Drum Washer Rotor Sensing for Non-Contact Opening Alignment
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Solution Overview
Problem
Top-loading drum type washers face issues with drum position alignment during stopping, leading to potential damage from kinetic energy and shock, as existing solutions rely on physical contact and locking mechanisms that can cause rotor damage.
Innovation Solution
Incorporation of a position detection sensor system using a Hall sensor to align the drum opening with the tub opening without physical contact, utilizing a rotor with magnets and a stator structure that includes a speed detection sensor and a position detection sensor to control the motor and ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a drum position fixing device with physical contact and locking mechanism is used, then the drum opening can be aligned with the tub opening, but the rotor may be damaged or broken due to shock and kinetic energy
Solution Approach 1:
The patent replaces the mechanical contact-based drum position fixing device with a magnetic field-based system. Magnets are embedded in the rotor, and a Hall sensor detects their position to determine drum opening alignment, eliminating the need for physical contact and locking mechanisms that cause shock and rotor damage.
Solution Approach 2:
The patent introduces a Hall sensor as an intermediary detection device between the rotor magnets and the control system. This allows non-contact detection of the drum opening position by sensing the magnetic field, avoiding direct mechanical contact that transmits shock to the rotor.
2Manufacturing precision
If a drum position fixing device with physical contact is used, then the drum opening can be aligned with the tub opening, but the device complexity increases due to additional locking mechanisms
Solution Approach 1:
The patent replaces complex mechanical locking mechanisms with a simplified magnetic field detection system. The Hall sensor detects the position of magnets embedded in the rotor, providing alignment information without requiring any mechanical locking components, thereby reducing device complexity.
Solution Approach 2:
The patent extracts and removes the complex locking mechanism from the drum position fixing device, retaining only the essential alignment function achieved through magnetic field detection and control system coordination.
3Ease of operation
If a top-loading system is used, then the user does not need to bend forward excessively, but the drum opening alignment with tub opening becomes difficult without physical contact mechanisms
Solution Approach 1:
The patent enables accurate drum opening alignment in top-loading washers by replacing mechanical contact mechanisms with a magnetic field-based detection system. The Hall sensor detects magnet positions on the rotor to determine when the drum opening aligns with the tub opening, achieving precision without physical contact.
Solution Approach 2:
The patent implements a feedback control system where the Hall sensor continuously monitors the drum position by detecting magnet positions, and the control system adjusts the drum rotation to achieve precise alignment of the drum opening with the tub opening in top-loading washers.
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 allows for accurate alignment of the drum opening with the tub opening without physical contact, reducing the risk of rotor damage, enhancing mechanical reliability, and simplifying the manufacturing process by reducing material weight and complexity in the stator design.
Implementation Method 1
a position detection Hall sensor detecting a position decision magnet provided to the rotor
Implementation Method 2
a sensing unit having a speed detection sensor detecting a plurality of the magnets
Data Source
AI summary
A drum opening is configured to be correctly aligned with a tub opening without physical contact with a drum or motor by using a position detection sensor. The drum type washer includes a tub and brackets on the tub to support bearings. A motor includes a rotor, which includes a rotor frame made of a steel plate, a multitude of magnets attached to an inner circumference of the rotor frame, and a position decision magnet coupled to one side of the rotor frame. The stator includes a sensing unit. The sensing unit has a speed detection sensor to detect a plurality of magnets and a position detection sensor to detect the position decision magnet. A washing shaft is coupled to a front, center portion of the drum to be connected to the motor. An assist shaft is coupled to a rear, center portion of the drum.