Active Balancing Module for Washing Machine Load Unbalance
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Solution Overview
Problem
Conventional washing machines face challenges in minimizing vibration and noise due to load unbalance in the rotating basket, as their balancers are unable to accurately move to compensate for unbalanced loads, leading to potential damage to components.
Innovation Solution
A washing machine with a balancer housing and a movable balancing module that includes a main plate with mass bodies, a drive unit, and a brush for electric power transmission, allowing the module to actively move and alleviate load unbalance by using a drive motor, gears, and position sensors to optimize its position during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a passive balancer is used in the washing machine, then the structure is simple, but the balancer cannot accurately move to compensate for load unbalance, resulting in increased vibration and noise
Solution Approach 1:
The balancer is transformed from a passive static structure to an active dynamic system by incorporating a drive unit with motor, gears, and brush. The balancing module can now actively move along the annular channel to dynamically adjust its position and compensate for load unbalance in real-time, thereby reducing vibration and noise while maintaining controlled complexity through modular design.
2Ease of manufacture
If a passive balancer is used in the washing machine, then the manufacturing cost is low, but the balancer cannot accurately move to alleviate load unbalance, leading to potential damage to rotating basket and motor
Solution Approach 1:
The passive balancer is upgraded to an active system with drive unit components (motor, gears, brush) that enable controlled movement. This dynamic capability allows the balancing module to accurately position itself to counteract load unbalance, preventing excessive vibration that could damage the rotating basket and motor, thereby improving reliability while remaining manufacturable through modular assembly.
Solution Approach 2:
The system incorporates a position sensor that detects the position of the balancing module and provides feedback to the control unit. This closed-loop feedback mechanism enables precise control of the balancing module's position, ensuring accurate compensation for load unbalance and preventing damage to critical components, while maintaining ease of manufacture through standardized sensor integration.
3Object-affected harmful factors
If an active balancing module with drive unit is implemented, then vibration and noise are reduced, but the device complexity increases
Solution Approach 1:
The balancing module is designed as a dynamic system with drive unit components (motor, gears, brush) that enable active movement along the annular channel. This dynamic capability allows precise positioning to counteract load unbalance, reducing vibration and noise. The complexity is managed through modular design where the drive unit, position sensor, and balancing mass are integrated as a self-contained module.
Solution Approach 2:
A position sensor detects the position of the balancing module and provides feedback to the control unit, which controls the drive unit to adjust the module's position. This feedback mechanism enables automatic compensation for load unbalance, reducing vibration and noise without requiring complex manual adjustment mechanisms, thereby managing device complexity through intelligent control.
4Measurement precision
If an active balancing module with position sensor and control unit is implemented, then load unbalance compensation accuracy is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The system employs a position sensor that detects the position of the balancing module and provides feedback to the control unit. This feedback mechanism enables precise detection and control of the module's position, allowing accurate compensation for load unbalance. The complexity is managed by integrating the sensor and control unit as a coordinated subsystem that automatically adjusts the balancing module's position based on real-time detection.
Solution Approach 2:
The control system replaces complex mechanical adjustment mechanisms with an electromechanical system comprising a drive unit (motor, gears, brush) and position sensor. This substitution enables precise positional control through electrical actuation rather than mechanical linkages, improving measurement precision while managing overall device complexity through standardized electromechanical components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces vibration and noise by actively compensating for load unbalance, enhancing the stability and longevity of the washing machine's components during high-speed rotation.
Implementation Method 1
a brush configured to transmit electric power supplied from an external power source to the drive unit
Implementation Method 2
a drive unit mounted to the main plate to assist the balancing module in moving to a position where the balancing module alleviates load unbalance
Data Source
AI summary
A washing machine having a balancer includes a rotating basket in which laundry is accommodated, the rotating basket being configured to be rotated upon receiving rotation power from a drive source, at least one balancer housing mounted to the rotating basket, the balancer housing internally having an annular channel, and at least one balancing module movably disposed in the channel to alleviate load unbalance caused during rotation of the rotating basket. The balancing module includes a main plate, at least one mass body provided at the main plate, a drive unit mounted to the main plate to assist the balancing module in moving to a position where the balancing module alleviates load unbalance of the rotating basket, and a brush configured to transmit electric power supplied from an external power source to the drive unit.