Shaftless Dual-Rotor Axial Air Gap Motor for Reduced Weight
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Solution Overview
Problem
Existing axial air gap motors in clothing processing apparatuses face challenges in reducing axial and radial sizes, suppressing vibration and noise, and minimizing weight due to the need for a shaft to support the stator and rotor, which limits the increase in washing capacity without expanding the cabinet size.
Innovation Solution
The axial air gap motor design features a frame with a stator on the outer side and two rotors on opposite sides, each supported by a rotor end supporting portion, eliminating the need for a shaft and integrating the rotors to offset magnetic forces, thereby reducing weight and size while maintaining operational stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a shaft is used to support the stator and rotor in an axial air gap motor, then the structural stability is improved, but the axial length and weight of the motor increase
Solution Approach 1:
The patent removes the shaft component from the motor structure. Instead of using a traditional shaft to support the stator and rotor, the invention employs an axial air gap configuration where the stator is mounted on the rotor assembly without requiring a separate shaft, thereby eliminating the shaft's contribution to axial length and weight while maintaining structural stability through alternative support mechanisms
Solution Approach 2:
The patent integrates the stator mounting structure directly onto the rotor assembly. The stator is positioned and supported in conjunction with the rotor components, merging what were previously separate supported elements into a unified structure that eliminates the need for a dedicated shaft, thus reducing overall axial length and weight
2Length of moving object
If the axial length of the motor is reduced, then the washing capacity is increased, but the torque output capability is reduced
Solution Approach 1:
The patent transitions from a traditional radial magnetic field configuration to an axial air gap configuration where the magnetic field is generated in the axial direction. This dimensional change allows the motor to produce sufficient torque with a reduced axial length by utilizing the axial space more effectively for magnetic flux generation, thereby maintaining torque output capability while reducing the motor's axial dimensions
3Device complexity
If the rotor is disposed in radial direction with respect to shaft, then the motor structure is simplified, but the axial gap cannot be constantly maintained due to magnetic forces
Solution Approach 1:
The patent employs a dynamic support mechanism for the rotor that can adapt to magnetic forces. The rotor is supported by bearings that allow for axial movement to maintain the air gap, and includes elastic elements or adjustable components that compensate for variations in magnetic attraction and repulsion forces, thereby constantly maintaining the axial gap despite changing operational conditions
4Strength
If a motor case is added to mount the stator, then the structural support is improved, but the weight and external size are increased
Solution Approach 1:
The patent integrates the stator mounting function into the existing rotor assembly structure. Instead of adding a separate motor case, the stator is mounted directly onto components that are part of the rotor assembly, merging the mounting function with existing structural elements and thereby providing necessary structural support without increasing motor weight or external size
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 effectively reduces the motor's axial length and weight, suppresses vibration and noise, and increases the clothing processing capacity by allowing a larger tub and drum without expanding the cabinet, resulting in a more efficient and compact motor setup.
Implementation Method 1
a motor, as is well known, is a device that converts an electrical energy to a mechanical energy
Implementation Method 2
an axial air gap type motor in which a stator and a rotor are disposed to be apart from each other with an axial gap along an axial direction
Data Source
AI summary
An axial air gap motor comprises: a frame; a stator that is arranged in an outer side of the frame in a radial direction; a first rotor that is spaced from one side of the stator in an axial direction, that has an air gap therebetween, and that is rotatably arranged in one side of the frame; and a second rotor that is spaced from the other side of the stator in the axial direction, that has an air gap therebetween, that is rotatably arranged in the other side of the frame, and that is connected with the first rotor in the axial direction.