Slim Stator Design for Drum Washing Machine Direct Drive
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Solution Overview
Problem
Conventional drum-washing machines with belt-pulley drive systems experience energy loss and noise due to indirect motor drive, and core type BLDC motors have high manufacturing costs and material losses, while radial type core motors face inefficiencies in stator core assembly and coil winding.
Innovation Solution
A slim type stator and motor design using a division core structure with successively wound coils on bobbins, integrated with a wiring box and electric power terminal block, eliminating the need for annular core support plates and reducing assembly complexity, and employing a double-rotor single-stator structure for direct drive in drum-washing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a core type BLDC motor with yoke structure is used, then high flux density and big torque are achieved, but material loss of yoke increases and manufacturing cost rises
Solution Approach 1:
The stator core is divided into multiple division cores (first division core, second division core, etc.) arranged around the rotor. Each division core is independently formed and can be manufactured separately, reducing material waste compared to a single large yoke structure. The division cores are assembled together to form the complete stator core, maintaining the magnetic circuit functionality while reducing overall material consumption.
2Ease of manufacture
If an integrally built-in type stator core is used, then manufacturing simplicity is improved, but coil winding efficiency decreases and dedicated expensive winding machines are required
Solution Approach 1:
The stator core is segmented into multiple division cores that can be manufactured separately using standard processes. Each division core has its own bobbin into which coils are wound independently. This segmentation allows the use of general-purpose winding machines instead of requiring expensive dedicated winding machines, while maintaining manufacturing simplicity through modular assembly of the division cores around the rotor.
3Productivity
If a radial type core motor with division core structure is used, then coil winding efficiency is improved, but stator assembly complexity increases
Solution Approach 1:
The bobbin is designed as an integrated component that combines multiple functions: it supports the division core, provides the winding form for coil fabrication, and serves as the assembly unit around which the division core is placed. This merging of functions simplifies the overall stator assembly process, as the bobbin acts as a pre-assembled module containing both the core and coil, reducing the complexity of final stator assembly.
4Stability of the object's composition
If an annular core support plate is used to assemble division cores, then stator structure stability is improved, but motor thickness increases
Solution Approach 1:
The separate annular core support plate is eliminated by integrating the support function directly into the bobbin structure. The bobbin itself provides the structural support for the division cores through its design features (such as flanges and mounting surfaces), removing the need for an additional support plate component. This extraction of the support function from a separate component reduces the overall motor thickness while maintaining structural stability.
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 productivity, reduces manufacturing costs, improves workability, and achieves a slim motor thickness, enabling efficient direct drive in drum-washing machines without compromising torque or efficiency.
Implementation Method 1
a stator coil wound around the division core in a bobbin
Data Source
AI summary
A slim type stator includes: a number of division cores; a number of bobbins that partially surrounds the number of the division cores; an electric power terminal block on the outer portion of which a connector is provided in which external electric power is applied through the connector and that has terminal pins that are extended to the inside of the stator from the connector; a wiring box that is integrally formed with each bobbin and that mutually connects a stator coil with the terminal pins per phase; and a stator holder that mutually connects a number of division stator cores around which coils are wound with the outer circumference of the bobbins and supports the number of division stator cores.