This invention relates to domestic products such as appliances and communication and diagnostic modules for domestic appliances. The term "domestic appliance" encompasses appliances for domestic functions such as cooking, dishwashing, clothes washing and clothes drying and cooling, whether the appliance is used or intended for use in a domestic or a commercial setting.

Many domestic appliances are capable of performing self-diagnostic functions. When a fault occurs they might display a fault code that assists an engineer to understand what the fault is. However, typical appliances suffer from a number of problems.

First, typical domestic appliances are unable to issue a warning in advance of a component failing. Rather than the appliance generating an alert when a component has failed, it would be preferable for the user to be warned in advance that the component might fail soon. Then the user could have the appliance repaired or replaced at a convenient time, and without being deprived of service from the appliance.

Second, it would be useful for the appliance to be able to alert the user to an actual or imminent failure of a component even if the user is remote from the appliance. One way to do this would be for the appliance to transmit a signal via the internet to a device such as a mobile phone carried by the user. This would require the appliance to be connected to the internet. Internet-connected appliances are known (see, e.g., US 6,393,848), but these may suffer from a number of problems. For example, wireless connectivity to built-in appliances may be poor due to signal attenuation by walls and partitions surrounding the appliances. This can lead to unreliable connectivity. Also, providing internet connectivity increases the cost of appliances, and some customers may prefer to have a more basic appliance. Third, there is a need to assist installers to commission appliances and to diagnose faults in appliances.

There is a need for an improved domestic appliance.

According to one aspect of the present invention there is provided a domestic appliance for performing a domestic appliance function, the appliance comprising: a housing defining the exterior of the appliance; functional apparatus for performing the domestic appliance function; at least one sensor for sensing the status of the functional apparatus; an electrical control circuit located within the housing for controlling the functional apparatus to perform the domestic appliance function; a connector port communicating with the exterior of the appliance, the connector port having a structure for physically restraining a module engaged in the connector port and a plurality of electrical connectors for electrical coupling to a module engaged in the connector port, the appliance being configured such that data indicative of the output of the sensor is provided to the electrical connectors; and a module configured for physical engagement with the connector port, the module having a plurality of electrical connectors for electrical coupling to the connectors of the connector port, and the module comprising: an output device; and a processor configured to analyse data received at the connector port to identify characteristics indicative of defects in the functional apparatus and/or the electrical control circuit and to, on identifying such a characteristic, cause that characteristic to be signalled by the output device.

The output device may be a wireless communication device.

The domestic appliance may have a front panel exposed to the front of the device. The connector port may be located in the front panel.

The output device may be a display device. The display device may be located in a surface of the module that is exposed at the front of the domestic appliance when the module is fully located in the connector port.

The electrical control circuit may be capable of controlling the functional apparatus to perform the domestic appliance function when the module is absent from the connector port.

The electrical control circuit may be capable of controlling the functional apparatus to perform the domestic appliance function without the use of a microprocessor.

The module may comprise a memory storing instructions for execution by the processor, the memory defining the said characteristics indicative of defects.

The or each characteristic indicative of a defect may comprise or be defined by one or more thresholds for a respective performance metric of the functional apparatus. The threshold may be a predefined threshold.

The processor may be configured to: analyse data received at the connector port to identify characteristics indicative of at least one major defect in the functional apparatus and/or the electrical control circuit and to, on identifying such a characteristic, cause that characteristic to be signalled by the wireless communication device; and receive data by means of the wireless communication device, identify whether that data is a message of a predetermined format indicative of a major fault with another domestic appliance, and if it is a message of that format, to cause data of that message to be signalled by means of the output device.

The processor may be configured to, on identifying a major defect in the functional apparatus and/or the electrical control circuit, inhibit an operation of the domestic appliance. The processor may be configured to cause data of the said message to be signalled by means of the output device by transmitting that data by means of the wireless communication device.

The processor may be configured to cause data of the said message to be signalled by means of the output device by displaying that data by means of the display device.

The said module may be of a first type, and the electrical control circuit may be responsive to a module of a second type communicating with it via the electrical connectors of the connector port to permit the electrical control circuit to undergo a diagnostic function that cannot be invoked by the module of the first type.

The said module may be of a first type, and the electrical control circuit may be responsive to a module of a second type communicating with it via the electrical connectors of the connector port to permit the electrical control circuit to undergo a configuration function that cannot be invoked by the module of the first type.

The present invention will now be described by way of example with reference to the accompanying drawings. In the drawings:

Figure 1 shows schematically an oven.

Figure 2 shows schematically a connector port and a removable module.

The oven of figure 1 comprises an outer housing 1 . Inside the outer housing is a cooking cavity 2. Access to the cooking cavity can be gained from the front of the oven by means of a door 3. One or more heating elements 4 disposed in or adjacent to the cooking cavity can be energised in order to heat the cooking cavity. The oven is connected to an electrical supply by means of a cable 5. The operation of the oven is controlled by a control unit 9. In this example the control unit operates by means of software executed by a processor 10. The control unit comprises processor 10 and a memory 1 1 . The memory stores program code for execution by the processor to enable the control unit to perform the functions described of it herein. The memory stores the program code in a non-transient way. The memory may be a non-volatile memory. The controller receives inputs from user controls 13 and from sensors 14, 15. In this example sensor 14 is a current sensor which senses current flowing to the heating elements 4 and sensor 15 is a temperature sensor which senses the temperature in the cooking cavity 2. By executing the program code stored in the memory 10 the control unit can cause the oven to function in accordance with the settings signalled by a user by means of the controls 13. For example, the controls may be set so as to designate a desired temperature for the cooking cavity. The control unit can compare the temperature sensed by the temperature sensor 15 with the temperature designated by controls 13. If the temperature in the cavity is below the designated temperature then the program code may cause the controller to turn on the electricity supply to the heating elements. Otherwise the program code may cause the controller to turn off the electricity supply to the heating elements 4. The oven also includes a display unit 16 located on a front panel 17 of the oven. The controller may control the display unit to display information such as the current time of day or the difference between the set temperature of the cooking cavity and the current temperature of the cooking cavity. In other embodiments these essential functions of the oven may be performed by dedicated hardware circuitry, rather than by a processor. Such circuitry may, for example, control the essential functions of the oven with or without the use of a microprocessor to execute instructions that result in control signals being passed to the primary (e.g. material processing) components of the appliance - in this instance the elements 4. As will be described in more detail below, the essential functions of the oven can be provided irrespective of whether a module 30 is present in the connector port. This has a number of advantages. For example, the appliance can perform its essential function whether or not a purchaser opts to install the module 30, and the module can be removed and updated without affecting the essential functioning of the appliance. A connector port 20 is provided on the oven. The connector port is preferably located so that it is readily accessible to a user of the oven. It may be accessible through the front panel 17. The connector port is shown in more detail in figure 2. The connector port comprises a physical element and an electrical element. In this example the physical element is an opening 21 in the front panel 17 of the oven and a slot 22 extending from the opening 21 into the region behind the front panel. At the inner end of the slot are a series of electrical connectors 23 which constitute the electrical element of the connector port. The electrical connectors are exposed to the interior of the slot. The slot communicates physically with the opening 21 . The slot is accessible through the opening. The physical and electrical elements of the port could take any convenient form. For example, the opening could be rectangular, round or any other convenient shape. The electrical connectors could be located at the innermost end of the slot and/or along one or more sides of the slot and/ or elsewhere.

To help prevent dust or other material entering the slot there could be a closure element such as a shutter which can extend across the opening and can then be retracted by linear and/or rotational movement with respect to the body of the oven to provide access to the slot. The closure could be biased into its configuration in which it covers the slot. Alternatively, a removable plug could be provided which closes the slot when applied to the opening when no module 30 is in the port.

The port 20 gives access to the electrical connectors of 23. The electrical connectors 23 connect to the control unit 9 or to user controls 13. The electrical connectors could, if desired, be spring-loaded to improve the quality of connections to them.

A module 30 is configured to be inserted into the slot. At its exterior the module comprises a housing 31 , a front surface 32, electrical connectors 33 and indicators 34, 35. Inside the housing are a processor 36, a memory 37 and a wireless communication device 38. The housing of the module is configured to be received snugly through the opening 21 of the port and into the slot 22 of the port. The electrical connectors 33 of the module are configured to mate with the electrical connectors 23 of the port when the module is fully inserted into the slot 22. The memory 37 stores program code for execution by the processor 36 to enable the module to perform the functions described of it herein. The memory stores the program code in a non-transient way. The memory may be a non-volatile memory. The processor is coupled to the communication device 38 so as to enable to the processor to: (i) cause the communication device to transmit data formed by the processor and (ii) receive data that has been received wirelessly by the communication device.

When the module is fully home in the slot 22 (i.e. it is inserted to its fullest extent into the port 20) its front surface 32 is preferably substantially flush with the front surface 17 of the oven. The housing may have a lip 39 protruding laterally around its front surface to inhibit excessive insertion into the slot 22 and/or to help it be gripped in order to withdraw it from the slot. At least part of the module is visible to a user when the oven is in its normal configuration. This allows it to display messages to a user. Preferably the module is exposed on the front panel of the oven when any primary door of the oven (i.e. one provided for gaining access to a material processing area of the appliance) is closed.

In this example, indicator 34 is a light-emitting device such as a light-emitting diode and indicator 35 is a seven-segment display device. The indicators could take other forms.

Instead of a female socket extending into the front panel, into which a male part of the module is to be inserted, the connector port could be of another form. For example, it could be defined by rails for engagement with the module, a magnetic zone for holding the module to the oven or a male plug protruding from the oven that is to be inserted into a female socket on the module. In the case of a magnetic zone, that zone is advantageously positioned so that it is sufficiently remote from any magnetically sensitive components of the appliance that those components will function properly. The zone may be a mechanical or electrical zone for holding the module to the appliance. It may be electrically locked to the appliance.

The operation of the oven will now be described.

The oven is capable of functioning for its essential purpose (i.e. cooking) when no module is present in the connector port 20. The control unit 9 is configured to control the heating elements 4 to heat the cavity 2 to, and maintain the cavity at, a temperature designated by means of the controls 13. Other functions may be provided by the control unit 9. For example, a user may designate a time by means of the controls. Then the control unit 9 may be configured to begin heating the cavity at the designated time. A fan 40 may be located in or adjacent to the cavity 2 for circulating air in the cavity. The control unit may control the fan to be active in dependence on inputs from the controls 13, for example to turn the fan on or off directly or to designate a cooking program in which the fan is predefined as being active or inactive.

The control unit 9 causes information regarding the state of the oven to be communicated to the contacts 23. That information may include and one or more of:

(a) whether one or more functions of the oven is/are turned on or off: for example, whether the elements 4 and/or the fan 40 are active;

(b) the settings of the controls 13;

(c) data received from sensors, e.g. sensors 14, 15;

(d) identity and/or capability information for the oven: for example, its model, serial number, available functions, nominal rated power and information to permit the other data to be interpreted (e.g. a definition of the relationship between analogue or digital values received from a temperature sensor and the corresponding sensed temperature).

Other sensors may be provided, whose outputs can be passed to the control unit 9 and/or to the contacts 23. Examples of other sensors include: a sensor for sensing the ambient temperature where the oven is located, an additional sensor for sensing the temperature in the cavity 2 at a different location from sensor 15; and a sensor for sensing the humidity in the cavity 2.

When the module 30 is engaged with the contacts 23 of the body of the oven it is powered by the oven through the contacts. Alternatively, it may be powered by a battery located in the module. The module receives the information communicated by the control unit 9. The processor 36 of the module performs processing on that information in accordance with code stored in memory 37. In dependence on that processing it may then perform actions such as causing the wireless communication device 38 to transmit data, operating the display devices 34, 35 and transmitting data to the control unit 9. Examples of these operations will now be described.

In one mode of operation the processor 36 compares the data received from the oven's control unit 9 with one or more predetermined performance criteria. Each performance criterion defines a performance characteristic of the oven. Examples of the performance criteria may include:

- a predetermined rate of heating of the cavity 2 when the elements 4 are active;

- a predetermined rate of cooling of the cavity 2 when the elements 4 are inactive;

- a predetermined power consumption of the elements 4 when they are active;

- a predetermined temperature differential between the upper and lower parts of the cavity 2 when the fan 40 is active (this may be sensed by comparing data from multiple temperature sensors in the cavity 2).

Other examples of the performance criteria may include a change of a predetermined amount or at a predetermined rate of each of the above candidate criteria over time (this may signify a deterioration in the appliance's performance that may subsequently lead to a material failure). The predetermined rates, power consumption, temperature differential and amount may be selected in dependence on the make, model and/or type of the appliance. The module may store such thresholds for a number of appliances, may read the make, model and/or type of the appliance and may then select for use the threshold relevant to that appliance. The threshold may also be selected in dependence on ambient or other local conditions, for example the ambient temperature in the vicinity of the appliance as sensed by a temperature sensor in the module.

If the data received from the oven's control unit indicates that the oven's performance is outside a predetermined threshold defined with respect to the predetermined performance criteria (e.g. above or alternatively below a performance criterion) the processor 36 may take an action such as transmitting data regarding the event via the wireless communication device 38 and/or displaying information by means of the display units 34, 35. This enables the module to alert a user to the event.

The predetermined performance criteria and the thresholds may be defined so that the event is indicative of a certain condition of the oven. For example:

- if the rate of heating of the oven is below a predetermined value then that may indicate that the elements 4 have failed or may fail soon;

- if the rate of cooling of the oven is above a predetermined value then that may indicate a defect with a seal around the door 3;

- if the power consumption of the elements is higher or lower than an expected range then that may indicate that they have failed or may fail soon;

- if the temperature differential between the upper and lower parts of the cavity 2 is greater than a predetermined value when the fan 40 is set to be on, that may indicate that the fan has failed or may fail soon.

The performance criteria and the thresholds may depend on data received from the oven or otherwise collected by the module. For example, the rate of heating of the oven below which an event is triggered may depend on the average ambient temperature where the oven is located.

One action the module may take in response to detecting such an event is to cause the light 34 to illuminate. It may illuminate steadily or in a flashing and/or pulsing pattern. This may alert a user to an error condition. Another action the module may take is to display a value or pattern (e.g. a picture or series of icons or pictograms) using the display 35. This may indicate the nature of the error. Another action the module may take is to cause the wireless transceiver 38 to transmit a message addressed to a server or hub. The message may indicate the identity of the appliance and the nature of the event and optionally raw or processed data derived from the sensors in the oven. The server or hub may then perform diagnostics on the received data. The server or hub may transmit an alert to an address associated with the appliance (e.g. to an email address or mobile phone number) to alert a user to the event.

In this way, the removable module 30 can perform diagnostics on the oven and trigger local or remote alerts in dependence on its analysis. Decisions about whether to trigger an alert may be made by the module 30 and/or by devices such as a hub or server remote from the oven, with which the module 30 communicates.

The module may determine that a dangerous fault has arisen in the oven. For example, it may determine that the temperature in the cavity 2 is above a predetermined limit. In response to such a determination the module may determine that the oven should be shut down. In this situation it is desirable for the module to trigger an alert to a user of the appliance, for example in the manner described above, and then shut the oven down. That may also shut the module down if it is powered by the oven. Before the module implements the shutdown, it may be desirable for it to transmit a message to a local device regarding the shutdown. That message may indicate the identity of the appliance and the nature of the event and optionally raw or processed data derived from the sensors in the oven. If this message is transmitted to a local device, that device may forward it on to a hub or a server for processing after the oven has been shut down. This is useful if the oven has limited network capability (e.g. because its local internet connection is down) when the shutdown occurs. The local device could be a hub or another similar module in another appliance. Thus, the module may be configured to:

(a) establish a connection to a like module within wireless communication range of the wireless transceiver 38, and transmit a message as described above to it; and

(b) on receiving such a message from another like module or a hub, store that message and forward it on to a hub or server for further processing. The other similar module may display a signal using its own displays 34, 35 to indicate that it has received an error message from a nearby appliance different from the one in which it is installed.

The wireless transceiver 38 may operate according to any convenient protocols. Examples include IEEE-801 .1 1 (Wi-Fi) and Bluetooth. The protocol may be one that uses the ISM (instrument, scientific and medical band). An advantage of the module being located in the front panel of the appliance is that its wireless communications may suffer less attenuation than if the module is located elsewhere. An advantage of the module being removable is that it may readily be replaced by a user with a module that supports an updated wireless protocol.

The wireless transceiver may be connected to the internet. It may be configured, to communicate with a local hub (e.g. a WiFi access point or hub or a Bluetooth device configured to act as an access point) which provides it with internet connectivity. The wireless transceiver may be configured in known ways to search for and attempt to connect to a nearby access point.

The module may also act as the hub by utilising a master/slave model of communication where one module has unidirectional control (i.e. master or device 0) over one or more other modules (i.e. slaves or device 1 s). A module engaged with a first appliance and having a first level of functionality (e.g. set of communication standards it supports, or physical range) may serve to receive and forward communications from a module engaged with the same or a second appliance and having a lesser level of functionality.

When the module is connected to a local network or a publicly accessible network the internet, data from the module may be accessed by an application running on a device that is also connected to the network. For example a user, an installer, a repairer or a monitoring station may receive data from the module at a device local to them. That device may then present the information to the respective individual. In one convenient embodiment, the information can be received and presented by a mobile app running on a smartphone. The application may also be used to configure the module. The module may require an application to authenticate to it before providing status information to the application. An additional level of security authentication may be required to configure the module over that required to read status data from the module.

There may be modules that support different modes of operation. For example, a first ("user") module may support the functions described above. A second ("installer") module may support other functions which are not supported by the user module. Examples of those other functions include more elaborate diagnosis of faults with the appliance than the user module is capable of and configuring the appliance for first use. Thus, in one scenario the appliance may be installed by an installer. The installer may then insert an installer module in slot 22 and use that module to configure the device for first use. Then a user module may be inserted in slot 22 for normal use. In another scenario a user module inserted in slot 22 may detect a fault or potential fault. Then an installer may remove that module from slot 22 and replace it with an installer module. Then the installer may use the installer module to help diagnose and/or rectify the fault. Examples of diagnosis functions that the installer module may be capable of performing and that might not be supported by the user module may include:

- causing the control unit 9 to operate in a self-test mode;

- outputting raw data received from sensors in the appliance;

- toggling the operational state of components of the appliance.

Examples of configuration functions that the installer module may be capable of performing and that might not be supported by the user module may include:

- storing in memory 1 1 an identity of the appliance;

- storing in memory 1 1 an identity of a user of the appliance;

- causing the appliance to switch from a shipping mode in which one or more primary functions of the appliance are disabled to an operational mode in which those functions are enabled;

- enabling premium functions of the appliance which are not enabled by default;

- upgrading the program code in the memory 1 1 ; - disabling certain functions of the appliance, e.g. for safety reasons.

The control unit 9 may require the installer module to be authenticated to it in order to perform any of the above tasks.

In the example given above, data from the sensors passes to contacts 33 via the control unit 9. Alternatively, the sensor data may pass directly to both the control unit 9 and the contacts 33, for example by the sensors, the control unit 9 and the contacts 33 being connected to a common communications bus.

In the examples given above, the appliance is an oven. The appliance may be of a different type. For example, and without limitation, it could be a hob or stove whose function is to heat pans by means of a hotplate, a refrigerator whose function is to chill food by means of a refrigeration unit, a freezer whose function is to freeze food by means of a refrigeration unit, a washing machine whose function is to wash clothes by means of a washing vessel, a tumble dryer whose function is to dry clothes by means of a drying vessel, a dishwasher whose function is to wash crockery etc., a vacuum cleaner whose function is to perform cleaning, a toaster whose function is to toast food, a space heater whose function is to emit heat or a lighting unit whose function is to emit light. The features described in respect of an oven in the foregoing description may be applied mutatis mutandis to such appliances. For example, in the case of a refrigerator, the control unit 9 may control the operation of the refrigeration unit in dependence on temperature setting made by a user on a user interface and in dependence on one or more temperatures sensed by sensors in a cooling cavity of the fridge. Data from that refrigerator control unit may be passed to a module inserted in the front panel of the refrigerator. The module may then analyses the received data and determine whether it is indicative of a state of the refrigerator regarding which an alert should be transmitted. The appliance may be a built-in, free-standing or mobile appliance. The appliance may be a kitchen appliance. The appliance may be an electrical appliance. The appliance may be configured to use mains electricity. The appliance may be a heating (including cooking), cooling, air handling (including air extraction and filtering) or cleaning (including dishwashing, room cleaning and laundry) appliance. The applicant hereby discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the present specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the present invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.