101

International Peer Reviewed Journal

Converting Malfunctioned Fully 
Automatic (Electro-Mechanical Driven) 

to Semiautomatic Washing Machine

MANUEL A. BAJET,JR.
manuelbajet@gmail.com

ORCID No. 0000-0002-7545-971

NELSON A. BAJET
nelsonbajet@gmail.com

ORCID No. 0000-0001-5853-3983

OSWALD T. TOLENTINO
Otolentino1017@gmail.com

ORCID No. 0000-0001-9430-9751
University of Northern Philippines
Vigan City, Ilocos Sur, Philippines

ABSTRACT 

This study converted a damaged fully automatic washing machine into a 
semi -automatic washing machine. Conversion of the machine was done due to 
unavailability of its electronic spare parts in the local market and to recycle the 
equipment. Thus, the study explored the conversion the washing machine that can 
be shared to the local technician to enhance their knowledge, skills and minimize 
environmental waste. It involved dismantling and rewiring, identifying the terminal 
leads of the motors, and testing recycled parts. Replacement of unserviceable part was 
done to turn into operation the said machine. Findings disclosed that the automatic 
washing machine converted into a semi-automatic have the similar operation cycles. 

Vol. 12 · March 2013 
Print ISSN 2012-3981 • Online ISSN 2244-0445
doi: http://dx.doi.org/10.7719/jpair.v12i1.216

JPAIR Multidisciplinary Research is produced 
by PAIR, an ISO 9001:2008 QMS certified 

by AJA Registrars, Inc.



102

JPAIR Multidisciplinary Research

The only difference between the two washing machines was the controls and sequence 
of washing. In semiautomatic washing machine, it requires human intervention to 
control and to add and drain water. Cost incurred in converting the malfunction 
automatic washing machine into a semi-automatic function was much cheaper than 
buying a brand new one. 

Keywords: Discarded Electronics, Washing Machine, Semi-Automatic, Vigan 
City, Ilocos Sur, Philippines 

INTRODUCTION

Washing clothes have been a long-time practised by people across the globe to 
keep oneself tidy. Thousands of years, people washed their clothes by beating them 
against wood and rocks or by using their own hands which somehow a primitive 
approach. However, over the years, the primitive way of washing clothes had been 
changed. The development of advanced technologies or state-of-the–art facilities are 
now made available to people such as the use of washing machine. Technologies make 
life of many individuals very easy when doing certain job such as washing of clothes.

The development of commercial laundry machine started way back in the 1850’s. 
After that, several brands of washing machines came to market. Improvements in 
washing technology came very fast. Part of inventor’s development was the washing 
and wringing machine. The machine was semi-automatic to fully automatic 
electromechanical or microcontrollers made up the cartridge that programmed the 
different operation cycle. The technology of washing machine played an increasing 
important role in the world economy and not by households alone (Maxwell, 1982).

Washing machine is a term mostly applied only to machines that use water. It is 
different from dry cleaning which uses alternative cleaning fluids and is performed 
by specialist businesses or ultrasonic cleaners. Washing entails immersing, dipping, 
rubbing, or scrubbing in water accompanied by detergent or bleach. The simplest 
machines may agitate clothes in water while switched on. Automatic machines may 
fill, empty, wash, spin and heat in a cycle. Most washing machines remove substantial 
amounts of water from the laundry at the end of a wash cycle but do not completely 
dry clothes (Jefferson, 2013).

Stabber Industries released the system 2000 washing machine in 1994, which is 
the only top-loading, horizontal-axis washer to be manufactured in the United States. 
The hexagonal tub spins like a front-loading machine, only using about third of the 
water as conventional top-loaders. This factor has led to an Energy Star rating for its 
high efficiency.



103

International Peer Reviewed Journal

On the other hand, James Dyson, a British inventor launched in 2000 the CRO1 
Contra Rotator, a type of washing machine with two cylinders rotating in opposite 
directions. It was claimed that this design reduced the wash time and produced 
cleaner washing than a single cylinder machine. In 2004, there was the launch of the 
CRO2, which was the first washing machine to gain the British Allergy Foundation 
Seal of Approval. However, neither of the “ContraRotator’’ machines are now in 
production as they were too expensive to manufacture (Jefferson, 2013).

Moreover, Boscolo and Stebili (1980) and Cheng et al.( 2001) had introduced 
a new sensing device and motor for washing machines. The new method proposed 
remote sensing of pressure inside the wash load of domestic washing machines via 
a wireless data acquisition system. Intelligent and fozzy logic based controllers for 
washing machines were also successfully introduced since the 90s and quickly gained 
sizable market share

Top-loading electro-mechanical is a fully automatic washing machine. 
Automation is the use of control systems and information technologies to reduce the 
need for human work in the production of goods and services. Also, automation is 
a step beyond mechanization. It greatly helped human operators with less muscular 
requirements at work thus, automation greatly decreases the need for human sensory 
and mental requirements as well (Monroe, 2012).

Though automation plays an increasingly important role in the world’s economy 
and daily experience, it has both advantages and disadvantages to the users. 
Advantages of automation include replacing human operators in tasks that involve 
hard physical or monotonous work and tasks done in a dangerous environment. 
Obviously, it performs tasks which are beyond human capabilities of size, weight, 
speed endurance and others therefore, an economy improves. However, automation 
or mechanization increased unemployment rate due to machines replacing humans 
and putting those humans out of their jobs, technical limitation, security threats or 
vulnerability, unpredictable development costs and high initial cost (Selsor, 2013).

 At present, it is very tangible that Philippines is trying to be globally competitive 
but not yet fully advance when it comes to automation. Nevertheless, the use of 
technology is now adopted by many people both in rural and urban communities. 
But, using the technology gave problems to users like in the case of washing 
machine. If the equipment will be destroyed sometimes it becomes disposable due 
to unavailability of its spare parts in the local market. Thus, making equipment a 
garbage.  

However, Filipinos are truly gifted as innovators that they have converted some 
technologies. It is because of the scarcity of resources, financial limitations they have or 
to increase and extend the usability of certain equipment. Conversion made includes 



104

JPAIR Multidisciplinary Research

motorcycle into tricycle and a damaged rice cooker into a modified cooking stove 
using charcoal. The concept of conversion done by Filipinos is not just to improve or 
extend the functionality of a good or damaged equipment. It is also an opportunity 
to have a lucrative business as local entrepreneurs and earning income from what they 
are converting. Also, converting damage equipment into a useful one adheres the idea 
on recycle, reuse and at the same time reducing garbage in the community. 

Inspired by the creativity and innovativeness of Filipinos, researchers conducted 
this study to find solutions to a malfunctioned electronic controlled top-loading 
washing machine. Further, conversions was done because of unavailability of its 
spare part in the local market. Hence, conversion of malfunctioned fully automatic 
washing machine into a semiautomatic operation was conducted.

OBJECTIVES OF THE STUDY

This study aims to look for a way to convert a malfunctioned fully automatic 
washing machine into a semiautomatic function. Primarily, to gain knowledge on 
how to convert the machine in order provide new knowledge and skills of a local 
technician the proper procedures through trainings. Also to inculcate among the 
concept of recycling, maintaining, repairing and converting washing machine to 
minimized environmental waste.

FRAMEWORK

The conceptual model showing the variables for the development of the project 
which guided this study is depicted below in the form of paradigm. The input includes 
the ideas on converting on design and developing fully automatic to semi- automatic 
washing machine, the billing of supplies and materials used, tools and equipment 
needed and alternative ideas from the study. The throughput involved the designing, 
developing, and rewiring the electrical connection of a washing machine utilizing old 
malfunctioned and discarded one.



105

International Peer Reviewed Journal

The output of the study is the completed semi-automatic washing machine.

 

The study revolved around the paradigm

Related Literature 

 In 1998, the application of complex mechanical action as well as spinning during 
the wetting phase was considered to lead to a reduction of suds volume by 2-31 and 
to savings of 100 to 50 Wh per cycle ( due to reduced heating).In 2005, the European 
Commission specifically considered the use of advanced motors as a good option to 
further improve the mechanical action (Faberi et al., 2007).

In 2005, 09% of all washing machines in the EU were expected to contain at least 
some sort of simple mechanical (friction or high pressure) shock absorbers. More 
sophisticated absorbers, capable of detecting an unbalance of the load, were applied 
to 5% of marketed machine ( Faberi et al., 2007). 

This development, it is even more important that washing machines also 
have a sensor capable of estimating the weight of the laundry load and which is 
able to automatically adjust programme duration, energy and water consumption 
accordingly. A half loaded machine would theoretically lead to a reduction of 50% 
of electricity and water consumption compared to a full load. Under real-world 
conditions, a reduction of about 15 to 20% can be achieved through load sensors. 
Load control features should be accompanied by an eye-catching visual indication in 
case of failure, to prevent full-load setting as default for long periods (Josephy et al., 
2011)

 



106

JPAIR Multidisciplinary Research

Fully automatic electronics driven washing machine is the latest edition by 
technology. Manufacturer claim that it is blessed with easier operation methods and 
zero maintenance costs of its some of the advantages. More efficient and it can wash 
as well as dry simultaneously and is an excellent option for all those who have little 
time to spare for the washing purposes. It will transfer the clothes from the washer to 
dryer without any manual efforts.( Aqua, 2013).

Whirlpool Corporation introduced in 2001 the Calypso, the first vertical-axis 
high efficiency washing machine to be top-loading cleaning. A wash plate at the 
bottom nutated or has a special wobbling motion that bounce, shakes, and tosses 
the laundry around. Simultaneously, water containing detergent was sprayed on the 
laundry. The machine proved to be good at cleaning, but gained a bad reputation due 
to frequent breakdowns and destruction of laundry. The washer was recalled with a 
class-action lawsuit and pulled off the market ( Tabler, 2012).

Manufacturer clamour in zero maintenance costs.( Aqua, 2012). This may be 
true, when no spare parts of an electronic controlled machine is locally available. 
In cases where in no spare parts available, conversion of a fully automatic to semi-
automatic washing machine can be done substituting some spare parts. Hence 
converting is much cheaper and need only a less amount to most of the consumer 
in the developing countries like the Philippines. Converting an electronically driven 
to semi- automatic washing machine instead of buying a new one is also minimizing 
solid waste.

MATERIALS AND METHODS

This study utilized the discarded and or malfunctioned fully automatic electronically 
driven top-loaded washing machine for converting it into a semiautomatic operation. 
Conversion of the equipment was done due to unavailability of its electronic spare 
parts in the local market because these types of machine is a product in developed 
countries.

A project type of research was used in the conduct of this study. Materials 
utilized includes the motors and electrical wiring of the malfunctioned washing 
machine. Dismantling and rewiring was done to identify the terminal leads of the 
motors followed by testing recycled parts to evaluate its usability. Replacement of 
unserviceable part was also done to turn into operation the sample equipment used 
in the study.



107

International Peer Reviewed Journal

RESULTS AND DISCUSSION

Automatic washing machine used cartridges to program different wash cycles. 
This system, called the “keymatic”, used plastic cartridges with key-like slots and 
ridges around the edges. The cartridge was inserted into a slot on the machine, 
and a mechanical reader operated the machine accordingly. The system did not 
commercially succeed because it offered no real advantages over the conventional 
program dial, and the cartridges were prone to getting lost. In hindsight, it can be 
seen as a marketing gimmick rather than offering any really useful functionality 
(Jefferson, 2013).

Further, Jefferson (2013) disclosed that automatic washing machine is dependent 
on electromechanical timer controls to sequence the washing and extraction process. 
Electromechanical timers consist of a series of cams on a common shaft driven by 
a small electric motor via a reduction gearbox. At the appropriate time in the wash 
cycle, each cam actuates a switch to engage or disengage a particular part of the 
machine. 

 
 

          
     

Figure 2. Malfunctioned fully automatic washing machine 
before conversion

Despite the high cost of automatic washers, manufacturers had difficulty in 
meeting the demand. An example of fully automatic electromechanical driven 
washing machine is showed in Figure 3.



108

JPAIR Multidisciplinary Research

 
Figure 3. The electrical diagram of fully automatic washing machine

Semi-automatic washing machine      
 

A semi-automatic machine requires the user to intervene at one or two points in 
the wash cycle. Some machines included two tubs: one with an agitator or impeller 
for washing, plus another tub for water extraction or centrifugal rinsing some are 
single tubes the model in the showed in Figure 4

 

Figure 4. Electrical diagram on the conversion of malfunctioned 
washing machine into semi-automatic operation

The primary objective of this study was to convert the malfunctioned fully 
automatic washing into semi-automatic operation and to make it functional. The 
electromechanical cam of the machine is no longer capable to perform. In order that 
the malfunctioned fully automatic washing machine will be used again. This part was 
replaced as shown in Figures 7 to 9.

  

 



109

International Peer Reviewed Journal

Conversion Process 
        
Convention began by disassembling housing frame of the washing machine. This 

is necessary for all the electronic and electrical wiring to be visualized. The next step 
was examining the electronic control panel. If found that no available spare parts 
to substitute, then decision to convert into semi- automatic operation can be done.

 

  
  Figure 5             Figure 6
        Testing individual components         Re installation of the housing 

Individual Testing-Individual testing of the main component is necessary 
to identify the worn out and functional part. First, test on the motor as the heart 
of the machine was done. followed by the test for grounded, shorted, and open 
windings. Also, checking of the capacitor was done to determine if it was still in 
good condition. Further, the main component was also tested using the multi-tester. 
After testing, all mentioned parts were found to be in good condition thus, the 
motor was energized and measured on its ampere rating to check if it’s high. Other 
testing conducted includes verifying if the bearing/ bushing were in good condition. 
Another component for testing was the solenoid and the mechanical component of 
the machine. If all the testing conducted found to be operational, then it warrants the 
conversion as the component and converting of the machine continues. Expenditure 
at this point was at the ranged of Php 2500 to Php 3000.

Additional gadgets purchased in the conversion process
    
Toggle switches. There are two toggle switches needed. It selects or chooses on 

what operation that the washing machine will execute, whether it is to wash or spin 



110

JPAIR Multidisciplinary Research

cycle operation. The second switch is for the drain motor that will drain the water 
from the tub.  

Spin Drier Cycle Timer- a part of the converted washing machine that limits the 
operating time of the spin drier. Readjustment the time of drying period was done 
manually. It will control the dry cycle spins at very fast speed of up to several hundred 
revolutions per minute, wringing as much water as possible from the clothes.

Wash cycle timer - is a part of a converted washing machine that limits the 
washing time and to vary the rotation from forward to reverse. Also, it was used to 
readjust the time of washing by manually setting the number of minutes in operation. 
It will use to control the agitator motion to move the clothes through the water at 
the tub.

      Figure 7               Figure 8      Figure 9
 Toggle Switch     Spin Dry Cycle Timer          Wash Cycle Timer

III ASSEMBLING of MALFUNCTIONED WASHING MACHINE into 
SEMIAUTOMATIC OPERATION

To assemble the machine into semi- automatic washing machine, the researchers 
were guided to follow the working diagram as shown in Figure 3. However, before 
any reinstallation of each component will be made, body repair of the malfunction 
washing machine and repainting should be done. The following diagram is the 
procedures followed during the conversion process:

 



111

International Peer Reviewed Journal

Service Cord. This is an electrical device used as a path for flow of current to the 
machine. Provide at least three meters size number 16 stranded wires and connect 
to the other end which is a heavy duty male plug. The one line terminal will be 
connected to one terminal of the toggle switch while the other line of the cord will be 
connected to the common terminal of the wash/drier motor.

Wash and Drier circuit – is a part of a washing machine attached to the motor 
assembly to the original set up. Space was provided in mounting the wash and dryer 
timer and the toggle switch. Lay outing of the wire connection of the motor was also 
performed. The circuit for wash and the dryer is separated. The toggle switch was 
used to select the operation for use. The timer used to limit the washing and spinning 
the dryer time and to vary the rotation from forward to reverse. To re-adjust the 
operating time, it was done manually by setting the number of minutes in operation.

Drain plug motor – is used to reinstall the motor to its original location in the 
converted washing machine. It is a separate circuit that operates only when removing 
the water after washing and during spin drying. All joints and connection must be 
insulated with an electrical tape.

DEVELOPED SEMI-AUTOMATIC WASHING MACHINE

A fully automatic washer requires the user to put the clothes in, and returns 
them to you clean and dry whether a top-loading or front loading, semi-automatic 
machine, by contrast, requires that a human control and oversee the process of adding 
and draining water. Aside from that, the basic principle is the same: moving clothes 
around in water and detergent until they are clean, spinning them until they are 
partly dried. Most, if not all, semiautomatic machines are a top-loading which means 
that the user is the one that puts the clothes in the top of the machine. 

Top- loading washer whether automatic or semiautomatic use an agitator, which 
stands up in the center of the wash basin and designed to move clothes in and out of 
the water. In some semiautomatic machines like the study, the wash tub is a double 
layer unit, with an outer tub that holds water and inner tube that has holes in it 
to allow water to drain out. Other machines have two tubs, one for washing and a 
perforated basket for spin-drying.



112

JPAIR Multidisciplinary Research

Figure 10. Dry run after the rewiring to semiautomatic operation

 

Figure 11. Actual appearance of converted malfunctioned fully automatic 
washing machine into a semiautomatic operation

  
OPERATION in USING a SEMIAUTOMATIC MACHINE

Starting a Load. To start a load of laundry using a semiautomatic machine, the 
first step is to add clothes and detergent. Then, using a tap or hose, add enough 
water at the desired temperature to fill the wash tub. The agitator, in the center of the 
wash tub, spins about three fourth of the way around, and then does the same in the 
opposite direction. This motion pulls clothes down into the water, which then work 
their way back up until they get pulled back down by the agitator.



113

International Peer Reviewed Journal

The Rinse Cycle. Once the cycle is finished, the user needs to manually drain the 
water from the wash tub. The next step is to add clean water for rinsing, up to the 
correct water level as specified for your washer. After adding water, restart the washer. 
It will use the same agitator motion to move the clothes through the water, rinsing 
the dirty water and soap away and leaving your clothes clean.

Spin Drying. The spin dry cycle of a semiautomatic washer uses centrifugal 
force. The pressure generated when the inner drum or wash basket spins to squeeze 
excess water from the clothes. The dry cycle spins at a very fast speed of up to several 
hundred revolutions per minute (rpm), wringing as much water as possible from the 
clothes. In a machine with a single, double-layer tub, the user is required the drain 
the water from the wash tub before starting the drying cycle. In two- tub units, you 
will need to move the clothes from the wash tub into the drying basket before starting 
the spin drying. When the drying cycle is complete, hang the clothes to finish drying.

CONCLUSIONS

The study provides skills of local technicians in converting the machine. 
Assembling the machine into semiautomatic operation, dismantling, body repair and 
repainting was done. The motor from malfunctioned washing machine as well as its 
wirings and components were recycled after found usable for converting the machine 
into a semi-automatic operation. However, other parts needed for conversion was 
purchased to make a malfunctioned washing machine into a functional one. 

The converted washing machine has similar operation cycles of the original or the 
fully automatic top loaded washing machine. On the other hand, similar principles 
was noted on the moving clothes around the water and detergent soap and on 
spinning until clothes are partly dry. However, there was difference on the controls 
and sequence of washing machine. In the newly converted washing machine, it 
requires human intervention such as adding and draining water. 

Further, the semiautomatic washing machine unlike most fully automatic where 
most of the components were made out of plastic materials. Thus, rust formation is 
minimized. The newly converted semi-automatic washing machine is ideal not only 
domestic purposes but for local businessmen engaged in laundry business. 

Finally, malfunctioned fully automatic washing machine can be converted into 
semiautomatic washing machine by utilizing most of its parts in the conversion 
process.



114

JPAIR Multidisciplinary Research

RECOMMENDATIONS

Automatic washing machine used cartridge to program the different operation 
cycles. It is relied on electromechanical timer control or sequence the washing and 
extraction process. Its cam actuates a switch to engage or disengage a particular part of 
the machine. It is true that manufacturers clamour that machine is zero maintenance 
costs, but it may be true if spare parts are available in the locality. However, due to no 
available spare parts, there is a need to convert these machines into semiautomatic, 
by substituting the electronics cartridge cam controls with toggle switches, wash cycle 
and spin drier cycle timers.

LITERATURE CITED

AEA
2009. Discussion Report: EU Ecolabel for Washing Machines, September 

2009,AEA consulting group, http://www.endseurope.com/docs 90922a.
pdf

Aqua, E.
2013. IFB 6.0 kg Top Load Washing Machine AW60-205T is fully automatic…

www homeshop 18.com>…>Fully Automatic Machine

Bocolo, A. and S. Stibelli
1988. A New Sensing Device for Washing Machines, IEEE Trans. Ind. Appl,. 

Vol.24 Issue 3, pp499-502

Cheng,W.,H. Zhiwei, and G. Jinian,
2001. The Application of a Novel Motor in Washing Machines,” Proc, 5th Int. 

Conf. Electr, Mach.Syst. (ICEMS), Vol. 2, pp.1030-1033

Defra
2009. Reducing the environmental impact of clothes cleaning-BIO intelligence 

Service in collaboration with Giraffe and Intertek, A research report 
completed for the Department for Environment,Food and Rural 
Affairs,December 2009, http//randd.defra.gov.uk/Document.
aspx?Document-EVO419_8628_FRP.pdf



115

International Peer Reviewed Journal

Faberi, S.: Presutto, M;Stamminger,R.; R., Sciadoni, R.
2007. Preparatory Studies for Eco-design Requirements of EuPs ( Tender REN/

DI/40-2005 ),LOT 14: DomesticWashing Machines and Diswashers Final 
Report, Draft Version, Tasks 1-2 www.ecowet-domestic. Org

Jefferson, G.
2013. Full-Automatic/ Buy elewctronics in multan/ Electronics Store I multan…

www abdullahelectronics.com/fully auto

Jefferson, G.
2013 How to Wash Your Clothes.9 steps_wikihow www. Wikihow.com>…

>Housekeeping>cleaning>laundry

Josephy, B.: Bush, E.; Nipkow, J., Attali, S.
2011 Washing Machines, Key Criteria for Best Available Technology (BAT), 

Toplen International Services (Paris, France), http://www.topen.eu/
uploads/File/039_Barbara_Josephy_final Washing.pdf

Maxwell, L.
1982 History of Washing Machine.inventors.about com/od/wstartinvention/a/

washing machine htm

Selsor, N.
2013. IndustrialAutomation/Selsor.www.selsor.com/application/industrial 

automation.

Pursuant to the international character of this publication, the journal is 
indexed by the following agencies: (1) Public Knowledge Project, a consortium of 
Simon Fraser University Library, the School of Education of Stanford University, 
and the British Columbia University, Canada; (2) E-International Scientific 
Research Journal Consortium; (3) Philippine E-Journals; (4) Google Scholar; (5) 
Index Copernicus; (6) Scholastica; (7) Researchgate; (8) Lacriee of France; and, 
(9) University Library of Leipzig, Germany.