Outer Rotor Motor Stator Core Pressing to Cut Waste and Labor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for fabricating stator cores and back yokes for drum type washing machines with BLDC motors require separate processing, leading to increased working hours, material waste, and inefficiencies due to separate fabrication steps and material usage.
Innovation Solution
A method where a stator core and back yoke are fabricated simultaneously from a single base metal using a pressing process, forming a back yoke at the periphery and a stator core inside it, or forming an annular core, to reduce material usage and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate fabrication processes are used for stator core and back yoke, then each component can be manufactured independently, but working hours increase and material waste increases
Solution Approach 1:
The patent combines the fabrication of stator core and back yoke into a single integrated pressing process. A single press operation simultaneously forms both components from one base metal sheet, eliminating the need for separate fabrication steps and reducing total working hours while maintaining manufacturing independence through modular tooling design.
Solution Approach 2:
The pressing process is designed to perform multiple functions simultaneously: it forms the back yoke structure, creates the stator core geometry, and prepares both components for assembly in one operation. This multi-functional approach increases productivity without sacrificing the ability to manufacture components independently when needed.
2Ease of manufacture
If separate fabrication processes are used for stator core and back yoke, then each component can be manufactured independently, but material waste increases
Solution Approach 1:
By merging the fabrication processes, the patent utilizes the entire base metal sheet efficiently. The single pressing operation forms both the stator core and back yoke from one continuous sheet, minimizing scrap material compared to separate processes where each component would require its own dedicated metal sheet and generate independent waste streams.
Solution Approach 2:
The integrated process allows for optimized material utilization where the base metal sheet is strategically formed to create both components with minimal excess. Any remaining material after forming can be more effectively recovered or reused since it comes from a single source rather than multiple separate sheets.
3Adaptability or versatility
If separate fabrication processes are used for stator core and back yoke, then manufacturing flexibility is maintained, but fabrication steps increase
Solution Approach 1:
The patent merges multiple fabrication steps into one integrated pressing operation. The single press simultaneously performs forming, cutting, and shaping operations that would otherwise require separate processes, thereby reducing fabrication step complexity while maintaining the flexibility to produce different component configurations through tooling changes.
4Productivity
If integrated fabrication is used for stator core and back yoke, then working hours are reduced, but process complexity increases
Solution Approach 1:
While integrating the fabrication process, the patent applies segmentation through modular tooling design. The pressing system uses separate, independently controllable forming zones that can be adjusted separately, allowing complex integrated manufacturing while maintaining operational simplicity and enabling easy modification of individual component geometries without affecting the entire process.
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 approach reduces material requirements and working hours by integrating the fabrication of stator cores and back yokes into a single process, enhancing productivity and minimizing waste.
Implementation Method 1
pressing the base metal to form a back yoke at a periphery of the base metal, and a stator core on an inside of the back yoke
Data Source
AI summary
A method for fabricating a stator core and a back yoke of an outer rotor type BLDC motor in a direct coupling type washing machine, including the steps of providing a base metal of a circular electric sheet having a predetermined diameter, and punching the base metal to form a back yoke at a periphery of the base metal and divisional cores on an inside of the back yoke of the base metal at the same time, whereby forming the stator core and the back yoke at the same time reduces working hours and saves material.