Electrical Product Pathfinder Group Washing Machines

Transcription

1 Electrical Product Pathfinder Group Washing Machines Identifying failure drivers and opportunities for life extension. Version 1 December 2013

2 About this project Submit This work aims to provide simple and accessible guidance on how to reduce return rates and improve brand value by building more durable products. Between September 2013 and March 2014 WRAP is working with a consortium of specialists to develop these outputs through targeted research and engagement with industry and other bodies. This document is the first step in this process and presents the consolidation of evidence around perceived failure rates and opportunities that will be further expanded upon from November About the Electrical Product Pathfinder Group How to use this deck 1. Please view in Slide Show to activate hyperlinks. 2. To access the slide s content either browse one page at a time or use the navigation bar below to jump between the main sections. Throughout the deck there are links to external sources of interest. 3. We would like to encourage on the contents of this deck and your thoughts on the identified failure points, drivers and resolutions. Please click the Submit links on each page to contribute. WRAP is helping the electrical and electronic product sector to cut costs, reduce resource use, and build reputation for corporate responsibility. The EPPG aims to: identify the most significant changes in the supply and sale of electrical and electronic products in the UK that would use less material resources, reduce cost and reduce business risk, while improving profit; implement changes on key products, measure the benefits and distil good practice; and share insight on consumers understanding and attitudes to product lifetime. Short-Term Failure Long-Term Failure Best Practice Opportunities

3 Purchase Failure Failure Point Why product is being returned Smell / dirty tray and seal Noise Electronic fault / valves Drum Paddles come off Driver Why failure has occurred Expected Life Low temperature washing, using too much detergent, user error in not undertaking service wash / cleaning Foreign objects from washing, uneven placement of machine, poor design (counter weights/damping) Control board or motor controller; Water inlet valve and level sensor; Poor design or manufacture Poor design (e.g. clip fit) or manufacture (fixing insecure) Notes Submit Failure points based on very limited published data, mainly from Which? surveys and from anecdotal evidence. Early failures are mainly due to poor designs that result in customer returns. Poor instructions/user error contribute to some faults but users often do not read instructions. There is a clear correlation between least reliable brands and price Door interlock / latch failure; hinge cracks or drops Poor design / materials / manufacture; user error if weight put on door hinge (body weight, wet clothes etc.) Short-Term Failure Long-Term Failure Best Practice Opportunities

4 Purchase Failure Point Why product is being replaced Motor failure (main motor or pump motor) Bearing failure / damper failure resulting in noisy machine Filter/pump blockage Driver Why failure has occurred End of Life Brushes too short/poor quality. Burn out of windings. Failure of electronic control circuit (rectifier/inverter etc.) Water ingress through seal; poor design or manufacture of seal, bearing (generally simple ball bearings), dampers/attachment point User error in not cleaning filter or poor filter design allows some debris through Notes Submit Failure points based on very limited published data, mainly from Which? surveys and from anecdotal evidence. There is a clear correlation between least reliable brands and price Heating element failure Control faults Poor design / materials / manufacture Facia switches/dials, control valves etc. Poor design / materials / manufacture Short-Term Failure Long-Term Failure Best Practice Opportunities

5 Submit Component Specification Specifications are required for durability of: Motor; e.g. 3000hr (~8 to 9 yr) with no maintenance Control electronics Bearings and seals; 3000hr (~8 to 9 yr) no maintenance Paddles, latches and hinges Heating element Facia switches and dials Also see previous WRAP Buying Specs for Repairability aspects Design Washing Machines need to give good performance using very little energy/water and making little noise to achieve high standards (A+ etc.) under EU labelling. Good design features for durability include automatic flagging of service wash cycle an filter blockage; load sensor and uneven load protection; ceramic heating element; double sealed/screened bearings; bolted rather than welded tub; brushless motor; gold plated connectors to prevent fretting (common with tin plated); vibration and corrosion protection on electronics. Testing Standards There are no standards on Washing Machine durability even in latest eco-design regulation EU eco-labels only specify years of warranty/parts availability EN and EN on safety Various performance standards: IEC/EN 60456; IEC/PAS 62473; EN :2002; EN ; BS EN see last slide User Instruction Need to be clear and short with diagrams Emphasise need for correct dosing Emphasise that service wash cycles are essential Emphasise need to clean filter, trays and seals regularly Explain how users can clean filter, trays and seals Short-Term Failure Long-Term Failure Best Practice Opportunities

6 Failure Mode Cause Early/ Late Opportunity Implementation Mechanism Cost Implications Submit Motor Worn brushes; overload/ burn out Late Fit brushless motor; some brushless motors have been certified to last for at least 20 years/4,400 cycles (220 p.a.). Fit longer brushes; Improve quality of windings; improve surge suppression; Fit re-setting thermal overload switch. Provide manufacturer with design specifications; motor life > 3,000 hours; thermal switch to comply with EN Annex D Brushless motors most expensive option; Auto reset switches cost ~ 1. Longer brushes ~ 0.01 each Bearing Leaking seal or gradual wear Late Provide overload and unbalanced load sensor; Use better seal or shielded seal; Use better quality bearings, e.g. case hardened roller bearings Provide manufacturer with design specifications; bearing / seal life > >3,000 hours; Standard? High cost of sensors/controls? ; better seal and better bearings a little more expensive. TBD Electronics Poor design; poor connectors; no surge protection; no humidity or vibration protection Both connectors (gold plated) and looms; surface mount on PCBs where possible; better loom support; provide vibration and water protection e.g. rubber mounts, conformal acrylic PCB coatings, better overall encapsulation Specification and better quality control at factories to ensure good quality parts/pcbs and manufacture; Standard? Better quality parts will be slightly more expensive. E.g. gold plating connectors adds maybe 1 to unit cost Short-Term Failure Long-Term Failure Best Practice Opportunities

7 Submit Failure Mode Cause Early/Late Opportunity Implementation Mechanism Smelly / dirty seal / tray / feed hose etc. Drum paddles Heating element Narrow detergent hose from tray; overdosing of detergent; low temp wash; inadequate cleaning or no high temp service wash Poor attachment to drum Corrosion/ poor connectors Can be quite early Both Both Wide bore detergent hose; automatic dosing (as in Siemens i- dosing system); Provide better instructions for users; LCD display to flag need for service wash; Make integral part of steel drum; screw or bolt on not clip fit or rivet Replace with ceramic element as Samsung machines Specify hose diameter and material; specify systems and develop clear user instructions in manual, easy peel label or LCD display attachment to be used element and connectors (gold plated) to be used; Standard? Cost Implications Development cost and unit cost increase. Better instructions cheap; reprogrammed display more expensive. TBD Slightly higher cost due to extra manufacturing time Slightly higher cost TBD Short-Term Failure Long-Term Failure Best Practice Opportunities

8 Submit Failure Mode Cause Early/Late Opportunity Implementation Mechanism Facia dials and switches Door latches/hinges and interlocks Blocked filters / pump Poor design/manufa cture/wear Poor design/ manufacture/ Corrosion/wear /user error User error or poor filter design Can be both Can be both Can be both Individual micro-switches per position rather than potentiometer type / brush connector Better quality solenoids/actuators; corrosion protection; humidity/water ingress protection; mechanical design strength in hinges to withstand someone leaning on door Better user instructions/easy peel label; Better quality filter; Sensor and LCD display message to tell user when to clean filter switch / dial / solenoid; Standard? solenoid/actuator and protection; Specify repeat load that door hinges must withstand. Standard? Specification of user instructions to be provided; specification of filter performance. Standards? Cost Implications Will increase costs slightly Will increase costs slightly Instructions low cost; Sensors and display message high cost Short-Term Failure Long-Term Failure Best Practice Opportunities

9 Submit Failure Mode Cause Early/Late Opportunity Implementation Mechanism Water inlet valve or level sensor failure Dampers resulting in noise and vibration Poor design/manufa cture/wear Poor design/ manufacture/ wear Can be both Late most likely Better quality sensors/ solenoids/actuators; corrosion protection. Better quality seals, humidity/water ingress protection; mechanical design strength in attachment points valve / solenoid etc. damper and seals. Cost Implications Will increase costs slightly Will increase costs slightly Short-Term Failure Long-Term Failure Best Practice Opportunities

10 International Standards - performance EN ; Safety standards for electrical appliances IEC Ratings and Performance of electric motors IEC/EN 60456; Clothes washing machines for household use Methods for measuring the performance BSI DD IEC/PAS 62473; Clothes washing machines for household use - Methods for measuring the mechanical action BS EN :2002; Specification for automatic electrical controls for household and similar use. Particular requirements for electrically operated water valves, including mechanical requirements BS EN 60734:2012; Household electrical appliances. Performance. Water for testing BS EN ; Household and similar electrical appliances - Test code for the determination of airborne acoustical noise Part 2-4: Particular requirements for washing machines and spin extractors BS EN 61770; Electric appliances connected to the water mains - Avoidance of backsiphonage and failure of hose-sets ISO 6804:2009 Ed 3; Rubber and plastics inlet hoses and hose assemblies for washing-machines and dishwashers. AS/NZS 2040:2000 Performance of household electrical appliances clothes washing machines. JIS C9811:1999 Electric clothes washing machines for household use Methods for measuring the performance Federal register:10 CFR Section (j) Test methods for domestic and commercial washing machines Heating Elements: e.g. BS 7351 is Specification for Metal-sheathed heating elements for industrial use; DIN Electric immersion heating elements; requirements, DIN Ceramic parts for electric heating elements; open multiple hole tubes; dimensions, TSE TS 5101/T1 Electrical Heating Elements Metal Tube Sheated Submit Short-Term Failure Long-Term Failure Best Practice Opportunities Standards