Washing Machine Drive Clutch for Spin Speed Synchronization
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Solution Overview
Problem
Existing washing machine drive systems fail to effectively synchronize the rotational speed of the output shaft and rotor shaft between spin-drying initial and spin-drying modes, leading to issues such as increased motor size, noise, shift shock, and difficulty in wiring due to the need for a solenoid clutch with a large coil and complex wiring, and they do not provide sufficient durability and noise performance.
Innovation Solution
A drive system with a dynamic clutch that moves axially on a ring gear shaft, allowing for a synchronization mode between spin-drying initial and spin-drying modes, reducing the need for high torque in the initial mode, and using a planetary gear set with helical gears to enhance durability and noise reduction, along with a clutch driving portion for precise positioning of the dynamic clutch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a solenoid clutch is used to change gear ratio between spin-drying initial mode and spin-drying mode, then the washing machine can operate at different speeds and torques, but the weight and volume of the solenoid clutch increases due to the requirement of a larger coil for sufficient electromagnetic force
Solution Approach 1:
The patent replaces the solenoid clutch with a mechanically operated dynamic clutch that uses a lever unit and spring mechanism to change the gear ratio between spin-drying initial mode and spin-drying mode. This mechanical substitution eliminates the need for electromagnetic coils, thereby reducing the weight and volume of the clutch assembly while maintaining the gear ratio adjustment capability.
Solution Approach 2:
The patent changes the operating parameters of the clutch by using a mechanical lever system that adjusts the engagement position of the dynamic clutch along the axial direction. This allows the clutch to engage with different gears (first gear for spin-drying initial mode, second gear for spin-drying mode) without requiring electromagnetic force, thus reducing the weight and volume.
2Adaptability or versatility
If a solenoid clutch is positioned behind the rotor and stator to change gear ratio, then the washing machine can switch between operating modes, but it is disadvantageous to secure the volume of the washing machine and requires complex wiring configuration
Solution Approach 1:
The patent replaces the solenoid clutch with a mechanically operated dynamic clutch that uses a lever unit and spring mechanism. This mechanical system eliminates the need for electromagnetic coils and complex wiring, thereby reducing the volume occupied by the clutch assembly and simplifying the overall wiring configuration of the washing machine.
Solution Approach 2:
The patent positions the dynamic clutch in a different spatial arrangement within the drive system, allowing it to engage with different gears along the axial direction without requiring placement behind the rotor and stator. This spatial reconfiguration reduces the volume occupied by the clutch while maintaining mode switching capability.
3Adaptability or versatility
If a planetary gear set with spur gears is used to transmit rotational force, then the washing machine can operate at different speeds and torques, but noise is generated due to the engagement of spur gears
Solution Approach 1:
The patent changes the gear type from spur gears to helical gears in the planetary gear set. Helical gears engage more gradually and smoothly compared to spur gears, reducing the impact shocks and noise generated during gear engagement while maintaining the ability to transmit rotational force at different speeds and torques.
4Device complexity
If the output shaft is supported by only one bearing in spin-drying mode, then the structure is simplified, but the durability is reduced due to high speed operation
Solution Approach 1:
The patent changes the bearing configuration from a single bearing to multiple bearings that support the output shaft at different positions. This structural modification distributes the mechanical loads more evenly during high-speed spin-drying operation, thereby improving the durability and reliability of the output shaft without significantly increasing device complexity.
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 configuration enables efficient synchronization of rotational speeds, reduces motor size and noise, and improves durability and noise performance, allowing for a smaller intelligent power module and lower manufacturing costs by eliminating the need for large-capacity motors and simplifying wiring.
Implementation Method 1
a planetary gear set including a ring gear shaft surrounding a part of a circumference of the rotor shaft, and transmitting a rotational force of the rotor shaft to the output shaft at a ratio of 1:1 or by reducing at a gear ratio of n: 1
Implementation Method 2
a dynamic clutch coupled to the ring gear shaft, and moving in an axial direction on the ring gear shaft
Data Source
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AI summary
A drive system of a washing machine includes a rotor shaft (300) and an output shaft (400) positioned apart from each other; an n:1 stage (500) positioned on the rotor shaft; a 1:1 stage (600) positioned behind the n:1 stage, coupled to the rotor shaft (300) and integrally rotating with the rotor shaft (300); a planetary gear set (700) including a ring gear shaft (740) surrounding a part of a circumference of the rotor shaft (300), and transmitting a rotational force of the rotor shaft (300) to the output shaft (400) at a ratio of 1:1 or by reducing at a gear ratio of n:1; a dynamic clutch (800) coupled to the ring gear shaft (740) between the n:1 stage and the 1:1 stage, moving in an axial direction on the ring gear shaft (740), and integrally rotating with the ring gear shaft (740); and a clutch driving portion (900) for moving the dynamic clutch (800) in the axial direction. Between the spin-drying initial mode in which the output shaft (400) rotates at low speed and high torque and the spin-drying mode in which the output shaft (400) rotates at high speed and low torque, the rotational speed of the output shaft (400) and the rotor shaft (300) can be effectively synchronized by implementing the synchronization mode.