Multi-Component Rotor Hub With Recessed Polymer Locking
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Solution Overview
Problem
Existing rotor designs for electric motors in laundry appliances face challenges in securely attaching polymeric materials to central hubs, leading to potential detachment under rotational forces and noise generation due to cyclic stresses.
Innovation Solution
A dual-ring rotor hub design featuring a central core and perimetrical ring with recesses that securely engage polymeric materials, providing a strong attachment and mitigating noise through the use of rigid polymeric and metallic components, allowing for efficient torque transfer and reduced deflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polymeric material is used for rotor frame, then noise is reduced and damping is improved, but attachment strength to central hub deteriorates under rotational forces
Solution Approach 1:
The rotor hub is segmented into multiple functional zones: a central core, a perimetrical ring offset from the core, and recesses defined between them. This segmentation allows the polymeric material to be received and secured in specific attachment portions, distributing rotational forces across multiple engagement points rather than a single attachment area, thereby maintaining attachment strength while preserving the noise-reducing properties of the polymeric material.
Solution Approach 2:
The rotor assembly employs a composite structure combining polymeric material for the rotor frame with metallic or rigid components for the central hub and perimetrical ring. This composite approach allows the polymeric portion to provide noise damping while the rigid hub structure provides strong attachment surfaces. The recesses create mechanical interlocking between the polymeric material and the hub, ensuring secure attachment under rotational forces.
2Ease of manufacture
If simple attachment method is used, then manufacturing complexity is reduced, but reliability of attachment under cyclic stresses deteriorates
Solution Approach 1:
The recesses are pre-formed as integral features of the central hub and perimetrical ring structure before the polymeric material is installed. This preliminary action ensures that the attachment portions are already configured to receive and secure the polymeric material, providing reliable mechanical interlocking from the outset without requiring complex post-assembly attachment procedures. The design inherently guides the polymeric material into the recesses, ensuring proper engagement.
Solution Approach 2:
The recesses and attachment portions are designed to automatically secure the polymeric material through mechanical interlocking and friction fit, without requiring additional fasteners, adhesives, or complex assembly steps. The structure itself provides the attachment mechanism, allowing the rotor frame to be securely fixed to the central hub through the inherent geometry of the recesses and perimetrical ring configuration.
Data Source
AI summary
A motor for a laundry appliance includes a drive shaft coupled to a drum at a first end. The rotor frame is coupled proximate the second end of the drive shaft, where the rotor frame includes at least one polymeric material. A central hub includes a core and a perimetrical ring that extends circumferentially around the core. A plurality of recesses are defined within a planar surface of the perimetrical ring, wherein a portion of the polymeric material is received within the plurality of recesses to secure the rotor frame to the central hub.