitable for household washing machines (57), a different application is needed for industrial washing machines (51). Figures 65-73 show an exploded view of a balance system applied to an industrial washing machine. Said balance system comprises a separate balance weight movement motor (306) for each balance weight for 2-weights balance system (302) positioned on drum front circular base/opening side (109) and drum rear circular base/shaft side (110), means for transferring movement from said balance weight movement motor (306) such as gear chain/belt (311) driven by a gear, a gear chain/belt guide channel (314) to ensure that said chain or belt follow the circular path passing through the connection point in a taut
manner, a gear chain/belt-weight connection (315) for connecting the weight to gear chain/belt (311), a weight-guide path lock system (309) for locking the weight in the bearing, a push mechanism comprising a weight-lock pin spring (318) placed in a weight-lock pin housing (317) embedded in the balance weight to push a weight-guide path lock wheel (316) whereby the balance weight travels on the lock path into the lock bearing and a weight- lock pin (319), a weight bearing for 2-weights balance system (302) such as a circular channel or rail acting as a bearing and ensuring that the weight travels in a circular path and where parts for carrying the weight inside the bearing channel such as weight transfer wheels (320) are inserted and a balance-fixed parts connection sheet (321) for connecting all fixed parts of the system together to form one part.
The balance problem of the spin cycle will be solved by mounting two of these systems on drum front circular base/opening side (109) and drum rear circular base/shaft side (110) in connection with each other.
While balance weights (301) of 2-weights balance system (302) may be placed parallel to drum front circular base/opening side (109) and drum rear circular base/shaft side (110), they may also be placed around the drum on cylindrical perforated drum sheet (106), where balance weights (301) have a cylindrical shape suited to the shape of said cylindrical perforated drum sheet (106) as shown Figures 73. Placing the balance system around drum entrance/inlet opening (108) on drum front circular base/opening side (109) causes said drum inlet opening to be deep. If increasing the diameter of drum (104) does not cause a problem in terms of machine size or design, it would be beneficial especially to place the front balance system (300-f) on the cylindrical perforated drum sheet (106) in front of the drum. Another advantage of placing balance system on cylindrical perforated drum sheet
(106) is that, balance weights (301) are farther away from their axis of rotation, because balance weights, which have the same mass of the balance weight, create more centrifugal forces than the same mass of the balance weight which are close to the rotation axis.
During the other operations than extraction stage, fixed home position sensors (323) are mounted on weight guide path (307) for each balance weights (301) to ensure that both balance weights are in the home position to balance for each other. At the end of the extraction operation, both balance weights (301) go into the home position to balance each other. During the balancing process, the movements are monitored by an encoder or similar position tracking sensor so that during the balancing operation, the position of the weights will be known by the balance control system (300-C).
The application of the balance system to household washing machines (57) will be comparatively simpler. It will be possible to combine all the parts listed as separate for industrial washing machines into one part. Figures 74 and 75 show an example of a 2-weights balance system applied to the drum of a household washing machine. The weight providing portion of plastic molded balance part (630) may consist of plastic or may also include an additional single metal weight (631). When the weights are made of a metal having high density, they will take up less space and can be used by embedding them into plastic molded parts. As single metal weights (631) on plastic molded balance part are embedded into plastic, the balance part will appear as a plastic molded balance part (630). The weight part may be a single plastic molded balance part (630) on plastic molded balance part or alternatively, two weight parts (632) on plastic molded balance part (630). Plastic molded balance part (630) comprises a balance part bearing wheel (634) system for the balance part to rotate along balance part bearing (633).
Four balance part movement motors (635) to rotate balance parts via rotating system on the bearing are embedded on balance motor housings on drum sheet (636) on drum front circular base/opening side (109) and drum rear circular base/shaft side (110). When balance motor movement gears (637) are mounted to be engaged with balance part movement gear (638), they can move the balance part to the desired position. The working principle is the same as for industrial machines.
There are many systems known in the art for determining the position and magnitude of a force created by an unbalanced load at drum front circular base/opening side (109) and drum rear circular base/shaft side (110) during the spin cycle. There are hundreds of types of balance machines referred to as "dynamic balance machine" wherein these systems are implemented. It is possible to use electronic sensors, hardware and software used in these known systems for checking the balance and determining the position of the counterweights with the embodiments of the present invention. Some of the required parts will be mounted outside and some will be mounted inside of drum (104). The parts of balance control system located inside and outside drum (104) operate together and communicate using electronic connected or wireless communication systems.
53- The placement of the front balance system G300-P on drum front circular base/opening side G109) and the rear balance system G300-G) on drum rear circular base/shaft side fllCD according to the present invention is explained below via Figures 1, 2, 5-9, 18, 32, 34, 51-78.
If drum front circular base/opening side (109) and drum rear circular base/shaft side (110) where the balance system is located is outside of water
tank/outer drum (101), the addition and removal of balance weights (301) can be done easily and quickly depending on the loading and operating conditions of the machine. The amount of the unbalanced load generated in drum (104) during the extraction cycle may vary a lot depending on the type and amount of material being treated therein. If the drum (104) is fully loaded, the chances of the material being distributed homogeneously in the drum (104) are higher than the drum loaded with fewer amounts. If the material in the drum comprises large and heavy pieces containing rubber such as carpets, rugs and dust mats that are not easily distributed, there is a larger chance of unbalanced load distribution compared to a laundry washing machine operating at full capacity. As it is generally not known beforehand for what purpose and under what conditions the washing machine will be used, and as said purpose and conditions can change over time, if it is not possible to make adjustment when needed, it is most advantageous to design the washing machine considering the worst possible conditions. If the balance weights (301) mounted to the balance system (300) during manufacturing are selected according to the worst loading condition and load distribution, the machine will use much more energy to rotate these extra weights with the drum. If the systems proposed by the invention allow additional balance weights (303) to be added or removed as necessary onto balance weights (301) for 2-weights balance system (302) or a weight carrying apparatus as shown in Figure 67, it will be possible to adjust the balance system for operating under the current conditions. Therefore, problems of being unable to start the spin cycle due to unbalanced load distribution and repeated load distribution steps seen in industrial washing machines can be eliminated. In machines where drum (104) is taken out of water tank/outer drum (101), the front and rear regions of the drum will be convenient to reach and the balance weights will be easily adjustable. Each balancing front balancing
system (300-f) and rear balancing system (300-r) has own balance weight movement motor (306) and balance weight bearing system (302-S).
As the imbalance generated inside drum (104) during spin cycle will be detected by sensors detecting the stress, stretching, applied or changing forces in the system instead of by sensors detecting movement; the washing machine comprising said balance system does not need to contain parts such as springs, suspensions, vibration wedges, air bags, etc. In this case, said washing machines may be in the form of machines known as fixed chassis machines having limited speed spin cycles. A fixed chassis machine capable of vibrationless spin cycles at high speeds will provide many advantages in terms of application areas.
54- A balance system comprising two balance liquid container (331) placed opposite each other according to the present invention is explained below, via
Figures 76.
Liquid container weight balance system (330) is a balance system, similar to balance system (300) described above utilizing balance weights (301), where two balance liquid container (331) placed opposite each other are used as balance weights. Liquid container weight balance system (330) having two balance liquid containers (331) are mounted on drum front circular base/opening side (109) and/or drum rear circular base/shaft side (110). Two balance liquid containers (331) are positioned opposite each other and are connected by two balance liquid transfer connection lines (334-L), where one balance liquid transfer connection line (334-L) has a balance liquid pump (333). One of balance liquid transfer connection lines (334-L) between two balance liquid containers (331) is a balance liquid transfer connection line (334-L) providing balance liquid (337) transfer while the other is an air transfer connection line (334-G) providing the air replacing the displaced
balance liquid (337). When the centrifugal force on balance liquid tanks (331) during the extraction cycle, spin speed rises over the force of gravity (G), balance liquid (337) transfer will occur between said balance liquid containers
(331) along balance liquid transfer connection line (334-L) until the amount of balance liquid (337) is equal in both balance liquid containers (331). Each volume of a balance liquid container (331) is large enough to be able to contain all balance liquid (337) in the system. Balance liquid (337) is distributes equally between balance liquid containers (331) at the beginning of the extraction cycle, other than when balance is taken, therefore, they do not cause imbalance in drum (104) because they have equal weights. When the extraction begins, the direction of the unbalanced load vectors in drum (104) is determined by balance control system (344) in drum front circular base/opening side (109) and drum rear circular base/shaft side (110). Balance control system (344) rotates balance liquid container moving chassis
(332) so that balance liquid container axis (339) corresponding to the center of gravity of balance liquid containers (331) overlaps with the imbalance load vectors in drum (104). Said rotation is realized by a balance liquid container movement motor (335). Balance liquid container movement transfer system (336) is mounted onto drum (104) via a bearing so that their axes of rotation overlap. Balance liquid container movement transfer system (336) can rotate more than 180° on the bearing and ensures one balance liquid container (331) is positioned to balance the unbalanced load in drum (104). Balance liquid container movement transfer system (336) is driven by balance liquid container movement motor (335) and may comprise gear to gear, chain to pulley or chain to balance liquid container movement transfer system (336). When balance liquid container movement transfer system (336) is rotated by balance liquid container movement motor (335) the centrifugal force vector (Fi) of one of balance liquid containers (331) overlap with the imbalance
force vector (Fx) and the centrifugal force vector (F2) of the other is positioned 180° away from said imbalance force vector (Fx). Because equal amounts of balance liquid (337) is present in each balance liquid container (331), there is initially no change in the balance conditions caused by the imbalance force of the unbalanced load in drum (104). At this stage, balance liquid pump (333) pump the necessary amount of balance liquid (337) to balance the imbalance force of the unbalanced load in drum (104) from the first balance liquid container (331) where imbalance force vector is to the second balance liquid container (331). Therefore a counter balance force is created to balance the imbalance force of the unbalanced load in drum (104). When balance is established pumping operation needs to be stopped and balance liquid transfer connection lines (334-L) need to be blocked so that balance liquid (337) cannot flow back. If stopping the operation of balance liquid pump (333) is not enough to block balance liquid transfer connection lines (334-L), a balance liquid valve (338) needs to be installed on said block balance liquid transfer connection line (334-L). If balance liquid pump (333) is capable of pumping balance liquid (337) from one balance liquid container (331) to the other in two directions, then rotating balance liquid containers (331) 180° around the axis of rotation of drum (104) will be sufficient for the imbalance force of the unbalanced load in drum (104) and balance liquid container axis (339) to overlap. The direction and magnitude of the imbalance force of the unbalanced load in drum (104) will change during the spin cycle due to the materials being displaced within drum (104) and water discharge from the materials. It is possible to change the position of balance liquid containers (331) and, if necessary, transfer balance liquid (337) between balance liquid containers (331), depending on the position of the changing imbalance force of the unbalanced load in drum (104). The magnitude of the imbalance force of the unbalanced load in drum (104) will
decrease during the spin cycle as water is discharged from the materials. When the magnitude of the imbalance force of the unbalanced load in drum (104) decreases, balance liquid (337) transferred to the other balance liquid container (331) will need to be transferred back. This can be achieved using balance liquid pump (333) or opening balance liquid valve (338) so that balance liquid (337) can flow back. When the rotation of drum (104) slows down at the end of the spin cycle, balance liquid valve (338) can be opened to balance the amount of balance liquid (337) in the two balance liquid containers (331). If the volume of balance liquid containers (331) is large enough, it is possible to supply additional balance liquid (337) to said balance liquid containers (331) during the balancing process. This can also be done before the wash cycle, before the spin cycle, and if the necessary fittings are present, during the spin cycle, in view of the possible magnitude of the unbalanced load in drum (104) depending on the type of materials being treated. Therefore, the machine with the desired balancing capacity can be designed.
55- A balance system comprising one rotatable balance liquid container (340) according to the present invention is explained below via Figures 77.
A balance system similar to the one described above, but having one rotatable balance liquid container (340) capable of rotating 360°. This system utilizes an equilibrium weight (341) positioned opposite rotatable balance liquid container (340) to balance it. When rotatable balance liquid container (340) is rotated and positioned opposite the imbalance force of the unbalanced load in drum (104), the necessary amount of balance liquid (337) can be transferred from an equilibrium liquid container (342) to rotatable balance liquid container (340). In this embodiment, the liquid transferred to rotatable balance liquid container (340) is returned to equilibrium liquid
container (342) at the end of the spin cycle. As alternative to equilibrium liquid container (342), balance liquid (337) may be supplied by balance liquid fittings (343) connected to drum (104). Water fed to drum (104) and used as balance liquid (337) in rotatable balance liquid container (340) can be removed via the discharge line during and/or at the end of the extraction cycle.
56- Balance weights moving awav from the center according to the present invention is explained below via Figures 60.
An exemplary system is a system comprising bodies of equal weight that can balance each other when positioned equal angles apart on weight guide bearing for 3-weights balance system (304) as close to weight starting position for 2-weights balance system (322) as possible. Threaded balance weight movement screw connected to balance weight movement motors (306) positioned close to cylindrical perforated drum sheet (106) as shown in Figure 85 is passed through threaded holes on balance weights to provide bearing on the drum sheet for said balance weights. Figures only show an embodiment comprising worm gears as bearings for the balance weights on drum (104). Other embodiments may comprise any bearing system known in the art wherein balance weights can move thereon. When worm gear is rotated by the motor, the balance weight moves away from the rotation axis and towards the edge of the cylinder. As the balance weight moves away from the rotation axis, the generated centrifugal force will increase. As the system comprises at least three balance weights, two weights can be moved together depending on the position of desired counterweight force vector if needed to create a force vector of desired direction and magnitude. Therefore, counterweight force of desired direction and magnitude may be created using weights that are displaced to different degrees towards the
outside of drum (104). To achieve this, the highest imbalance load possible to be generated in drum (104) for the spin cycle must be determined beforehand. It is possible to increase the proportion of the counterweight force to the total weight by dividing the weights into smaller weights and increasing the number of weights while keeping the total weight constant. However, it should be taken into account that each weight requires its own motor gear system.
In addition, the addition/removal of extra weights described above for two- weights balance systems can also be applied to this embodiment. Depending on the imbalance load, additional balance weights (303) may be added to balance weights for 3-weights balance system (301-w).
57- A balance weight rotating and getting further away from the center according to the present invention is explained below.
It is possible to combine the two exemplary systems explained above to create a third embodiment as well as design different embodiments. It was mentioned above that the balance systems must comprise at least two weights. Said two weights are mounted opposite each other close to the rotation axis of the drum on the frontal and/or rear section of the drum on a bearing system capable of rotating 360° as in the first example. Different to the two-weight balance system described above, in this embodiment while one weight is fixed in position near the center, the other weight can move towards cylindrical perforated drum sheet (106) as in the three-weight balance system. In the balancing step, the system rotates until the moving weight is positioned against the imbalanced load. The moving weight then moves towards cylindrical perforated drum sheet (106) until a counterweight equal to the imbalanced load is generated.
While it is preferable that the mechanical and electrical systems of the balance systems are placed in water-free zones (100) of drum (104), said balance system is also applicable to currently available drums (104) rotating in water tank/outer drum (101). The motors used in the system are chosen from among motors capable of operating in water or the whole of the balance system including the motors are isolated against water. When the balance system is isolated in this manner, it can be used with drums (104) rotating in water tank/outer drum (101).
The "mechanical and dynamic balancing method" described in detail for washing machines with a drum can be applied to any type of weight rotating at high speed and having changing imbalance conditions. It is to be noted that systems rotating horizontally or at an angle with the horizontal axis also include centrifuge machines rotating at high speeds at a 90° angle with the horizontal axis. While these vertically rotating systems do not have the resonance issues associated with horizontally rotating systems, it is known that said vertical systems used for spin cycles also have significant balance issues. In vertically rotating centrifugal spinning machines, the water exiting drum (104) is discharged from the machine directly via a discharge channel; therefore precautions for protecting the balance system against water can be easily taken.
58- motors, moving transfer systems, liquid and/or gas connection systems simplify the application of many possible balancing systems on the drum.
The fact that a practical balancing system could not be applied successfully to the washing machines (50) before the present invention was due to the fact that the drum (104) was in a water-filled water tank/outer drum (101). When poly-rib system (60) is applied, we have had the possibility to remove a very important part of the drum (104) out of the water tank/outer drum (101) due
to no more need for an outer drum that pack the drum completely. This allows us to place many useful moving parts inside drum (250) in the drum, while at the same time enabling the application of a wide range of balance systems (300) that can be driven by balance weight movement motor (306), motion transfer systems, fluid/water connection, pressurized air/gas supply, pneumatic or hydraulic systems on the outer surface of the drum. So not only examples giving above but all other known balance systems (300) having self-moving systems consuming any kind of feeding energy be able to apply on the drum. It is not the technique of the balancing system that is important, but applicability of the said technique on the drum is valuable.
59- The electrical and control systems on drum (104) according to the present invention are explained below.
It is possible to mount electric, electronic, control systems (900) on a drum (104) fully packed in a water tank/outer drum (101) of a conventional washing machine by taking the necessary isolation precautions so that they are not adversely affected by water. To achieve this, it is possible to isolate the areas where said systems are located or using devices that are manufactured to be waterproof. However, it is clear that a drum (104) having some water-free zones (100) or drum (104) being partially taken out of water tank/outer drum (101) has many advantages in terms of use and maintenance of electrical devices on drums (104) over a drum operating in a water tank/outer drum (101) at least partially full with water. Therefore, as it will be possible and easy to provide electrical connection to drum (104) without needing insulation, mounting electric, electronic, control systems (900) will be possible. It is possible to mount the sensors, motors, electronic control cards/circuits, control and programming devices such as PLC-PC or similar to drive and control moving parts outside drum (251), and the
associated inlet/outlet modules, wired and wireless communication receiver/transmitter devices and similar electric and electronic devices and all types of equipment used for the mounting thereof, power sources such as accumulators or batteries to ensure said devices are operational under any condition and all cables and equipment necessary for connecting electric, electronic, control systems (900) directly on drum (104) inside or outside electric system panel on drum (901). While it is possible for electronic control systems on drum and main control systems of the machine to communicate via a communication cable it will be difficult to realize. On the other hand, recent developments in robotics have made it possible to apply slip rings for electric, electronic cables (902) providing energy and data transfer between moving parts onto drums (104). However, it is preferable that control systems are mounted on drum (104) and in wireless communication with other units outside of drum (104). The most suitable place for electric system panel on drum (901) for mounting electronic, control systems on drum is the area around drum shaft (103), as it will be easier to reach this area and provide maintenance to said panels. Providing all requirements of devices mounted on the drum by direct electrical connection to drum and the devices on the drum and having no electrical connection other than the slip ring on drum shaft (103) will be advantageous in ensuring that the system operates practically and smoothly.
60- Mounting pneumatic systems on the drum according to the present invention is explained below.
It is clear that pneumatic or hydraulic hardware are necessary for cases where means such as covers, pistons and valves are used on the drum. Therefore, hoses and connections and related fluid based control, directing, opening/closing systems need to be present on the drum so that said
systems can operate. While it is possible to use different systems such as pressurized air, steam, hydraulic oil or water systems; pressurized air systems are most preferable as they are sufficient, economic and easy to use. The pressurized air required by the pneumatic systems may be provided via drum shaft (103). However if the amount of air required is small enough to be generated on the drum, an air source such as a small air compressor/pump (907) would be sufficient.
61- Transfer of electricity and fluids to drum (104) according to the present invention is explained below via Figures 79, 80.
The energy required by moving mechanisms, all types of devices and systems operating on the drum must be conducted to the drum. The most suitable means for conveying resources such as electricity, pressurized air, steam etc. via equipment such as cables, hoses and pipes is drum shaft (103). Electricity may be transferred to the drum by a continuous cable system having a slip ring for electric, electronic cables (902, 908). As shown in detail in Figure 79C, said slip ring comprises a slip ring copper ring (909) on drum shaft (103) that is rotatable along with said drum shaft (103), a cable connected to said ring, and a mechanism on the fixed side comprising a slip ring spring mechanism (910) providing a strong connection to said copper slip ring and having a slip ring conductive coal (911) connected to an energy source from the other end. When the electric current coming from the energy source is transmitted to slip ring copper ring (909) via slip ring conductive coal (911), electricity is transferred from the fixed side to the drum.
Transfer of fluids such as air and steam to drum (104) may be done by a rotatable fluid connection element (912) operating with similar basic principles. As shown in Figures 79B and 80, the suitable connection point for said rotatable element will be the rotation axis of drum shaft (103) at the
outside end of said drum shaft (103). The rotatable element may be used to convey one or more fluids. Therefore, it is possible to transfer different fluids to the drum at the same location.
After energy transfer via electricity transfer slip ring (908) and fluid transfer via rotatable fluid connection element (912) to drum shaft (103) are realized, they are transferred to drum surface via holes inside the shaft or by connecting to the surface of the shaft. A suitable solution would be to embed them in hose/cable recess (915) or positioning them on holes made on the surface, under parts such as pulleys, bearings and ball bearings between the location where hoses/pipes embedded in drum shaft (903) are embedded in hose/cable recess (915) on drum shaft (103) and the drum.
62- Transferring pressurized fluids to the drum according to the present invention is explained below via Figures 79, 80.
Aside from pressurized air, pressurized water or other fluids may be needed on the drum. Pressurized fluid connection may be realized by a rotatable fluid connection element (912) allowing transfer of pressurized water on the shaft, same as the pressurized air connection. The main issue with transferring fluids such as air and water via rotatable elements is sealing. The seals must be constantly maintained and replaced over time. Whereas, having electrical energy on drum (104) allows for generation of pressurized water on drum (104), just like pressurized air. Having reasonable pressurized water requirements makes it possible to fulfill said requirements by a pump and pressure tank on the drum.
63- Direct pressurized steam connection to drum and heating thereof according to the present invention are explained below via Figures 79, 80.
The pressurized fluid connection to the drum as proposed by the present
invention also allows the heating requirement common to many treatments in drum (104) to be fulfilled efficiently and directly inside the drum. Pressurized steam is conveyed to drum (104) via fluid transfer line (912, 903) and enters inside through suitable places on the drum sheet and provides heat in a controlled manner to drum (104), materials being treated in said drum and the present fluids. Steam may be conveyed into the drum from one position or via multiple pulverizers distributed inside the drum. If the directly or indirectly heated drum (104) is desired to be isolated, it will be possible to isolate drum outer surface (104-s) using a suitable isolation system, will provide energy savings as well as decrease the time required for heating and increase efficiency.
64- Electric drum heating elements according to the present invention are explained below.
In machines where drum (104) is rotated inside a water tank/outer drum (101), the water is heated in said water tank/outer drum (101). In a system proposed by the invention having a water accumulation chamber (502) and the circulation system can collect a certain amount of water therein, it is possible to apply a heating system comprising electric heating elements in drum wet-outer surfaces (104-w). Additionally, in embodiments comprising a water circulation system electric heating elements or steam injection systems may be placed in said water circulation system to provide heating. However, in the embodiments of the present invention where water tank/outer drum (101) is removed and there is not enough water in the circulation line when all the water in water tank/outer drum (101) is discharged, electrical heating elements or steam injection system must be placed in a different location. Being able to transfer electricity, steam and pressurized air to drum (104) provides a solution to this problem as well. An embodiment of the invention
as shown in Figure 116 comprises drum heating elements (913) mounted inside drum (104) can heat both the water and the textiles inside drum (104) by direct contact at the desired speed and, as they are monitored by sensors, allow water and textiles to remain at the desired temperature. When drum heating elements (913) mounted inside drum (104) are applied to cover large surfaces, they can be operated at low temperature differences so that they do not harm the material inside the drum through contact. When steam connection is provided to the drum, heating can be done directly via drum heating steam injection system (914) or indirectly by steam passing through a steam jacket placed in a no-hole region of the drum.
65- Use of heaters inside drum (104) as dryers according to the present invention is explained below.
Applying electric drum heating elements in drum (104) in the manner that they do not come directly into contact with the materials allows said drums to also be used as dryers. The water circulation system of the system can be used to provide air circulation in this treatment supplication. In this way, the steam mixed with the air in the heated drum can be discharged via the circulation line and can be discharged directly or after condensation through a discharge line.
66- Use of aas burner f921j to heat drum fl04j from the outside according to the present invention is explained below, via Figures 1, 2, 9, 24, 30, 69
One of the most important aspects of the invention is direct heating of drum (104) using gas, for previously explained reasons. This invention also provides solutions to many problems associated with embodiments disclosed elsewhere in this document. One problem that needs to be solved in relation to washing operation taken place in a closed drum (104), especially as
explained in section 24 titled "Discharging water from drum (104) via drum discharge chamber water discharge valve (519) to create completely closed drum", the problem of heating the water once it is in drum (104). A way of heating water without taking it out of drum (104) is using drum heating elements (913) placed in drum (104). However, as drum heating elements (913) require electrical systems and fittings to supply the required energy, which increases with drum capacity and can therefore only used with machines having low capacity. It was stated before that machines with high capacity require use of steam for heating. This is achieved by injecting steam directly into drum (104) using rotatable fluid connection element (912) described by the invention or passing steam through a serpentine or jacket around drum (104) to heat the water within. While it is possible to utilize these two heating systems, use of gas burners (921) to heat drum (104) is preferable due to its practicality and low cost. In order for this system to be applied to drum (104) in an efficient manner, there must be a large non- perforated heating area (920) on drum outer surface (104-s). Methods for creating said non-perforated heating area (920) was explained in section 18 titled "the features of the drum and drum perforations in peripheral zone (509) forming a peripheral perforated narrow band zone (510)." When exit of water from drum (104) is confined to drum perforations in peripheral zone (509) in a peripheral perforated narrow band zone (510), the area outside said narrow area, cylindrical drum sheet having holes in the said peripheral perforated narrow zone (510) can be used for other purposes. Cylindrical drum sheet having holes in the peripheral perforated narrow zone (510) is not perforated and is very suitable to use as a non-perforated heating area (920) for drum (104). The heat produced by the fire created by the combustion of gas in the gas burner (921) placed under cylindrical drum sheet having perforations in the peripheral perforated narrow zone (510)
reaches cylindrical perforated drum sheet (106) via heat transfer leaves/fins (922) placed on the surface of drum (104). Gas burner (921) system is also applicable for all drum types that has peripheral perforated narrow zone (510). Gas burner (921) placed under the non-perforated cylindrical or protrusive drum surface part of the drum. Having an open flame is not suitable for the technique, safety regulations, guidelines for using gas equipment, the standards and the desired efficiency of the machine. First the flame must be secured and flue gases need to be removed. Therefore, a combustion chamber (923) needs to be created; starting from the gas burner (921) and encompassing the areas where heat transfer leaves/fins (922) placed on the surface of drum (104) are located. A tank that is similar to drum discharge chamber (517) used for water leaving drum (104) from drum perforations in peripheral zone (509) is placed surrounding the area where areas where heat transfer leaves/fins (922) are placed on the surface of drum (104) as a combustion chamber. The hot air mixture passes between heat transfer leaves/fins (922) placed on the surface of drum (104) and rises to the top of drum (104) through said combustion chamber. Said combustion chamber comprises a fume hood and flue connection (924) for collecting flue gases. It is clear that there needs to be an opening between the combustion chamber and drum (104). A combustion chamber flue fan (925) is positioned in the combustion chamber at the flue connection (924) to create negative pressure so that flue gases do not escape through this opening.
Another advantage of heating drum (104) directly using the heat produced by the gas burner (921) aside from the speed of heating is the speed of the change in the temperature of the washing water. When combustion starts in gas burner (921), the effect of heat in drum (104) can be seen quickly. Therefore, it will be easier to maintain the washing water temperature at the desired value.
It is clear that the most suitable fuel for gas burner (921) used to heat drum (104) is liquid petroleum gas or liquid natural gas. However, it should be noted that any other type of fuel suitable for gas burners (921) may be used.
Heating the water and materials within drum (104) directly is a preferable method due to its practicality and low cost as well as its speed. However, its application requires that a large section of drum (104) be non-perforated and that drum perforations in peripheral zone (509) are located in a peripheral perforated narrow zone (510). Such an application is only one of the embodiments described by the present invention, and is not possible to use with many of the embodiments. In this case, this heating system may be applied to water chamber (500), half water chamber (505) or water tank/outer drum (101) instead of directly to drum (104). In these embodiments, the water leaving drum (104) is collected by water chamber (500) or water tank/outer drum (101) and discharged. When the interior of drum (104) is desired to be heated, water chamber (500), water storage chamber (504), water chamber discharge line (511-d), half water chamber (505) or water tank/outer drum (101) can be heated by one of the heating methods described above.
67- Use of electrical heating coils (926) to heat drum (104) from the outside according to the present invention is explained below.
The method of heating drum (104) from the outside directly by a gas burner (921) was explained above. In addition, heating the washing water via drum heating elements (913) placed within drum (104) was also explained. A disadvantage of this method is the difficulty of transferring electrical energy to the interior of drum (104). Transferring energy to drum via contact marks on electricity transfer slip rings (908), which are usually coal, will limit this application. On the other hand, it is possible to use electrical heating coils
(926) instead of a gas burner (921) to heat drum (104) from the outside. Moreover, this application has a wide variety of possibilities in terms of power and resistance. Unlike the gas burner (921), it is not necessary for electrical heating coils (926) to be placed beneath drum (104), so a wider area of drum (104) can be used as a non-perforated heating area (920). This application also eliminates the need for a flue connection (924).
68- Use of steam to heat drum 104") from the outside according to the present invention is explained below.
The method of heating drum (104) from the outside by electrical heating coils
(926) was explained above. A similar application is the use of a steam jacket
(927) surrounding drum (104). However, as said steam jacket (927) will not be indirect contact with drum (104), the heat transfer from steam jacket (927) to drum (104) will be delayed. This will extend the heating time and make it difficult to control the temperature within drum (104).
69- Sensors on the drum according to the present invention are explained below.
The present invention makes possible many applications in drum (104) that were not possible until now. Mounting monitoring and control systems that have so far not been used directly on the drum interior surface in order to closely monitor and control conventional applications and allow for new and more sensitive applications and makes close monitoring and control of the conditions of the ongoing treatment in drum (104) and the effects of said treatment on the materials therein possible. The state of the treated materials can be monitored by sensors inside the drum instead of taking samples by regularly stopping the operation of the machine.
70- Lighting units inside drum (918) according to the present invention are
explained below via Figures 24, 32.
Monitoring the conditions of the treatment operation inside drum (104) makes it possible for the user to increase efficiency by changing operating conditions, detecting and solving problems and finding new ways to improve drum design. However, because the inside of drum (104) is dark, it is not easy to monitor visually. Lighting provided through the glass on the cover is limited and cannot fulfill the desired function. Whereas Figure 115 shows an embodiment comprising a lighting system comprising lighting units inside drum (918) dispersed on drum inner surface (104-n) surface, wherein said lighting system can be programmed so that only the lighting units having the desired angle based on the position of drum is turned on during rotation of drum, thereby providing optimum lighting for visual monitoring of the drum interior.
71- A fluid injection system injecting fluid into drum fl04j according to the present invention is explained below.
Necessary fluids, such as chemicals are transferred to drums (104) rotating in fully closed water tank/outer drum (101) via said water tank/outer drum (101). In some applications, liquid or gaseous chemicals are directly injected into the drum via drum door (118). As water does not enter drum (104) via water tank/outer drum (101) according to the present invention, it is generally not possible to convey fluids via drum door (118) and circulation system. If homogeneous and fast distribution of the chemical within drum (104) and homogeneous contact of the chemical with the material is desired, it would be advantageous to inject the chemical from multiple locations. The proposed invention makes it possible to provide chemical inlet from every surface of drum (104). The desired chemicals are conveyed to drum (104) via drum shaft (103) using rotatable fluid connection element (912) and
hose/pipe embedded in drum shaft (903) and transferred to a distribution system in order to reach pulverizing nozzle inside drum (919) placed along drum outer surface (104-s) and are injected into the drum as shown in Figure 105. Fluid may be injected into drum (104) by pulverizing nozzles inside drum (919) adjusted to the pressure required by the treatment. The chemical to be injected may be concentrated or dissolved in water or another suitable solvent. When chemicals are injected into drum (194) from multiple locations, injection time will decrease and the efficiency of chemical treatments that require homogeneous results such as dyeing and bleaching will increase.
72- High pressure pulverizing system in drum fl04j according to the present invention is explained below.
Flaving the water inside drum (104) be drawn out, pressurized and injected back onto the materials by pulverizing nozzle inside drum (919) will aid in increasing the physical effect imparted during the treatment. In order to achieve this, a high pressure pump mounted on drum (104) will direct the water exiting the drum that is collected in drum discharge chamber (517) via the pressurized water line at its outlet to pulverizing nozzles inside drum (919) whereby it is injected back into the drum. This embodiment is advantageous for industrial textile washing machines (52) and industrial parts dyeing machines (53).
73- High pressure chemical pulverizing system by a pump on drum fl04j according to the present invention is explained below.
Chemicals are transferred to drum (104) via hose/pipe embedded in drum shaft (903), pressurized in a high pressure pump on the drum and the injected in to drum via pulverizing nozzles inside drum (919) in concentrated form or after being diluted by the solvent present in the drum.
74- Simultaneous transfer of multiple fluids into the drum according to the present invention is explained below via Figures 80.
If the treatment requires transfer of different fluids at different points during the process, hoses/pipes embedded in drum shaft (903) can be used for different functions at different times as in the embodiment shown in Figure 104A. Hoses/pipes embedded in drum shaft (903) may be used for transferring steam to the drum (104) to provide heating at the beginning of the treatment may be used for transferring chemicals later on in the process. In treatments where multiple fluids need to be transferred at the same time, multiple hoses/pipes embedded in drum shaft (903) must be used. In the embodiment shown in Figure 105, a gradually rotatable fluid connection element (912) is placed on drum shaft (103). In this embodiment, a wider hose/cable recess (915) in drum shaft is needed in order to accommodate the multiple hoses/pipes embedded in drum shaft (903) having different diameters that need to be placed on drum shaft (103). This will be possible by creating housing(s) on drum shaft (103) surface. Fluids are transferred to the drum via each rotatable fluid connection element (912) placed on the rotation axis of drum shaft (103), through hoses/pipes embedded in drum shaft (903) placed in hose/cable recess (915) in drum shaft and reach drum outer surface (104-s) surface by passing under drum pulley (116), drum shaft bearing (102), drum shaft ball bearing (102-b), electricity transfer slip ring (908) on drum shaft (103). If systems for controlling the flow of these fluids are placed here, the fluids are transferred into drum (104) in a controlled manner via distribution lines and injectors or pulverizing nozzles inside drum.
75- The machine having a fixed chassis (111) according to the present invention is explained below.
One feature of the invention is that because there is no drum (104)-water
tank/outer drum (101) connection, drum is directly connected to fixed chassis (111). The mechanical structures required by a system wherein the drum is connected to a fixed chassis by bearings is vastly different than that required by a drum (104)-water tank/outer drum (101) connection system. Conventional machines with a fixed chassis have a simpler structure compared to machines having high speed spin cycles; however, they must have a strong drum (104)-water tank/outer drum (101) connection due to the stretching during low speed spin cycles. In freestanding machines wherein drum (104) and water tank/outer drum (101) have a flexible structure, this connection must be even stronger. The system proposed by the invention
76- The method of performing stone-washing operation bv decreasing the amount of water and washing operation bv increasing the amount of water according to the present invention is explained below.
It is not expected for the adverse effects caused by problems such as pump malfunction or power failure to have a serious adverse effect for industrial type machines with the proposed system. As industrial washing machines are used in places where precautions against flooding have been taken, it will not be a major problem if the water exiting the drum and collecting in water collection and accumulation chambers (501, 502) overflows. However, the same is not true for household washing machines (57). Nowadays, washing machines are used even in spaces where flooding will cause a serious problem. Therefore, machines with these features must comprise a water accumulation chamber (502) with a large enough capacity to contain the maximum amount of water that drum (104) can hold without overflowing into water-free zones.
Eccentric rollers oscillating in left-right direction will have a wide range of applications in washing machines for providing rubbing effect.
This is why it is important to place molded roller housing water discharge holes (235) described above at the bottommost sections of the molded housing where the materials being treated cannot reach them.
List of Parts
The following numerals are referred to in the detailed description of the present invention:
Washing machine 333 Balance liquid pump
Industrial washing machine 334-L Liquid transfer line between balance containers
Industrial textile washing machine 334-G Air transfer line between balance containers
Industrial piece dyeing machine 335 Balance liquid container movement motor
Balance liquid container movement transfer
Industrial stone washing machine ^35
system/gear
Industrial heavy material washing machine 336-b Balance liquid container movement belt/chain
Commercial washing machine 337 Balance liquid
Household washing machine (Household W.M.) 338 Balance liquid valve
Front Loading Commercial Washing machine 339 Balance liquid tank axis
Side Loading Commercial Washing machine 340 Rotatable balance liquid container
Poly-Rib System 341 Equilibrium weight
Eco-Drum System 342 Equilibrium liquid container
Water-free zones 343 Balance liquid fittings
-w Wet areas/ surface 344 Balance control system
Water tank/ outer drum
Drum shaft bearing 400 Motor system
-b Drum shaft ball bearing 401 Movement transfer system
Drum shaft 402 Movement transfer part such as belt
-C Water entrance to drum through drum shaft 403 Drum peripheral rotation pulley
Drum
-n Drum inner surface 411 Movable belt for drum peripheral rotation pulley-s Drum outer surface 412 Motor directly connected to roller
-w Drum wet-outer surface 413 Motor driving multiple movable parts
Drum perforations/holes 414 Gear connected to motor
Perforated drum sheet 415 Pulley transferring movement to rollers
Lifter ribs 416 Idler pulley bearing
Drum entrance/inlet opening 417 Idler pulley
Drum front circular base /opening side 418 Gear connecting to rollers and each other
Drum rear circular base /shaft side 419 Roller pulley
Fixed chassis 420 Roller pulley belt
Circulation pump
Circulation line 500 Water chamber
Water chamber surrounding partially perforated
Drum drain chamber circulation line 501
cylindrical drum surface
Drum opening drain chamber circulation line 502 Water accumulation chamber
Gap around drum opening between drum and
503 Water chamber drain outlet
front panel
Drum rotation motor 504 Water storage chamber
Drum pulley 505 Half water chamber
Outer frame of the machine 506 Water chamber around drum opening gap
Water chamber-water storage chamber Drum door 507
connection
Machine front panel 508 Flow path on water chamber
Outer frame chassis 509 Drum perforations in peripheral zone Water tank service door 510 Peripheral perforated narrow zone
Water barrier 510-n Peripheral non-perforated zone
Water Circulation/discharge line valves 511 Water chamber barrier
511-0 Water chamber overflow line
Motor to move parts on the drum 511-d Water chamber discharge
Cylindrical or conical drum sheet having holes in Pneumatic system to move parts on the drum 512
the narrow belt zone
Electrical drive motor on drum 513 Steam/gas flue outlet from water chamber
Electrical drive motor on fixed chassis 514 Steam/gas flue fan
Motor connected to moving part 515 Steam/gas flue chimney systems
Moving parts system 517 Drum discharge chamber
Isolated areas in movement system 518 Drum discharge chamber water valve opening- Cover for isolated areas in movement system 519 Drum discharge chamber water discharge valve
Pneumatic piston of drum discharge chamber
Isolated units in movement system 520
discharge valve
521 Drum discharge chamber water valve door
Moving parts 522 Tank-front panel connection
Roller 523 Tank-drum chassis connection
Abrasive roller 524 Water channel/Poly-Channel
Brush roller 525 Poly-Ribs / protrusions / sheet bar / grate bars Eccentric roller 525-S Protrusive drum surface forms
Roller bearing 525-m Movable protrusive parts over drum surface Roller frontal bearing 526 Water channel grate
- Roller rear bearing 527 Angularly cut water channel sheet/grate bars
Drum opening water collection chamber
Abrasive grindstone roller 528
circulation pump
Grindstone pieces 529 Drum chassis
Fixed brush between rollers 530 Gasket at the outside of the water chamber
Recessed protruding threaded roller 531 Tent on the protrusions
Tab of recessed protruding threaded roller 531-g Gap under the protrusions/tents
Recess of recessed protruding threaded roller 532 Water inlet
Grindstone of recessed protruding threaded
-s 532-a Drum collection chamber circulation entrance roller
Cylindrical grindstone 532-b Drum opening gap chamber circulation entrance Spherical/buckled grindstone 533 Hinged drum door
Grindstone carrier 534 Hinged drum door water inlet hole
-2 2 flat surface on circular shaft carrier 535 Hinged drum door hinge
-4 Quadrangular grindstone carrier 536 Hinged drum door lock
Roller frontal bearing shaft 537 Hinged drum door rotatable buffer gasket Roller frontal bearing shaft housing 538 Hinged drum door gasket
Roller frontal bearing lock system 539 Hinged drum door rotatable buffer
Fixed grindstone piece 540 Fixed chassis drum safety door
Fixed grindstone rod 541 Bearing for rotatable door on fixed door Material holding part 542 Rotary door carried by a door with a bearing Protrusive surface of fixed grindstone
Water discharge recess in household drum sheet Water channel 601
around perforated area
Oscillating part 602 Household drum bearing system
Vibrating part 603 Household drum shaft
Vibrating part connection spring 604 Household drum
Vibrating part platform 605 Household drum holes/perforations
Vibrating part vibrator 606 Cylindrical household drum sheet
Roller shaft lock 607 Household lifter ribs
-2 Roller shaft lock part 608 Household drum entrance/inlet opening
Protrusions on protruding parts in rollers 609 Household drum frontal circular base sheet
Protruding parts in rollers 610 Household drum rear circular base sheet
Propeller parts in rollers 611 Household water chamber
Roller rear bearing shaft 612 Household circulation pump
-f Shaft-roller connection 613 Household circulation pipeline
-fl Shaft-roller cornered lock structure 614 Household door bellow
-f2 Shaft-roller wedged lock structure 615 Household drum opening water chamber-r Shaft-movement system connection 616 Household outer frame
Roller ball bearing 617 Household drum door
Roller shaft seal ring 618 Household frame frontal sheet
Roller bearing water discharge hole 619 Water discharge chamber
Household water discharge chamber peripheral
Molded roller housing 620
cover sheet
Molded roller housing water discharge hole 621 Household drum water channel / Poly-Canals Fixed part housing in molded roller housing 622 Household drum water channel grate
Molded roller housing lock system 623 Household grate bars / Poly-Ribs
Household water collection chamber -storage Molded roller housing-drum connection 624
tank connection
Shaped sheet roller housing 625 Household water collection/storage tank
Household drum opening water collection tank- Conically molded roller housing 626
water collection/storage tank connection Conically molded roller housing water channel 627 Household drum entrance opening gap
Drum sheet in the form of roller housing 628 Household drum rotation motor
Fixed grindstone 630 Plastic molded balance part
Single metal weight on plastic molded balance
Roller side bumper prevent material entrance 631
part
Two metal weights on plastic molded balance
632
part
Moving parts inside of the drum 633 Balance part bearing
Moving parts outside of the drum 634 Balance part bearing wheel
Moving abrasive parts 635 Balance part movement motor
Protrusions on cylindrical drum surface 636 Balance motor housing on drum sheet Recess between protrusions on cylindrical
637 Balance motor movement gear
drum surface
Abrading inner drum surface 638 Balance part movement gear
Abrading sheet
Abrading hard parts 700 Movable drum fin
Abrasive/ perforated/Protrusive surface structure
701 Movable fin side sheet hinge
of drum
702 Movable fin side sheet
Balance system 703 Movable fin topsheet
-C Balance control system 704 Movable fin jack
-f Front balance system 705 Movable fin motor
-r Rear balance system 706 Movable fin jack gear shaft
707 Movable fin jack gear shaft nut
Balance weights 708 Movable fin jack cross arm
-S Balance weight handling and rotation structure 709 Movable fin jack gear nut joint
-W Balance weight system 710 Movable fin topsheet - cross arm connection joint
2-weights balance system 900 Electric, electronic and control systems-w Balance weights for 2-weights balance system 901 Electric system panel on drum
-S Balance weight bearing system 901-C Electric system panel cover
Additional balance weight 902 Slip ring for electrical, electronical cables
Balance weight pieces for 3-weights balance
-P 903 Hose/pipe embedded in drum shaft
system
-w Balance weight for 3-weights balance system 904 Electric dynamo in drum
Weight guide bearing for 3-weights balance
905 Direct gas heating system
system
Threaded balance weight movement screw 907 Air compressor/pump
Balance weight movement motor 908 Electricity transfer slip ring
Weight guide path 909 Slip ring copper ring
Balance weight handling and rotation structure 910 Slip ring spring mechanism
Weight-guide path lock system 911 Slip ring conductive coal
Gear connected to motor 912 Rotatable fluid connection element
Gear chain/belt 913 Drum heating element
-b Balance sensor 914 Drum heating steam injection system
Claims
Ij _ A washing machine (50) for performing wet, dry, physical or chemical treatments on materials, comprising a front loading (58) or side loading (59) perforated drum (104) which is mounted respectively by means of a drum shaft (103) at the rear or by means of the drum shafts
(103) at both sides horizontally or having an angle with the horizontal axis to a drum shaft bearing (102) system so as to rotate around the bearing axis characterized in that said washing machine (50) comprises said drum (104) comprises a motor system (400) generating and/or transferring movement and dynamic moving parts (200) connected to said motor system (400) and electric, electronic and control systems (900) required for and/or connected to said systems (400, 200) for the operation thereof with the systems (400, 200, 900) being mounted outside and/or inside the drum (104) so as to, during the performance of all processes with water in the drum (104) required by the functions of the washing machine (50), contribute to the operation of the washing machine (50) and/or to the performance of the process carried out in the washing machine (50) and/or to provide savings on water, energy, chemicals or time used by the washing machine (50) and/or to increase the capacity of the washing machine (50) and/or to generate physical effect on the material treated in the drum
(104) or increase the physical effect generated by the movement of the drum (104) and/or to increase the quality of the product.
2} _ A washing machine (50) as described in Claim 1, characterized in that; at least one element of said motor system (400) generating and/or transferring movement and dynamic moving parts (200) is mounted outside drum (104) and said moving parts (200) connected thereto and electric, electronic and control systems (900) necessary for the operation of
said motor systems (400) outside drum is positioned on drum surface of the drum (104) such that it does not come into contact with water and continue its operation under any condition.
3} _ A washing machine (50) as described in Claim 2, characterized in that; said motor system (400) mounted outside the drum (104) and generating and/or transferring movement comprises at least one of the motor to move parts on the drum (130), movement transfer parts such as belt (402) in order to generate or transmit movement, said motor system (400) comprises the required ones among sensor, control systems, electrical and/or electronic pressurized air systems, vapor systems, cable, hose, connection means, panel components or systems as mounted to the drum (104) which are used together with said movement transfer parts such as belt (402).
4} _ A washing machine (50) as described in any preceding Claim, characterized in that; said motors to move parts on the drum (130) providing movement in the moving parts (200) outside and/or inside the drum (104) are devices which are operable in the atmospheric conditions and the ambient conditions suitable for the operation of the washing machine (50) and apparatuses and equipment related to the washing machine (50), said drum (104) comprises sources of electricity or pressurized air required for the operation of said motors to move parts on the drum (130) are provided on the drum (104), and said drum (104) contains the conditions suitable for the operation of said motors to move parts on the drum (130) and all types of electric, electronic and control systems (900) which should be provided on the drum (104) as connected to the motors to move parts on the drum (130).
5} _ A washing machine (50) as described in any preceding Claim, characterized in that;
said electric, electronic and control systems (900) required for the operation of said motors to move parts on the drum (130) can be mounted onto the drum (104), said motors to move parts on the drum (130) are directly connected to the moving parts (200), groups or systems, or said motors to move parts on the drum (130) are connected to the moving parts (200) by means of movement transfer parts such as belt (402) such as belt, gear, chain, joint, etc.
6} _ A washing machine (50) as described in any one of Claims 1 to 4, characterized in that; said washing machine (50) comprises at least one of electric, electronic and control systems (900) such as motor, dynamo, pump, compressor, ventilator, valve, piston, etc. which are mounted outside the drum (104), said electric, electronic and control systems (900) comprise devices that do not possess isolation properties that allow them to be operable in contact with or submerged in water, said drum (104) comprises the electrical connections required for the operation of said electrical devices are provided on the drum (104), and all types of electrical or electronic systems required for the operation of said electrical devices can be mounted onto the drum (104).
7} _ A washing machine (50) as described in any preceding Claim, characterized in that; the components of the motor system (400) generating movement outside the drum (104) and the mechanical, electrical or electronic components of the movement transfer system (401) and the components of the motors to move parts on the drum (130) mounted onto the drum (104) to move said moving parts (200) in a controlled manner are positioned on drum.
8} _ A washing machine (50) as described in any preceding Claim, characterized in that; said moving system components and/or electric, electronic and control systems (900) and motor system (400) components which should be positioned in the drum wet-outer surface (104-w) of the drum (104) as connected to the moving parts (200) located on the drum (104) as well as all types of support or auxiliary components or systems for said systems (900, 400) are insulated so as not to be affected from water in case of contact with water.
9} _ A washing machine (50) as described in any preceding Claim, characterized in that; said washing machine (50) comprises the volumes containing said moving system components and/or electric, electronic and control systems (900) and motor system (400) components as well as all types of support or auxiliary components or systems for said motor systems (900, 400) which should be positioned on water-free zones (100) of the drum (104) as connected to the movement generation or transfer motor system (400) located on water-free zones (100) of the drum (104) and the systems moving as connected to said motor systems (400) contain isolated areas in movement system (142) which can be opened/closed such as gasket, compartment, cover, barrier, etc.
10) A washing machine (50) as described in any preceding Claim, characterized in that; said drum (104) comprises motor(s) to move parts on the drum (130) which provides/provide the movement of said moving parts inside of the drum (250), which are directly connected to the drum (104) and which is/are operated with electrical or pressurized air energy.
11) A washing machine (50) as described in Claim 10, characterized in that; said washing machine (50) comprises control systems, electrics, electronics, cables, hoses and other connection equipment and auxiliary devices required by said motor systems (400) in electric system panels on drum (901).
12) A washing machine (50) as described in any preceding Claim, characterized in that; the pneumatic systems to move parts on the drum (131) which operate with pressurized air or pressurized liquid fluid such as air motor, air valve, air piston, etc. and devices which operate with pressurized steam to provide the operation of the moving parts and moving systems on the drum (104) are provided on the drum (104).
13) A washing machine (50) as described in any preceding Claim, characterized in that; said machine (50) comprises a pressurized air and/or liquid line which is connected to the drum (104) or electrical components which are mounted onto the drum (104) such as water pump, hydrophore, compressor, air pump and the required ones among any kind of electric, electronic and control systems (900) and sensors which, when required, monitor and control said devices or the process being performed in the drum (104) can be operated inside or on the drum (104).
14) A washing machine (50) as described in any preceding Claim, characterized in that; said washing machine (50) comprises electricity, pressurized air or liquid fluid and steam connection from the fixed part of the washing machine (50) to the rotating drum (104) via cables and/or hoses so as to provide the energy required for the operation of the moving parts in the drum (104).
15) A washing machine (50) as described in Claim 22, characterized in that; said electricity connection is provided by means of electricity transfer slip rings (908) which are positioned on the drum shaft (103).
16) A washing machine (50) as described in any preceding Claim, characterized in that; the electric, electronic and control systems (900) which provides and controls the operation of any kind of device on the drum (104) is positioned on the drum (104), wherein the data exchange between the electric, electronic and control systems (900) on the drum (104) and other control systems of the machine (50) is carried out via the electricity transfer slip ring (908) on the drum shaft (103) and/or by means of wireless communication methods.
17) A washing machine (50) as described in any preceding Claim, characterized in that; said washing machine (50) comprises a pressurized liquid hose connected to a rotatable fluid connection element (912) which is connected to the end of the drum shaft (103) visible from the outside so as to provide the connection of air, liquid and steam fluids to the drum (104) and which transfers a plurality of pressurized air, liquid or steam fluids from outside the drum (104) onto the rotating drum (104) as well as a distribution center which is connected to said hose on the drum (104).
18) A washing machine (50) as described in Claim 25, characterized in that; the fluid hose which provides the pressurized fluid passage to the fluid center in the drum (104) via said rotatable fluid connection element (912) and the energy or communication connection cables on the drum shaft (103) are placed into the holes bored into the drum shaft (103) or hose/cable recess in drum shaft (915) formed on the visible areas of the drum shaft (103) surface.
19) A washing machine (50) as described in any preceding Claim, characterized in that; said energy or communication connection cables are placed into the hose/cable recess in drum shaft (915) bored onto the drum shaft (103) surface so as to pass under the ball bearing,
bearing or pulley components mounted onto the drum shaft (103) at the areas where such components cover the drum shaft (103) surface.
20) A washing machine (50) as described in any preceding Claim, characterized in that; said washing machine (50) comprises heating devices suitable for electrical or steam energy sources which can be directly placed into the drum (104) and which provide the heating of the material or liquids in the drum (104) when required.
21) A washing machine (50) as described in any preceding Claim, characterized in that; said washing machine (50) comprises heating devices suitable for electrical, gas, liquid or steam energy sources which can be directly placed outside the drum (104) and which provide the heating of the material or liquids in the drum (104) when required.
22) A washing machine (50) as described in any preceding Claim, characterized in that; the steam which is transferred to the drum (104) via a fluid transfer connection line (912-903), that is a pressurized fluid line to the drum (104) providing the heating of the drum (104) with direct pressurized steam connection, enters via the rear sheet of the drum (104) and controllably heats the drum (104) and the material being treated in the drum (104) as well as the existing fluids.
23) A washing machine (50) as described in any preceding Claim, characterized in that; said drum perforations/holes (105) of said drum (104) are provided in a peripheral perforated narrow zone (510) surrounding the drum (104) so as to cover a part of the cylindrical perforated drum sheet (106),
said washing machine (50) comprises a water chamber surrounding partially perforated cylindrical drum surface (501) which encloses the wet peripheral perforated narrow zone (510) area where the drum perforations/holes (105) are provided on the cylindrical perforated drum sheet (106).
24) A washing machine (50) as described in any preceding Claim, characterized in that; said washing machine (50) comprises a combustion chamber (804) which is placed so as to enclose the unperforated dry area of the cylindrical perforated drum sheet (106), said combustion chamber (804) comprises at least one heat source which heats the material washed with the washing water in the drum (104) in the desired time or which maintains the current heat level, wherein the heat supplied by said heat source is enabled to reach the cylindrical perforated drum sheet (106) in the combustion chamber (804) surrounding the drum (104) and the required amount of heat is transferred to the perforated drum sheet (106) and to the material washed with the washing water in contact with the perforated drum sheet (106).
25) A washing machine (50) as described in any preceding Claim, characterized in that; said drum (104) having at least one water-free zones (100) which cannot be accessed or contacted by the water draining from the drum (104) on at least one drum outer surface (104-S) of the drum (104) during all wet treatment application processes carried out by the washing machine (50) with water, at least one water chamber (500) surrounding the drum wet-outer surfaces (104-w) wherefrom water is discharged, for preventing water-free zones (100) coming into contact with water, collecting discharged water in the manner to prevent overflow and ensuring said collected water reaches a water chamber drain outlet (503) on said water chamber (500); and
water barriers (122) which prevent water passage from wet areas/surfaces (100-W) to said water-free zones (100) of said drum (104) to keep said part of the outer surface of the drum (104) dry.
26) A washing machine (50) as described in Claim 25, characterized in that; said water chamber (500) is designed so that at least one drum outer surface (104-s) is prevented from coming into contact with the water discharged from drum (104) in any situations and conditions, said water chamber (500) is configured to prevent the water leaving the drum (104) from reaching the level so as to reach the drum (104) again after its contact with the drum (104) is interrupted and/or prevent the water leaving the drum (104) from reaching areas or surfaces of the drum (104) which should not contact water and/or prevent the water leaving the drum (104) from leaving and/or overflowing from the water chamber (500), said water chamber (500) comprises a flow path on water chamber (508) on water chamber (500) which is configured to enable the water leaving the drum (104) to reach the water chamber drain outlet (503) and to leave the water chamber (500), the water flow capacity of said flow path on water chamber (508) to drain the water leaving the drum (104) toward the water chamber drain outlet (503) is higher than the drain flow rate of the water from the drum (104) in any case in order to prevent the water leaving the drum (104) from accumulating in the water chamber (500) in an uncontrolled manner.
27) A washing machine (50) as described in Claim 25 or 26, characterized in that; said washing machine (50) comprises a circulation pump (112) which pumps the water coming from the water chamber (500) into the drum (104) in order to provide the amount of water in the
drum (104) required during the process and to prevent the water from accumulating in the water chamber (500) up to a level to reach the drum (104) or leave the water chamber (500), the pumping capacity of said circulation pump (112) is, in any case, higher than the flow rate of the water leaving the drum (104) and reaching the circulation pump (112) via the flow path on water chamber (508).
28) A washing machine (50) as described in any one of Claims 25 to 27, characterized in that; said washing machine (50) comprises a circulation pump (112) having a pumping capacity higher than the flowrate of water flowing from drum (104) to water chamber (500) for pumping water flowing to water chamber (500) and flow path on water chamber (508) from drum (104) back into drum (104) to prevent water from accumulating to levels high enough to reach drum outer surface (104-s) or overflow into water-free zones (100).
29) A washing machine (50) as described in any one of Claims 25 to 28, characterized in that;
said water chamber (500) is in the form of a water tank/outer drum (101) which encloses the drum (104) such that the drum (104) is not visible from the outside, said water tank/outer drum (101) has two drum surface areas, namely the drum wet-outer surface (104-w) and the water-free zone (100), said tank/outer drum type water chamber (500) comprises a flow path (508) on water collection chamber having a structure suitable for collecting all water draining from the drum (104) in wet area/surface (100-w) of said water tank/outer drum (101) and ensuring the flow of all the water to water chamber drain outlet (503), said tank/outer drum type water chamber (500) comprises water chamber barriers (511) together with water barriers (122) on the drum surface which prevent the water passing from the drum wet-outer surface (104-w) to the water-free zone (100) of the drum surface.
30) A washing machine (50) as described in any one of Claims 25 to 29, characterized in that; said water chamber (500) is formed so as to enclose the wet areas/surfaces (100-w) of the drum (104) and to leave the drum water-free zone (100) of the drum (104) out, said water chamber (500) comprises a flow path on water chamber (508) which enables the water drained from the drum (104) to flow toward the water chamber drain outlet (503), said water chamber (500) comprises water chamber barriers (511) together with water barriers (122) on the drum surface which prevent the water from leaving the water chamber (500) or the flow path on water chamber (508) or from overflowing from the water chamber (500) while collecting the draining water from the drum (104) and enabling the water to flow toward the water chamber drain outlet (503) via the flow path on water chamber (508), said flow path on water chamber (508) on water chamber (500) has a water flowrate higher than the discharge flowrate of draining water from the drum (104) so that accumulation of water in water chamber (500) is prevented and removal of water from drum (104) without coming into contact with drum (104) again is ensured.
31) A washing machine (50) as described in any one of Claims 25 to 30, characterized in that;
in order to provide said water-free zones (100) on the drum outer surface (104-s) the water chamber (500) is in connection with a circulation pump (112) which has a pumping capacity higher than the drain flow rate of the drum and which pumps the drum (104) drain water reaching the water chamber drain outlet (503) to the drum (104), wherein said circulation pump (112) has a higher pumping capacity than the drum discharge flowrate, and wherein the drum discharge flowrate is lower than the pumping capacity of circulation pump (112) so that water flowing from drum (104) to water chamber (500) via the water flow path on water chamber (508) does not overflow from water chamber (500), reach drum outer surface (104-s) or overflow or pass to water-free zone (100).
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PCT/TR2019/050466 WO2020256659A1 (en) | 2019-06-18 | 2019-06-18 | Washing machine energy and motion systems on the drum |
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PCT/TR2019/050466 WO2020256659A1 (en) | 2019-06-18 | 2019-06-18 | Washing machine energy and motion systems on the drum |
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