Motor Rotor Frame With Axially Spaced Legs for Rigidity and Cooling

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Solution Overview

Problem

Existing motor designs for domestic laundry machines lack sufficient rigidity and cooling efficiency in their rotor structures, which can lead to inaccurate magnetic interaction with the stator and reduced motor performance.

Innovation Solution

A rotor design featuring a metal frame with interleaved legs that are axially spaced to provide rigidity, coupled with a reinforcing member and over-moulded plastic for secure attachment to the shaft, and a cylindrical side wall that encapsulates a backing ring and magnets, enhancing structural integrity and cooling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the rotor frame uses a simple structure with all legs attached at the same axial position, then the manufacturing process is simpler, but the rotor lacks sufficient rigidity leading to inaccurate magnetic interaction with the stator

Engineering Contradiction:
Improverotor rigidityVSAvoidframe structure complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent applies dimensionality change by transitioning from a two-dimensional planar attachment (all legs at the same axial position) to a three-dimensional distributed attachment (legs at different axial positions). This spatial distribution of legs along the axial dimension creates a more rigid frame structure that resists deformation during motor operation, thereby improving rotor rigidity without significantly complicating the manufacturing process.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Temperature

If the rotor lacks adequate cooling structure, then the manufacturing process is simpler, but the motor cooling efficiency is reduced

Engineering Contradiction:
Improvecooling efficiencyVSAvoidrotor structure complexity
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The patent incorporates cooling fins and axial spacing between legs that create porous-like structures within the rotor frame. These features allow cooling air to flow through the rotor structure, improving heat dissipation efficiency. The porous arrangement of cooling channels and fin structures enables effective thermal management while maintaining a relatively simple manufacturing process through standard forming operations.

Inventive Principle:
Principle #31Porous materials

3Manufacturing precision

If the legs are not axially spaced, then the frame structure is simpler, but the rotor frame lacks rigidity and allows inaccurate magnetic interaction

Engineering Contradiction:
Improvemagnetic interaction accuracyVSAvoidleg spacing structure
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the rotor frame into multiple legs that are axially spaced at different positions rather than being concentrated at a single location. This segmentation distributes the structural support functions across multiple axial levels, enhancing the overall rigidity of the frame and ensuring accurate positioning of the rotor relative to the stator for precise magnetic interaction.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS10079518B2Rotor for a motor, and a motor and an appliance comprising the rotor, and a method for making a rotor
Publication Date: 2018.09.18 FISHER & PAYKEL APPLIANCES LTD
  • US10079518B2 patent drawing
  • US10079518B2 patent drawing
  • US10079518B2 patent drawing

AI summary

A rotor for a motor comprising a frame having a hub for connecting the rotor to a shaft and a perimeter portion for interacting with a stator of the motor to cause the rotor to rotate about an axis of rotation. The frame comprises legs extending from an outer portion of the frame towards the hub, each leg having an inner end at the hub and an outer end at the outer portion of the frame, the inner ends of a first plurality of legs being spaced from the inner ends of a second plurality of legs in a direction along the axis of rotation.