Direct Drive Washing Machine Motor With Resin Connector Damping
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Solution Overview
Problem
The existing drum type washing machines face issues with energy loss, noise, increased assembly time, and vibration due to indirect power transmission through belts and pulleys, and have fabrication challenges with complex structures and poor processability of components like stainless steel tubs and bearing housings.
Innovation Solution
A direct drive motor system with a stator, rotor, and annular washer design that uses a steel plate rotor with a press-formed sidewall and rear wall, a resin connector with a different vibration mode, and a metal bearing housing integrated into the tub for improved rigidity and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If driving force is transmitted from motor to drum through belt and pulleys, then power transmission is achieved, but energy loss occurs and noise is generated
Solution Approach 1:
The patent removes the belt and pulley transmission components from the system, implementing a direct drive motor that connects the motor shaft directly to the drum shaft. This extraction of intermediate transmission elements eliminates energy loss and noise associated with belt-pulley friction and mechanical transmission, while maintaining effective power transmission from motor to drum.
Solution Approach 2:
The patent merges the motor assembly and drum assembly into a more integrated configuration by eliminating the belt transmission system. The motor shaft is directly coupled to the drum shaft, combining what were previously separate functional units into a unified direct drive system, thereby reducing energy loss and simplifying the power transmission path.
2Power
If motor pulley, drum pulley, and belt are used for power transmission, then driving force transmission is achieved, but noise is generated
Solution Approach 1:
The patent extracts and removes the noise-generating components (motor pulley, drum pulley, and belt) from the system. By implementing a direct drive mechanism where the motor shaft directly drives the drum shaft, the patent eliminates the mechanical friction, vibration, and impact noises that occur in belt-pulley transmission systems, while maintaining effective power transmission.
3Power
If many components are used for power transmission, then driving force transmission is achieved, but assembly time increases
Solution Approach 1:
The patent removes multiple transmission components (motor pulley, drum pulley, belt, and associated mounting structures) from the assembly. This reduction in component count directly decreases assembly time and complexity, while the direct drive configuration maintains effective power transmission from motor to drum with fewer parts requiring installation and alignment.
Solution Approach 2:
The patent merges multiple separate components into a more integrated direct drive assembly. By eliminating the belt transmission system and directly coupling the motor shaft to the drum shaft, the patent reduces the number of discrete parts that require assembly, thereby reducing assembly time and simplifying the manufacturing process.
4Power
If motor pulley, drum pulley, and belt are used, then power transmission is achieved, but number of faults increases
Solution Approach 1:
The patent extracts and eliminates the fault-prone belt and pulley components from the power transmission system. By implementing a direct drive motor configuration where the motor shaft directly drives the drum shaft, the patent removes components that are susceptible to wear, stretching, misalignment, and breakage, thereby significantly improving system reliability and reducing the number of faults while maintaining effective power transmission.
5Strength
If stainless steel tub is used, then durability is achieved, but processability deteriorates and weight increases
Solution Approach 1:
The patent employs composite material construction for the tub, combining stainless steel with other materials to achieve both durability and improved processability. This composite approach allows the tub to maintain the strength and corrosion resistance of stainless steel while incorporating materials that are easier to form, weld, and assemble, thereby improving overall manufacturability without sacrificing durability.
6Reliability
If bearing housing projects from tub, then bearing support is achieved, but assembly difficulty increases and space occupied increases
Solution Approach 1:
The patent merges the bearing housing with the tub structure, integrating the bearing support function directly into the tub body. This integration eliminates the need for a separate, projecting bearing housing component, thereby simplifying the overall assembly, reducing the space occupied, and maintaining reliable bearing support for the direct drive motor system.
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 reduces noise, faults, and power loss, enhances fabrication workability, and maintains concentricity, while the metal bearing housing and steel plate rotor improve processability and productivity, and the resin connector reduces vibration and overheating risks.
Implementation Method 1
a connector of resin having a vibration mode different from the washing shaft
Implementation Method 2
a direct drive motor in a washing machine including a stator 14 having a winding portion with coils wound thereon
Data Source
AI summary
A direct drive motor in a washing machine includes a stator having a winding portion with coils wound thereon, a rotor having a sidewall, and a rear wall with a pass through hole at a center, and fastening pass through holes around the pass through hole, an annular washer in close contact with, and fixedly secured to, the rear wall of the rotor, the annular washer having fastening pass through holes in a surface thereof in correspondence to fastening pass through holes in the rear wall of the rotor, a connector of resin having a vibration mode different from the washing shaft, fixedly secured to an inner side of the rear wall of the rotor for supporting the washing shaft, the connector having fastening pass through holes in correspondence to the fastening pass through holes around the pass through hole, bolts passed through the fastening pass through holes in the connector, the rotor, and the washer, and nuts fastened to the bolts for holding the connector, the rotor, and the washer together.