FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
AND
The Patents Rules, 2003
As amended by the Patents (Amendment) Rules, 2005
COMPLETE SPECIFICATION (See section 10 and rule 13)
TITLE OF THE INVENTION
An electric iron reliability testing system
APPLICANTS :
Crompton Greaves Limited, CG House, Dr Annie Besant Road, Worli, Mumbai 400 030, Maharashtra, India, an Indian Company
INVENTOR (S):
Sarma Budhavarapu Pavan Srinivas and Garg Damodar of Crompton Greaves Ltd, Reliability Centre, Centre, Global R&D, Kanjurmarg (East), Mumbai- 400042, Maharashtra, India; both Indian National.
PREAMBLE TO THE DESCRIPTION:
The following specification particularly describes the nature of this invention and the manner in which it is to be performed:

Field of the Invention:
This invention relates to the field of electronic and electrical engineering.
Particularly, this invention relates to testing systems and testing equipment.
More particularly, this invention relates to an electric iron reliability testing system.
Background of the Invention:
An electric iron is a home appliance which is used on clothes or a variety of fabric to remove creases and wrinkles from them. Ironing works by loosening the ties between the long chains of molecules that exist in polymer fibre materials. With the heat and the weight of the ironing plate, the fibres are stretched and the fabric maintains its new (and unwrinkled) shape when cool. Some materials such as cotton require the use of water to loosen the intermolecular bonds. Many materials developed in the twentieth century are advertised as needing little or no ironing.
The electric iron was invented in 1882 by Henry W. Seeley, a New York inventor Seeley patented his "electric flatiron" on June 6, 1882 (US patent no. 259,054). His iron weighed almost 15 pounds and took a long time to warm up. Other electric irons had also been invented, including one from France (1882), but it used a carbon arc to heat the iron, a method which was dangerous.
Electric irons developed over the years. Some advancements included automated thermostat regulation in accordance with a pre-defined fabric

setting, steam disposal off the base ironing plate for some fabrics, and the like.
However, any electric iron being marketed by any company needs warranted claims or guarantee claims to support its robustness and longevity. To prescribe this term under a warranty or a guarantee, and / or reliability, there is a need for a testing system
Objects of the Invention:
An object of the invention is to test an electric iron.
Another object of the invention is to test individual elements of an electric iron.
Yet another object of the invention is to test the various working modes of an electric iron.
Still another object of the invention is to test the reliability of an electric iron.
An additional object of the invention is to estimate the life of an electric iron and / or its component elements.
Yet an additional object of the invention is to provide a system for testing elements of an electric iron.
Still an additional object of the invention is to study the failure mode of an electric iron and its elements.
Another additional object of the invention is to find plausible reasons for failure of an electric iron and its elements.

Summary of the Invention:
According to this invention, there is provided an electric iron reliability testing system adapted to test reliability of said electric iron and its elements, said system comprises:
a. testing table adapted to test a plurality of electric irons
simultaneously, said testing table comprising:
b. flat surface over which fabric that is to be ironed is laid out such that
it covers said flat surface;
c. parallel elongate guides along its length which serve as rails for linear
motion of the plurality of irons over aid fabric wherein the irons are
held over said fabric, in communication with said fabric, by means of
independent fixtures, each fixture corresponding to each iron and to
each guide rail, which fixture glides over the elongate guides in order
to maintain linear and parallel motion of each of said electric irons
over said fabric;
d. drive screw guide in order to drive the fixtures over the fabric from
one end of the table to another end along the length of said elongate
guides;
e. motor equipped to drive said drive screw guide, and hence each of
said fixtures and said irons over said fabric;
f. proximity sensors are provided at each end of the table to sense iron
position and to provide signals to a drive unit (DU) to reverse linear
motion so that the fixture (and hence, the irons) move to and fro in a
linear manner up to defined time or movement cycles.

Typically, said system includes temperature sensors for sensing temperatures of the fabric at pre-defined intervals, said temperature sensors being located for each line or path of travel of each of said irons, so that each iron capability is tested individually and simultaneously.
Typically, said system includes current reading means adapted to read current related parameters for each iron being tested on said testing table.
Typically, said system includes input means adapted to input a plurality of input parameters in relation to said system, said input means adapted to input at least one parameter from a group of parameters consisting of speed parameter of the irons, distance parameter to be travelled by the iron; maximum allowed temperature parameter of the fabric, length of each stroke parameter, weight parameter of each iron, and current consumption duration parameter.
Typically, said system includes programmable logic controller means adapted to identify failure modes for each iron being tested based on predefined parameters.
Typically, said system includes display means to display error message according to identified error.
According to this invention, there is provided a method for testing irons, wherein said method includes the steps of: i. monitoring current consumption (as recorded by current consumption means) of each iron.

ii. verifying if the current consumption duration by the iron is crossing
the allowed time (as recorded by input means); iii. switching off the particular iron (by controller means) if verification is
true; and iv. displaying (at display means) a message declaring that particular iron
failed.
According to this invention, there is provided a method for testing irons, wherein said method includes the steps of:
1. monitoring current consumption (as recorded by current consumption means);
2. verifying if monitored current consumption by any particular iron is zero or close to zero for pre-declared current consumption duration time (as recorded by input means);
3. switching off the particular iron (by controller means) if verification is true; and
4. displaying (at display means) a message declaring that particular iron failed.
According to this invention, there is provided a method for testing irons, wherein said method includes the steps of:
a. monitoring temperature sensed by any of the temperature sensors;
b. verifying if monitored temeperature is more than the allowed limit (as
recorded by input means);
c. switching off the particular iron (by controller means) if verification is
true; and

d. displaying (at display means) a message declaring that particular iron failed.
According to this invention, there is provided a method for testing irons,
wherein said method includes the steps of: I. monitoring proximity sensor readings at the end of each stroke of iron movement along said elongate guide which will senses the moving lever (of fixture) when it reaches the end of the stroke; II. signaling to controller means which will again send a signal to motor to reverse its direction for reversing direction of travel of iron; and
III. providing another protection proximity sensor if earlier proximity sensor fails to detect the presence of lever to avoid the damage to motor which will sense the danger position of the lever and send stop signal to PLC (controller means).
Brief Description of the Accompanying Drawings:
The invention will now be described in relation to the accompanying drawings, in which:
Figure 1 illustrates a schematic of the an electric iron reliability testing system and equipment;
Figure 2 illustrates a top auxiliary view of the electric iron reliability testing system and equipment of Figure 1;
Figure 3 illustrates a bottom auxiliary view of the electric iron reliability testing system and equipment of Figure 1;

Figure 4 illustrates a top view of the electric iron reliability testing system and equipment of Figure 1; and
Figure 5 illustrates a partial auxiliary view of the electric iron reliability testing system and equipment of Figure 1.
Detailed Description of the Accompanying Drawings:
According to this invention, there is provided an electric iron reliability testing system.
Figure 1 illustrates a schematic of the an electric iron reliability testing system and equipment.
Figures 2 to 5 illustrate various views of the electric iron reliability testing system and equipment of Figure 1.
In accordance with an embodiment of this invention, there is provided a testing table (TT) adapted to test a plurality of electric irons (Ell, EI2, EI3, EI4) simultaneously. The testing table includes a flat surface over which fabric (F) that is to be ironed is laid out such that it covers the testing table. The testing table, further, has parallel elongate guides (Gl, G2, G3) along its length which serve as rails for linear motion of the plurality of irons over the fabric. The irons are held over the fabric, in communication with the fabric, by means of independent fixtures (FX1, FX2, FX3, FX4), each fixture corresponding to each iron and to each guide rail, which fixture glides over the elongate guides in order to maintain linear and parallel motion of each of said electric irons. Each electric iron is placed on to the fixture such that it

moves with respect to a corresponding rail guide. There is also a drive screw guide (DCG) on at least one of the guide rails, preferably on a substantially central guide rail, in order to drive the fixture over the fabric from one end of the table to another along the length of the rail guides. A motor (M) is equipped to drive the drive screw guide, and hence said fixture and said irons over said fabric. Further, there are provided temperature sensors (TS1, TS2, TS3, TS4) for sensing temperatures of the fabric at pre-defined intervals. A temperature sensor for each line or path of travel of an iron is provided, so that each iron capability is tested individually and simultaneously. Proximity sensors (PS1, PS2, PS3, PS4) are provided at each end of the table to sense iron position and to provide signals to a drive unit (DU) to reverse linear motion so that the fixture (and hence, the irons) move to and fro in a linear manner up to defined time or movement cycles.
In accordance with another embodiment of this invention, there is provided an input means (IM) adapted to input a plurality of input parameters in relation to said system. These include:
1. Speed of the irons (the speed with which the irons are to be travelled) across the testing table;
2. Distance to be travelled by the Iron (the total distance to be travelled by irons), thereby defining a cycle of testing;
3. Maximum allowed temperature of the fabric (to avoid the burning of the fabric);
4. Length of each stroke (preset distance which is travelled by to and fro strokes, of the fixture and iron, so each stroke length should be given as input);

5. Weight of each Iron; and
6. Current consumption duration (any iron should consume current for a duration less than the this value because iron function is declared like it has to consume current for stipulated time to reach particular preset temperature it should not consume more or less than that if it happens it will not heat the iron to required temp or over heats the iron)
In accordance with yet another embodiment of this invention, there is provided a current reading means (CRM) adapted to read current related parameters for each iron being tested on the testing table.
In accordance with still another embodiment of this invention, there is provided a programmable logic controller means (PLCM) adapted to identify failure modes for each iron being tested based on pre-defined parameters. It is coupled to a display means (DM) to display error message according to identified error.
Some exemplary failure mode identifications are provided below:
1. The current consumption (as recorded by current consumption means) of each iron is monitored by Current transducers. If the current consumption duration by the Iron is crossing the allowed time (as recorded by input means) then it (controller means) switches off that particular iron and displays (at display means) a message declaring that particular iron failed.
2. If the current consumption (as recorded by current consumption means) by any particular iron is zero or close to zero for pre-declared

current consumption duration time (as recorded by input means) then it (controller means) switches off that particular iron and displays (at display means) a message declaring that particular iron failed.
3. If the temperature sensed by any of the temperature sensors is more than the allowed limit (as recorded by input means) then it (controller means) switches off that particular iron and displays (at display means) a message declaring that particular iron failed. Since, sensors are fitted under the paths of each iron separately, it is possible to detect each iron cloth temperature separately and switch off that particular iron only.
4. There is one proximity sensor at the end of the stroke which will senses the moving lever (of fixture) when it reaches the end of the stroke and send a signal to the PLC (controller means) which will again send a signal to motor to reverse its direction. If this proximity sensor fails to detect the presence of lever, then to avoid the damage to motor there is another protection proximity sensor which will sense the danger position of the lever and send stop signal to PLC (controller means).
The major failure modes that can be detected are like thermostat failure, heating element failure, thermal fuse failure and the like. This equipment will also continuously monitor the current consumption of the individual irons and if any iron consumes out of specified range of the current then immediately it detects and stops current supply to that particular iron.

While this detailed description has disclosed certain specific embodiments of the present invention for illustrative purposes, various modifications will be apparent to those skilled in the art which do not constitute departures from the spirit and scope of the invention as defined in the following claims, and it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

We claim,
1. An electric iron reliability testing system adapted to test reliability of said electric iron and its elements, said system comprising;
a. testing table adapted to test a plurality of electric irons
simultaneously, said testing table comprising:
b. flat surface over which fabric that is to be ironed is laid out such that
it covers said flat surface;
c. parallel elongate guides along its length which serve as rails for linear
motion of the plurality of irons over aid fabric wherein the irons are
held over said fabric, in communication with said fabric, by means of
independent fixtures, each fixture corresponding to each iron and to
each guide rail, which fixture glides over the elongate guides in order
to maintain linear and parallel motion of each of said electric irons
over said fabric;
d. drive screw guide in order to drive the fixtures over the fabric from
one end of the table to another end along the length of said elongate
guides;
e. motor equipped to drive said drive screw guide, and hence each of
said fixtures and said irons over said fabric;
f. proximity sensors are provided at each end of the table to sense iron
position and to provide signals to a drive unit (DU) to reverse linear
motion so that the fixture (and hence, the irons) move to and fro in a
linear manner up to defined time or movement cycles.

2. A system as claimed in claim 1 wherein, said system includes temperature sensors for sensing temperatures of the fabric at pre-defined intervals, said temperature sensors being located for each line or path of travel of each of said irons, so that each iron capability is tested individually and simultaneously.
3. A system as claimed in claim 1 wherein, said system includes current reading means adapted to read current related parameters for each iron being tested on said testing table.
4. A system as claimed in claim 1 wherein, said system includes input means adapted to input a plurality of input parameters in relation to said system, said input means adapted to input at least one parameter from a group of parameters consisting of speed parameter of the irons, distance parameter to be travelled by the iron; maximum allowed temperature parameter of the fabric, length of each stroke parameter, weight parameter of each iron, and current consumption duration parameter.
5. A system as claimed in claim 1 wherein, said system includes programmable logic controller means adapted to identify failure modes for each iron being tested based on pre-defined parameters.
6. A system as claimed in claim 1 wherein, said system includes display means to display error message according to identified error.

7. A method for testing irons according to the system of claim 1, wherein
said method includes the steps of:
i. monitoring current consumption (as recorded by current consumption
means) of each iron. ii. verifying if the current consumption duration by the iron is crossing
the allowed time (as recorded by input means); iii. switching off the particular iron (by controller means) if verification is
true; and iv. displaying (at display means) a message declaring that particular iron failed.
8. A method for testing irons according to the system of claim 1, wherein
said method includes the steps of:
1. monitoring current consumption (as recorded by current consumption means);
2. verifying if monitored current consumption by any particular iron is zero or close to zero for pre-declared current consumption duration time (as recorded by input means);
3. switching off the particular iron (by controller means) if verification is true; and
4. displaying (at display means) a message declaring that particular iron
failed.
9. A method for testing irons according to the system of claim 1, wherein
said method includes the steps of:
a. monitoring temperature sensed by any of the temperature sensors;

b. verifying if monitored temeperature is more than the allowed limit (as
recorded by input means);
c. switching off the particular iron (by controller means) if verification is
true; and
d. displaying (at display means) a message declaring that particular iron
failed.
10.A method for testing irons according to the system of claim 1, wherein said method includes the steps of: I. monitoring proximity sensor readings at the end of each stroke of iron movement along said elongate guide which will senses the moving lever (of fixture) when it reaches the end of the stroke;
II. signaling to controller means which will again send a signal to motor to reverse its direction for reversing direction of travel of iron; and
III. providing another protection proximity sensor if earlier proximity sensor fails to detect the presence of lever to avoid the damage to motor which will sense the danger position of the lever and send stop signal to PLC (controller means).