Composite Rotor Hub Structure for Quiet Torque Transfer
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Solution Overview
Problem
Existing rotor designs for electric motors in laundry appliances face challenges in securing the rotor frame to the central hub effectively, leading to potential rotational force transmission inefficiencies and noise generation due to inadequate material distribution and attachment configurations.
Innovation Solution
A dual-ring rotor hub design featuring a central core and a perimetrical ring with recesses that receive polymeric material to secure the rotor frame, utilizing a combination of polymeric and metallic materials to enhance strength and reduce noise, with the polymeric material injected into recesses to form a strong and quiet connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional single-ring rotor hub design is used, then the structure is simple, but the rotor frame attachment is inadequate leading to noise and force transmission inefficiencies
Solution Approach 1:
The rotor hub is segmented into multiple functional rings: an inner ring for structural support, an outer ring for rotor frame attachment, and a perimetrical ring for additional securing. This segmentation allows each ring to perform its specific function optimally, improving attachment effectiveness while maintaining manageable complexity through modular design
Solution Approach 2:
The rotor hub employs composite construction combining metallic rings (for structural strength and torque transmission) with polymeric material (for noise reduction and secure attachment). This composite approach resolves the contradiction by using material properties to enhance reliability without proportionally increasing structural complexity
2Object-generated harmful factors
If polymeric material is used to secure the rotor frame, then noise is reduced, but the attachment strength may be insufficient without proper configuration
Solution Approach 1:
The polymeric material is strategically placed in specific locations where it provides both noise reduction and attachment strength. The material is positioned in circumferential grooves and at interfaces between rings, providing localized damping and securing functions where most needed, rather than uniformly throughout the entire hub structure
Solution Approach 2:
The combination of polymeric material with metallic rings creates a composite attachment system where the polymer provides noise damping and friction-based securing, while the metal rings provide structural strength and torque transmission. This composite approach allows both noise reduction and sufficient attachment strength to be achieved simultaneously
3Productivity
If the polymeric material is not properly distributed in the attachment portion, then manufacturing is easier, but rotational force transmission becomes inefficient
Solution Approach 1:
The attachment portion is segmented into discrete circumferential grooves and recesses that guide polymeric material distribution. These segmented features ensure the material is properly positioned in critical torque transmission zones without requiring complex manufacturing processes, as each groove can be independently formed using standard machining or molding techniques
Solution Approach 2:
The rotor hub design incorporates pre-formed grooves, recesses, and attachment features during hub manufacturing, before the polymeric material is applied. This preliminary action ensures that when the polymer is later installed (via injection, molding, or bonding), it automatically distributes itself correctly in the attachment portion, achieving efficient torque transmission without complex material distribution processes
Data Source
AI summary
A motor for a laundry appliance includes a drive shaft coupled to a drum at a first end. The rotor frame is coupled proximate the second end of the drive shaft, where the rotor frame includes at least one polymeric material. A central hub includes a core and a perimetrical ring that extends circumferentially around the core. A plurality of recesses are defined within a planar surface of the perimetrical ring, wherein a portion of the polymeric material is received within the plurality of recesses to secure the rotor frame to the central hub.