Double-Rotor Washer Motor Control Without a Clutch
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Solution Overview
Problem
Conventional washing machines with direct-drive motors require a complex and expensive clutch to selectively rotate a pulsator and dehydrator, increasing manufacturing costs and reducing efficiency.
Innovation Solution
A motor drive device with a double-rotor/double-stator structure that uses a motor controller, inverter, and rotor drive controller to generate and control three-phase AC power, allowing for independent rotation of the pulsator and dehydrator without a separate clutch, and adjusting the rotational direction based on the laundry operation mode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a clutch is used to selectively rotate the pulsator and dehydrator, then the washing machine can perform laundry and dehydration operations, but the device complexity and manufacturing cost increase
Solution Approach 1:
The motor is divided into two independent rotor-stator systems: an outer rotor-stator system for driving the pulsator, and an inner rotor-stator system for driving the dehydrator. Each system can operate independently, eliminating the need for a clutch mechanism while maintaining selective rotation capability.
Solution Approach 2:
The inner rotor-stator system is nested within the outer rotor-stator system. The inner rotor rotates within the inner stator, which is positioned within the outer rotor assembly. This nested configuration allows both systems to coexist in a compact space without requiring additional clutch components.
2Ease of operation
If a clutch is used to deliver rotating torque to the pulsator and dehydrator, then the motor can control rotation, but the manufacturing cost increases
Solution Approach 1:
The torque transmission path is segmented into two independent channels: one from the outer rotor to the pulsator, and another from the inner rotor to the dehydrator. This segmentation eliminates the need for complex clutch mechanisms and torque switching components, reducing manufacturing cost while maintaining full torque control capability.
3Device complexity
If a single motor is used to rotate both the pulsator and dehydrator, then the structure is simplified, but the ability to independently control rotation is lost
Solution Approach 1:
The single motor structure is segmented into two independent rotor-stator systems that can operate autonomously. The outer rotor-stator system controls pulsator rotation while the inner rotor-stator system controls dehydrator rotation, maintaining structural simplicity while achieving independent rotation control.
Solution Approach 2:
The inner rotor-stator system is nested within the outer rotor-stator system, allowing both systems to be integrated in a compact single-motor configuration. This nested structure enables independent control of both pulsator and dehydrator while maintaining overall structural simplicity.
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
This solution enables efficient washing and dehydration operations by individually controlling the pulsator and dehydrator, enhancing laundry efficiency and reducing power consumption while eliminating the need for a separate clutch, thus lowering manufacturing costs.
Implementation Method 1
an inverter that generates three-phase alternating-current (AC) power under the control of the motor controller
Implementation Method 2
outputs the three-phase AC power to a first three-phase stator coil for rotating an outer rotor in the motor for the washing machine, and a second three-phase stator coil for rotating an inner rotor therein
Data Source
AI summary
Provided is a motor drive device for a motor for a washing machine of a double-rotor/double-stator structure that can selectively rotate a pulsator and a dehydrator without having a separate clutch, and a motor control method thereof. The motor drive device includes: a motor controller that generates a drive signal according to a laundry control signal to thus control a motor for the washing machine to be driven: an inverter that generates three-phase alternating-current (AC) power under the control of the motor controller, and outputs the three-phase AC power to a first three-phase stator coil for rotating an outer rotor in the motor for the washing machine, and a second three-phase stator coil for rotating an inner rotor therein; and a rotor drive controller that is provided between the inverter and the second three-phase stator coil, to thus block or pass the three-phase AC power under the control of the motor controller and simultaneously change the direction of rotation of the inner rotor.