Washing Machine

Background
Mechanical washing machines appeared in the early 1800s, although they were all
hand-powered. Early models cleaned clothes by rubbing them, while later models
cleaned clothes by moving them through water. Steam-powered commercial washers
appeared in the 1850s, but home washing machines remained entirely hand-powered
until the early 1900s, when several companies started making electric machines. The
Automatic Electric Washer Company and Hurley Machine Corporation both began
selling electric washers in 1907, while Maytag offered an electric wringer washer in
1911. In 1947, Bendix offered the first fully automatic washing machine, and by 1953
spin-dry machines overtook the wringer types in popularity.
The last wringer washer manufactured in the United States was made in June of 1990
at Speed Queen's plant in Ripon, Wisconsin. The major U.S. manufacturers today are
General Electric, Maytag (Montgomery Ward), Speed Queen (Amana and Montgomery
Ward), Whirlpool (Kenmore), and White Consolidated (Frigidaire and Westinghouse).
Many models with many varying features are now available; however, with a few
exceptions, only the controls are different. The only difference between the washer in
your home and the top-load washers in the laundromat is the ruggedness of
construction.
The washing machine operates by a motor, which is connected to the agitator through a
unit called a transmission. The motor and transmission are near the bottom of the
machine, while the agitator extends up through the middle of the machine. The
transmission is similar to the transmission in your automobile in that it changes the
speed and direction of the agitator. In one direction (agitate), the transmission changes
the rotation of the agitator and spin tub—the inside tub with small holes in it—into a
back-and-forth motion. When the motor is reversed by the controls (spin), the
transmission locks up and the agitator, transmission, and spin tub all rotate as a unit.
Without the transmission changing the speed or direction, the unit uses centrifugal force
to remove as much water from the clothes as possible. The motor is also connected to a
pump. When the motor is moving in the spin direction, the pump removes the water
from the tub and discards it through the drain pipe.
Models designed for use in other countries offer different features. One component
required on all models sold in England (and possibly soon in the rest of Europe) is
called the lid lock. Normally when the lid is raised the washer must stop for safety
reasons. However, in England, when the washer is operating the lid must be locked
closed.

Raw Materials
Many parts of a washing machine are manufactured from sheet steel, usually coated
with zinc to improve rust resistance. The steel manufacturer supplies the metal in a coil,
which allows the material to be cut to size with minimum waste or automatically fed into
the forming process. On some models made by Speed Queen, the spin tub is made
of stainless steel. All other models use a steel (called enameling iron) designed for
a porcelain coating. For the wash tub, which

Most sheet metal parts, including the body, are formed by a machine that presses a piece of sheet metal
between two halves of a mold (die). Because metal in parts shaped by only one die tends to wrinkle, crack, or
tear, multiple dies are generally used to form each component.
The tub sub-assembly is manufactured automatically. After being rolled into a drum shape, the side is welded.
The weld is then smoothed out and the drum is placed on an expander, which stretches the tub into its final
shape. A bottom is then welded onto the drum, and this weld is also smoothed.

isn't visible unless you open the machine cabinet, enameling iron with
a porcelain coating is generally used. Whirlpool is the exception, using plastic instead of
enameling iron for the outer wash tub.
Many other parts are plastic as well. Manufacturers receive raw plastic from which they
fabricate parts in pieces about the size of a small ant, using them for machine
components that do not bear weight and/or require extremely good rust resistance.
Such parts include the pump, the tub guards (which prevent your clothes from being
thrown out of the spin tub into the wash tub or the cabinet area), and the agitator.
The transmission is generally made from cast aluminum, which arrives from the
manufacturer in ingots—20 pound slabs of aluminum. Scrap parts are usually remelted
and reused. Hoses, controls (timers, switches, etc.), and motors are purchased in
prefabricated form from other manufacturers.

The Manufacturing
Process
The manufacturing process is split into fabrication (making parts), sub-assembly (putting
parts together to make components), and assembly (putting the components together to
form the final product). The fabrication process comprises several different procedures,
each specific to a particular type of raw material—sheet metal, plastic, or aluminum.
Once the constituent parts have been made, they are assembled; major sub-
assemblies, or components, include the transmission, the pump, the spin and wash
tubs, the balance ring, and the painted parts. Finally, the sub-assemblies are put
together inside the shell of the washer, which is then complete.

Fabrication
 1 Most sheet metal parts are formed by a machine called a press. This name is
quite descriptive, as the machine actually presses (or squeezes) a piece of sheet
metal between two halves of a mold called a die. The metal will take the form of
the space between the halves of the die. Because metal in parts shaped by only
one die tends to wrinkle, crack, or tear, multiple dies are generally used to form
each component. Where possible, the metal is fed directly from a coil into the
press. When this is not possible, the metal is cut to length and manually (or, with
larger parts like the cabinet, automatically) placed into the die.
 2 Plastic parts are formed in an injection molding machine, a metal mold with one
or more cavities in the shape of the desired part. After being heated to its melting
point, the plastic is forced into the mold under high pressure. Next, water is
passed through the mold to cool and solidify the part. The mold is then opened
and the part pushed out by ejector pins. When you look at a plastic part, you
often can see small circles created by these pins.
 3 Aluminum transmission parts are formed into a rough shape in a die cast
machine, which works much like an injection mold except that it does not use
pressure. The
 Most of the key components—transmission, motor, broke assembly—are housed below the
agitator. The balance ring is a weighted ring that keeps the washer from moving around during
operation.

molten metal is mechanically ladled into the mold and cooled. The ensuing rough
casting is then given its final shape by various machines which drill holes, shave
excess metal off critical surfaces, or cut metal away from the part.

Sub-assemblies
 4 The transmission is assembled manually by workers who bolt, snap, or press
(tight fit) several shafts and gears together. Workers then add a metered amount
of oil and bolt the unit together.
 5 The pump is assembled automatically. Robots place the impeller and seals in
the cover and body, and seal the pump. Some manufacturers use heat and
others vibration (which generates heat) as a sealant.
 6 The tub parts are made in presses, and the sub-assembly is manufactured
automatically. After being rolled into a drum shape, the side is welded. The weld
is then smoothed out and the drum is placed on a unit called an expander, which
stretches the tub into its final shape. A bottom is then welded onto the drum, and
this weld is also smoothed. If the tub is stainless steel it is polished so it won't
 snag the clothes. Otherwise the tub is dipped in a solution called a ground
coat and heated to about 1600 degrees until this coating hardens. If the tub will
not be visible (the wash tub), the unit is done. If the tub will be visible (the spin
tub), a finish coat is applied following the same procedure used with the ground
coat; this final coat gives the tub either a white or blue color.
 7 The balance ring is a large weight that stabilizes the washer. Its outside
structure is plastic, with a ring of metal melted into the plastic for strength.
Cement is added and balanced precisely. This ring, which weighs more than
twenty pounds, keeps the machine from "walking," or moving about, when it is in
use.
 8 Washing machine manufacturers use any one of several painting processes.
One manufacturer uses steel that has been prepainted by the steel
manufacturer. Although cheaper, this type of steel does not offer the best rust
protection because the cut edges are not painted. Other companies treat their
parts with various chemicals to clean and ready them before applying paint. In
some cases, the paint comes in a powder with a flour-like consistency. Mixed
with air and given an electrical charge, the powder is sprayed on the part, which
is hung from an overhead conveyor and given an opposite charge so that it and
the powder will attract one another. After spraying, the conveyor moves the part
into an oven that melts the paint; when the part cools, the paint process is
completed.

Assembly
 9 This process begins with mounting the transmission on the balance ring. The
transmission is set on a bearing that is bolted on the wash tub; the wash tub is
sitting on a conveyor. Another bearing (the lower bearing), the brake assembly,
and the drive pulley are put on the end of the transmission. Next, a pivoting
mechanism called the pivot dome and legs are bolted on the assembly to hold all
the pieces together.
 10 Using a hydraulically operated mechanism, workers then lift this assembly,
called the module, onto the washer base. Springs are added to hold module and
base together. A seal is added, the spin tub is bolted to the transmission inside of
the wash tub, and its plastic covers are snapped into place. A plastic hub, which
attaches the agitator to the transmission, is bolted onto the output end of the
transmission shaft. Then the agitator is snapped onto the hub.
 11 The pump and a mounting bracket are now bolted onto the motor, which is
then fitted with a shield to protect against potential leaks. This assembly is bolted
to the base of the washing machine and connected to the transmission module
with a belt and hoses.
 12 Next, the lid hinges are attached to the lid and the top. The top of the washer
is bolted to the cabinet with a hinge for easy maintenance. A mixing valve to
control the mixture of hot and cold is bolted to the back of the cabinet. The
graphics panel, which provides words and pictures to explain the controls, is
mounted on the control panel; the controls themselves are attached from the
back. The wiring, connected as one unit, is called a harness. The harness is
 clipped to the control connectors at one end, and the other end is passed through
a hole in the top to be mounted to the motor. Because of its large size and
weight, the cabinet assembly is then placed in the washer by a robot.
 13 The cabinet is bolted to the base, and the controls are snapped together with
the mating connectors on the module and motor. The drain hose is pulled
through the cabinet and a part called the gooseneck is added. This part is what
gives the hose its hook shape so that it will fasten into the drain. After being
tested, the front panel is bolted on, and a packet of information and accessories
is added.
 14 The finished unit is crated automatically. A machine opens the cardboard box,
which was flat for shipment, and drops it over the washer. The top and bottom
flaps are simultaneously folded over and glued. Then the machine applies
pressure on the top and bottom of the crate to make sure the glue sets properly.
After the glue has set, the machine puts a banding strap around the top of the
crate to add strength for lift truck transportation (the units are carried from the top
to reduce the risk of damage).

Quality Control
All parts purchased from outside manufacturers are spot checked before use, and most
sub-assemblies are checked as well. For instance, all transmissions are automatically
tested for operation, noise, and vibration. All pumps are leak-tested using air,
automatically if their assembly was automated and manually if it was manual. All
painted parts are visually inspected for defects. Daily samples are put in detergent,
bleach, and steam baths for corrosion testing. Once it has been completely assembled,
the machine is filled with water and tested for noise, vibration, and visual defects, as
well as properly functional controls and mechanisms. After packaging, some units are
put through severe tests to simulate the transportation conditions to test the cartoning
process.

Byproducts/Waste
Leftover scraps of sheet metal are sold to metal recycling centers, and leftover
aluminum is remelted for use. The leftover plastic is ground into small chunks and
reused on non-visible parts because the color cannot be kept consistent. The unused
paint (in powder form) is reclaimed and reused automatically. The chemicals from
processes such as paint are reacted into forms of harmless waste and disposed of
safely.

The Future
As motors become less expensive and more durable, it will become economical to offer
washing machines driven directly by motors instead of by belts, making the washers
more versatile and less noisy. Another likely trend will be the gradual displacement of
top-load washers by front-load washers, which, because they require less water, satisfy
government restrictions on water use. In Japan, a washer is being tested that cleans
with bubbles rather than with an agitator. Using a computer, this machine "senses" how
soiled each load of clothing is and then generates the bubble activity necessary to
remove that amount of dirt. This is called "fuzzy logic" because it imitates human logic
more closely than normal computers. If successful, these machines will become
available elsewhere. Further in the future people may use washers that clean using
ultrasonics—sound waves that, vibrating at frequencies of more than

Although at present most home washing machines in the United States are top-loading, these will likely be
gradually displaced by front-load washers. Because they require less water, front-load washers satisfy
government restrictions on water use. Also, in Japan a washer is being tested that cleans with bubbles rather
than with an agitator. Using a computer, this machine "senses" how soiled each load of clothing is and then
generates the bubble acfivity necessary to remove that amount of dirt.

20,000 cycles per second, cannot be distinguished by the human ear.