MyGenWashy: From Vienna Hackathon to Open Source Smart Washing Machines — A Blueprint for Resilient Tech

I had a look at as much of this as I could find.

I'm baffled - there is talk of documentation - but where is it ?

There is a Github project for the pcb and some parts lists, a very, very top level presentation and ......

Where is the specification, the architecture description (software and hardware), some discussion about how washing machines work (and which subset is targeted by this project) etc.etc.

I'd expect to see some analysis of the efficiency of the washing machines (massively improved over the last 20 years) and how the Open Source Controller might contribute to that - or not.

I could get quite interested in this project (our own LG machine is getting on - about 12 years old and its rotary control is getting a little quirky) but I don't seem to able to find my way in.

MK

Thanks for the interest!

the documentation is right on the github https://github.com/mayermakes/MyGenWashy
The PCB is just the first outcome of the Hackathon, we are currently waiting on the pCb and PArts to build it up. Then write its firmware and integrate it into our test machine. 
Washingmachines have not changed at all at their core in the last 20 years the only thing that we found different in the various models we looked at are the control and User interface sections, but topological they were all pretty much the same. Our Control board hooks into these commone components and takes care of the basic functions like motor control, relays etc. and connects via I2C to the UI side which can be whatever you want( from. a simple tactile Knob and buttons, or ESP32 that hooks into your network and displays the UI on a phone).Architectural this is the central control unit that all washing machines have but open source and using generic  easily substituteable components.

The Safety interlock system is directly implemented in Hardware. The Relay logic is active as soon as the unit is powered and does not need the MCU at all to function. This includes door, heater and Water level Sensors. You can see it all within the schematic.

In essence Washing machines of current design, are topological : 2 Valves, a pump, an AC motor, Heater and the safety interlock system (I consider the Water level sensor part of it). 
Then there is a machine control and a UI powered by MCUs. we found soem machines use just a single MCU for both tasks, and utilize highly specialized ICs for tasks like motor control.
We decided to avoid any hard to source or even proprietary components, so we use a ATtiny3226 (replaceable with almost any other mcu in practice) strictly for control and a separate MCu for UI with strictly separated tasks. These are connected via an I2C bus that allows simple integration of more additional sensors.

Most efficiency gains seem to stem not from big technical changes but from better washing detergents that work sufficiently at lower temperatures and deliberate conservation of energy through washing programs that more targeted use heating, rinsing and tumbling cycles and are tailored to modern washing detergents.
We see almost all changes on the UI side while the actual working principle stayed the same and is already very robust, safe  and efficient.

There is no guarantee someone could come up with an even more efficient washing program than is already established, but in case a machine is broken, the most likely part to break could be replaced with a repairable open solution and keep the machine in ciculation. 
I'm personally interested most in the aspect of tailoring the User interface to my personal preferences,
so I don´t need to click through touch menus or confusing buttons and could implement an "even Clem can wash now" system that just has simple "underwear", "Work clothes" & "other" buttons.

So of course there no super extensive Documentation yet as we just started with our hackathon.
V1 pcb will be integrated into the machine in the pictures and used for Firmware Development.(that is why its tht so we can make easy bodges and probe all contacts from the back.)
V2 will implement any changes /fixes and move to mostly smd assembly for better component availability.
V3 will then start the roadmap towards certification and sealing for a unit that could actually be deployed.

So I would have loved to just link documentation for V3 but we are not there yet. ;-)

Hello Clem,

Thanks for the additional info.

I think maybe you are starting from a somewhat wrong assumption:

Washingmachines have not changed at all at their core in the last 20 years the only thing that we found different in the various models we looked at are the control and User interface sections, but topological they were all pretty much the same

I Googled (actually DuckDuckgoed)

"how many washing machines use direct drive motors"

Which will give you lots of useful information, although I didn't get the answer to my question.

https://faq-washer.com/direct-drive-washing-machines/

There are also inverter drive machines.

It's interesting that LG offer a 10 year warranty on their direct drive machines which also do clever stuff like load balancing and weighing by precision control of the drum rotation and measuring the motor current. This enables them to tune the washing time according to the load (and still get the delayed time right   - it times to the end of the cycle and the cycle can vary by 2:1 in length).

But I don't know what proportion of machines use direct drive.

OK, I understand that you are right at the start of the project -  but in the areas I've worked in documentation comes first (not all of it of course) - it does help avoid a great many issues.

The following is offered in a spirit of helpfulness although you might not like reading it much:

I've been looking at your PCB and I'm worried that you don't have the clearances you need for 230V AC (nominal) working in a damp environment. There is a lot of stuff on the web about PCB clearances and what's required for different voltages, environments and positions in the system.

The consensus would be that you need 2mm minimum for 230VAC unless failure will expose the operator to the dangerous voltage in which case you need a lot more. Some regulations if different places make very specific demands which must be met.

You've got 0.2mm clearance in several places on the board - (eg MOTOR_230_LIVE to Q1 gate) and many instances of less than 2mm separation. The 0.2mm clearances are so small that trouble is pretty much a certainty. Some of the larger clearances are not safe but might be acceptable if the whole board is isolated, but I can't tell if it is.

(BTW, this stuff really matters, a long time ago where I was working we had a lapping machine with a mains powered controller with mains and control stuff on the same PCB, and not enough clearance. The PCB was coated, but not well enough and every few months would get damp, develop a conductive path from mains to something, get hot, char the board, set the board on fire and then we would see the magic smoke coming out of the box. And fit a new board which we kept in stock.)

MK

I especially like to read critique!

Good point on the clearance. since the goal was to verify operation assumptions with V1 (and routing had to be done within a few hours) i just left approximate spaces, and mainly aimed to fit it within a space that wont make the pcb to expensive (its also only 2 layer) . In operation the whole board would be coated/covered for water tightness.
but we won´t do that step until V3.
For V2 I intend to put all 230V sections on its own board, just coupled via optoisolators which should also allow to tuck it into more models of washing machines with tighter spaces on the inside. and possibly easier access for repairs.

since we focused on getting broken machines back into operation, direct drive and other rather niche Variants were not in scope. So we basicalyl looked at the most common scenario: a  medium segment machine from the last 10-15 years breaks down-> get it back working.

the inclusion of the i2c bus is our route to include these newer niche features down the line, as it requires additional sensors.

In the area I come from we need to get stuff working first (somehow) and then we make it pretty. Once the pretty stage starts we can spend more time on documentation.
Since the project is open for more people to join , I would hope for a documentation enthusiast to take over that part as  such a person would certainly do a great job at it!

Awesome project, At a minimum it is a great way to introduce people to how commercial / consumer appliances are designed (Good and Bad :) I would think the same principles could also be applied to AC Home furnace , Fridge/Freezers, Cookers, Dryers etc, there all basically the same. Safety circuits, Monitoring, Power drivers (Relays or solid state) and motor control.

I do agree with the conclusion that most appliances have not fundamentally changed in decades. I have repaired many fridges, Dish washers, Cookers and the likes and within each type there all the same and you simply pay more for a fancy display or wifi etc. nothing that makes the actual process any better. Fridges and Washers are the most extreme example of these where you look at the schematics of a base model vs the top of the line (AKA Most expensive) and there all the same except the user interface. with a few examples like Steam being added.

If the replacement boards were not so overly expensive then there would be no need for this project outside of educational purpose but they are, control boards / interface panels costing a significant part of the original cost.

I look forward to seeing were this project goes.

I do agree with the conclusion that most appliances have not fundamentally changed in decades. I have repaired many fridges, Dish washers, Cookers and the likes and within each type there all the same and you simply pay more for a fancy display or wifi etc. nothing that makes the actual process any better.

Sorry - this just isn't the case.

A quick check shows that one of the simplest devices, a tumble drier, is available with a wide range of efficiencies and that they have been steadily improving. The EU have added new ratings for more economical machines A+++ rating and banned the worst category.  The most efficient tumble driers use heat pumps and are (approx) twice as efficient as those that don't. They do cost more. (And I wish the EU would use proper engineering units.)

I culled this data from Curry's (UK white goods retailer) website :

This is the cheapest heat pump model they sell  - they have others at prices up to over £1000.

Heat pumps in driers are quite new and (if you must use a drier at all) a good thing.

Washing machines have evolved quite a bit as well the most recent really big thing being direct drive which makes them much more reliable, capable and quieter. Some of the combined tumble drier + washing machines also have heat pumps. (Not sure if the heat pump can help the washing or only the drying).

The market for white goods isn't perfect but it is quite competitive, more innovation certainly wouldn't hurt but we should give credit to fellow engineers.

They also serve, who shave 1% of the electricity consumption of a washing machine motor !

MK

Dishwashers changed a lot. Recent ones default to a completely different process: lower temperature long time soaking, vs the traditional fast, higher pressure water spraying and hotter water...

But from a hardware perspective there still basically the same, low temp, longer soak etc, that's all programming and better / different detergent right ?

for heat pumps etc, laws of thermodynamics.. it still takes the same energy to convert x amount of water to steam / vaper to get it out of the clothes  and the control will still be basically calling for heat or not with a humidity sensor and temp sensor to provide feedback at best it adds another relay / sensor to assist (I have not looked at a schematic for a heat pump appliance but thats my educated guess from a control perspective )

so from a system building blocks there still fundamentally the same. DC / brushless motors etc still needs a motor controller and yes they may be more efficient 

A heat pump compared to a direct electric heater can provide more efficiency but im not convinced when compared to a gas powered dryer (Mine is natural gas powered for heat )

I like the idea.

Us older folk just want a simple device that is easy to use and does a good job.

DAB Absolutely.  When I went shopping for my last clothes washer, it had to have an agitator.  Forget that "gentle on your clothes" stuff.  I want to get back to "beat those suckers clean".  My clothes got cleaner with a 35 minute cycle inefficient washer than they did with my 70 minute cycle high efficiency washer.  If it doesn't get the job done, it doesn't really matter how efficient it supposedly is.  "It failed!"  "Yes, but if failed very efficiently."