A drum assembly for a washing machine and method for fabricating the same
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Solution Overview
Problem
The existing drum assemblies for washing machines, particularly barrier washing machines, require complex and costly tooling for welding, result in inefficient storage, and lack sufficient stiffness, leading to high manufacturing costs and potential failures.
Innovation Solution
A drum assembly design where the basic drum part and flanges extend only partly circumferentially, allowing for simpler and less expensive tooling, reduced material usage, and easier assembly, with a method involving welding of bended or arched pieces to form a continuous drum assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If all parts of the drum assembly are welded together to form a complete assembly, then the drum assembly provides structural integrity and stiffness, but complex tooling is required to maintain parts in contact during welding operation and manufacturing costs increase
Solution Approach 1:
The drum assembly is divided into separate modular components (drum part, frameworks, retaining flanges) that are manufactured independently and then assembled. This segmentation allows each component to be produced with simpler tooling while maintaining overall structural integrity through the assembly process.
Solution Approach 2:
Individual components are prepared in advance with pre-formed features (openings, mounting positions) before final assembly. This preliminary preparation reduces the complexity of tooling required during the welding operation, as components can be positioned and welded rather than requiring complex fixtures to maintain contact during formation.
2Ease of manufacture
If multiple separate parts are used to form the drum assembly, then manufacturing flexibility is improved, but storage space requirements increase
Solution Approach 1:
The modular components of the drum assembly are designed to nest within each other when not in use. Frameworks can be positioned inside or alongside the drum part, and retaining flanges can be stored in dedicated slots or attached to the drum surface, significantly reducing the storage footprint while maintaining manufacturing flexibility.
3Reliability
If traditional welding of complete drum assemblies is used, then structural integrity is achieved, but manufacturing costs increase and the process is time-consuming
Solution Approach 1:
By segmenting the drum assembly into pre-manufactured modules, the welding process is simplified to joining these modules rather than welding all components together from scratch. This reduces welding time and complexity while maintaining structural integrity at the joint interfaces.
Solution Approach 2:
Components are pre-prepared with all necessary features (openings, reinforcements, mounting points) before assembly. This preliminary action eliminates the need for complex tooling during final welding operations, reducing both time and cost while ensuring structural integrity through precise pre-formed connections.
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 design enhances stiffness, reduces manufacturing costs, minimizes material waste, and lowers the risk of failure, while providing a more efficient and cost-effective fabrication process.
Implementation Method 1
All parts of the drum assembly 1' are welded together to form the assembled drum assembly 1'
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
The main object of the invention is a drum assembly (1) for a washing machine comprising : - at least one piece of a basic drum part (2a, 2b) for receiving items to be washed, comprising or defining at least one opening (6a, 6b), - at least one framework (3a, 3b) comprising one drum opening (O1, O2) intended to face said at least one opening (6a, 6b) for access inside said basic drum part (2a, 2b), - at least one piece of a flange (4a, 4b, 4c, 4d) intended to be located at least partly at a lateral periphery of said at least one piece of a basic drum part (2a, 2b), characterized by the fact that at least one of said at least one piece of a basic drum part (2a, 2b) and said at least one piece of a flange (4a, 4b, 4c, 4d) extends only partly circumferentially.