Universal Motor Card Control for Brushless Washing Machines
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Solution Overview
Problem
The production of washing machines with brushless motors is hindered by the need for separate electronic cards for each motor model, leading to increased costs and compatibility issues, resulting in financial losses due to wasted old cards and time-consuming production changes.
Innovation Solution
A washing machine design that uses a single motor card compatible with different brushless DC motors by loading motor characteristics such as rotation speed, torque, and current bounds into the main card, allowing the motor card to operate based on these data and commands, eliminating the need for model-specific motor cards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate motor cards are produced for each brushless motor model, then motor control precision is improved, but manufacturing cost increases and production time is extended
Solution Approach 1:
The patent implements a universal motor card design that can control multiple different brushless motor models. The motor card is made multi-functional by loading specific motor parameter data (such as phase resistance, back-EMF constants, pole pairs) into its memory during operation, rather than having hard-coded parameters for each motor type. This allows a single motor card hardware design to adapt to various motor models, eliminating the need to produce separate motor cards for each motor variant, thereby reducing manufacturing costs and production complexity while maintaining precise control.
Solution Approach 2:
The patent changes the approach from fixed hardware parameters to flexible software-loaded parameters. Instead of designing different motor cards with different physical parameters for each motor model, the system loads motor-specific parameters (resistance, inductance, back-EMF, pole pairs, current limits) into the motor card's memory during runtime. This parameter change strategy allows the same motor card hardware to be configured for different motor types, resolving the contradiction between control precision and manufacturing ease.
2Manufacturing precision
If separate motor cards are produced for each brushless motor model, then motor control precision is improved, but production time increases and old cards are wasted
Solution Approach 1:
The universal motor card design enables a single motor card to serve multiple motor models, eliminating the need to produce and discard old motor cards when switching between motor types. The motor card's memory is cleared and reconfigured with new motor parameters during production, allowing the same physical card to be reused across different motor models, thus significantly reducing production time and eliminating card waste.
Solution Approach 2:
The patent implements a card recovery mechanism where motor cards are not discarded after use with one motor model but are instead recovered, reset, and reconfigured for use with different motor models. The system clears the previous motor parameter data from the card's memory and loads new parameters appropriate for the next motor type, thereby recovering the card for continued use and eliminating the waste associated with producing separate cards for each motor model.
3Manufacturing precision
If motor parameters are loaded in the motor card during production, then motor control accuracy is improved, but compatibility across different models decreases
Solution Approach 1:
The patent transforms the motor card from a static configuration to a dynamic one. Instead of having motor parameters permanently fixed in the motor card hardware, the system dynamically loads appropriate motor parameters into the card's memory based on which motor model is being controlled. This dynamic reconfiguration capability allows the same motor card to accurately control different motor models by loading their specific parameters, thereby maintaining both control accuracy and model compatibility.
Solution Approach 2:
The system performs preliminary loading of motor parameters into the motor card's memory before actual motor operation begins. During production or setup, the appropriate motor parameters (resistance, inductance, back-EMF, pole pairs, current limits) are pre-loaded into the card based on the motor model that will be controlled. This preliminary action ensures the motor card is properly configured for accurate control while maintaining the flexibility to be reconfigured for different models as needed.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a washing machine (1 ) comprising a motor (2), a main card (3) that provides the electronic control and a motor card (4) that enables the motor (2) to operate according to the commands provided by the main card (3).