Cover-integrated slimtype stator and direct drive apparatus for use in a drum-washing machine
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Solution Overview
Problem
Conventional drum-washing machines face challenges with the size constraint of the drive apparatus in built-in systems, leading to inefficiencies in direct drive systems due to the need for thicker motors, which results in reduced wash capacity and increased noise levels.
Innovation Solution
A slim type stator with a cover-integrated structure is developed, featuring a division core assembly with coils wound on division cores and a double rotor design, allowing for a compact motor installation while maintaining high driving torque and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional direct drive motor is used in a built-in drum-washing machine, then the motor can provide sufficient driving torque, but the motor thickness exceeds the 25mm space constraint
Solution Approach 1:
The motor is divided into modular components: the stator is segmented into multiple laminated cores that can be assembled in a compact configuration, and the rotor is separated into an inner rotor and outer rotor with distinct functions. This segmentation allows optimization of each component's dimensions to fit the 25mm thickness constraint while maintaining overall driving torque through the combined action of multiple segments
Solution Approach 2:
The patent employs a nested structure where the inner rotor is positioned within the stator, and the outer rotor encompasses the inner rotor. This nested arrangement allows multiple rotating components to occupy overlapping spatial volumes, effectively reducing the overall axial thickness of the motor assembly while preserving the torque-generating capability of each rotor layer
2Length of moving object
If the motor thickness is reduced to fit the 25mm space constraint, then the wash capacity is maintained, but the driving torque becomes insufficient
Solution Approach 1:
The patent uses composite construction where the stator combines laminated magnetic cores with coil windings, and the rotor integrates permanent magnets with magnetic circuits. This composite approach allows the compact 25mm-thick motor to achieve high magnetic flux density and efficient energy conversion, generating sufficient driving torque despite the reduced size
Solution Approach 2:
The patent optimizes critical parameters including increasing the magnetic flux density through high-performance permanent magnets, adjusting the coil winding density and configuration, and fine-tuning the air gap dimensions. These parameter changes enable the compact motor to compensate for its reduced size and deliver the required driving torque for medium-size/small-size drum-washing machines
3Ease of operation
If a belt-pulley indirect drive system is used, then the motor can be positioned below the drum, but energy loss increases and noise is generated during power transfer
Solution Approach 1:
The patent merges the motor assembly with the drum structure by directly coupling the rotor shaft to the drum, eliminating the intermediate belt-pulley transmission system. This direct drive configuration integrates the motor and drum into a unified assembly, removing the energy loss and noise associated with belt friction and pulley mechanics while maintaining positioning flexibility through integrated mounting structures
4Power
If a thick motor is used to provide sufficient driving torque, then the driving torque is adequate, but the wash capacity is reduced due to space occupation
Solution Approach 1:
The patent transitions from a conventional radial magnetic circuit to a axially-oriented magnetic circuit configuration, where the magnetic flux paths are arranged along the axial direction rather than radially. This dimensional reorganization allows the motor to generate sufficient torque in a shorter axial length, freeing up drum volume for increased wash capacity while maintaining the required driving performance
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 enables a direct drive apparatus that fits within the 25mm space constraint, enhancing wash capacity and efficiency while minimizing noise and material waste, suitable for medium-size/small-size drum-washing machines.
Implementation Method 1
a core style stator 50 that forms a rotating magnetic field by laminating a number of iron cores, winding a coil on the laminated iron cores, and making electric current flow through the coil
Implementation Method 2
an outer mode rotor 510 that is formed by making magnets disposed on the outer circumference of the stator in which the rotor 510 is rotated by the rotating magnetic field that is formed by the stator 520
Data Source
AI summary
Provided is a cover-integrated stator that is used to make a BLDC Brushless Direct-Current motor having a stator of a division core structure and a double rotor, a slim type motor, and a direct drive apparatus for use in a drum-washing machine. The direct drive apparatus includes: a rotating shaft whose one end is rotatably combined with a tub of a drum-washing machine and on the leading end of which a basket is fixedly combined; a double-rotor including inner and outer rotors that are disposed between the inner/outer portions and a rotor holder that connects respective one end of the inner and outer rotors, and that is extended and formed in a bushing combined with the rotating shaft; and a stator that is formed by integrating a division stator core assembly that is assembled in an annular form by winding coils on a number of division cores by a stator holder, in which the stator holder includes an inner extension portion that is axially extended and to the center of which the other end of the rotating shaft is rotatably supported, and an outer extension portion that is extended forwards from the outer circumference of the stator holder and that is fixedly combined with the tub, so as to form a cover surrounding the double-rotor.