Washing Machine Motor Stator Insulation for Larger Coil Windings
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Solution Overview
Problem
Existing washing machine motors face challenges in increasing the winding area or diameter of the coil to achieve high output power without enlarging the stator, which limits their performance.
Innovation Solution
The motor design includes a stator core with core teeth and insulators that allow for increased coil winding area by using insulation films and ribs to stabilize the insulation and prevent separation, enabling a larger winding diameter without increasing the stator size, and a fixing structure that securely attaches the motor to the tub.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the winding area or diameter of the coil is increased to obtain high output power, then the magnetic flux intensity is improved, but the size of the stator increases
Solution Approach 1:
The patent applies nesting by placing the insulation film inside the insulator structure, specifically within the groove formed by the insulator teeth. This nested arrangement allows the insulation components to occupy space that would otherwise be unused, enabling increased coil winding area without increasing the external dimensions of the stator.
Solution Approach 2:
The patent utilizes the radial dimension by extending insulator teeth inward from the outer circumference of the insulator body, creating a groove structure that accommodates the insulation film. This dimensional approach allows the coil to be wound with larger diameter without increasing the axial or external radial size of the stator, effectively using internal spatial arrangement to resolve the size constraint.
2Power
If insulation films are added to increase coil winding area, then magnetic flux is improved, but the structure complexity increases
Solution Approach 1:
The patent merges the insulator and insulation film into an integrated structure where the insulator teeth form a groove that precisely accommodates the insulation film. This combination creates a unified insulation system that provides both structural support and electrical insulation, reducing the need for separate components and simplifying the overall assembly process.
Solution Approach 2:
The insulator structure serves multiple functions: it provides mechanical support for the coil, electrical insulation between the coil and stator core, and structural integration through the groove design. The insulator teeth simultaneously create the mounting groove for the insulation film and provide the framework for coil winding, reducing the need for additional specialized components.
3Manufacturing precision
If insulators and insulation films are used to stabilize the coil structure, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements preliminary action by pre-forming the groove structure in the insulator during insulator manufacturing, before coil assembly. The insulator teeth are shaped in advance to create the precise groove that will accommodate the insulation film and guide coil placement, ensuring proper positioning and alignment without requiring complex assembly operations.
Solution Approach 2:
The insulation film acts as an intermediary element between the insulator groove and the coil structure. It fills the groove space and provides a stable interface that secures the coil in its proper position, ensuring precise alignment and preventing displacement during operation without requiring complex mechanical fastening systems.
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 motor performance by increasing magnetic flux and stability, allowing for improved rotation power without enlarging the motor, and simplifies assembly and durability by providing a secure fixing mechanism.
Implementation Method 1
When current is supplied to the coil, magnetic flux is formed at the stator core according to the principle of an electromagnet
Implementation Method 2
The rotor is rotated by force acting between a magnetic field and current flowing through a coil
Data Source
AI summary
A washing machine with a motor having a structure with improved performance. The washing machine includes a body, a tub disposed in the body, a drum rotatably disposed in the tub, and a motor including a stator coupled to a rear surface of the tub and a rotor rotatably disposed inside the stator. The stator includes a stator core including a core body and a plurality of core teeth extending inward from an inner circumferential surface of the core body in a radial direction of the core body, a first insulator and a second insulator covering both ends of the core body and the core teeth, a coil wound around the core teeth, and a plurality of insulation films disposed between the first insulator and the second insulator to electrically insulate the stator core and the coil.