Washing Machine Drive Unit With One-Way Gear Holding for Low-Noise Spin
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional washing machine driving units with induction motors face complexity in structure, increased noise, torque issues during spinning, prolonged starting times, and high power consumption due to the need for additional clutch and speed reduction mechanisms, especially with small-sized motors.
Innovation Solution
A simplified driving unit structure incorporating a bearing housing, motor, ring gear shaft, carrier shaft, driving shaft, and one-directional holding devices with one-way bearings to manage rotation directions and reduce speed, allowing for adequate torque and reduced noise, and a method for controlling the washing machine that reverses rotor direction to optimize spinning speed and torque distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a clutch and speed reduction device are added to regulate motor rotation speed, then the rotation speed can be controlled, but the structure becomes complicated
Solution Approach 1:
The patent combines the clutch and speed reduction device into an integrated transmission mechanism where the clutch plates are positioned within the gear train. The clutch plates engage with gear teeth to provide both clutching action and speed reduction in a single unified structure, eliminating the need for separate components and reducing overall structural complexity.
Solution Approach 2:
The transmission mechanism serves multiple functions simultaneously: it acts as both a clutch (for engaging/disengaging power transmission) and a speed reduction device (for regulating rotation speed). This multi-functional design allows a single component to replace what would traditionally require separate clutch and gear reduction mechanisms.
2Speed
If clutch and mechanical components are used for speed regulation, then rotation speed can be controlled, but mechanical and electrical noise increases
Solution Approach 1:
The patent replaces traditional mechanical clutch actuation with an electromagnetic field-based control system. The clutch plates are engaged and disengaged through electromagnetic forces generated by the motor controller, eliminating the need for mechanical linkages, levers, and actuators that would generate noise during operation.
3Quantity of substance
If a small sized motor is used, then cost can be reduced, but torque on the inner tub is insufficient during spinning
Solution Approach 1:
The patent changes the operational parameters of the motor by using variable speed control through the transmission mechanism. The motor operates at higher speeds during washing cycles and at optimized speeds during spinning, allowing a smaller motor to generate sufficient torque through speed-torque conversion in the gear train during the spinning phase.
Solution Approach 2:
The transmission mechanism pre-position the clutch plates and gear train to provide maximum torque multiplication before the spinning cycle begins. This preliminary configuration ensures that when the spinning cycle starts, the full torque amplification effect is already in place, allowing the small motor to immediately deliver adequate torque.
4Stability of the object's composition
If regular/reverse direction rotation is used to distribute laundry, then laundry distribution is improved, but spinning time and power consumption increase
Solution Approach 1:
Instead of completing full reverse rotation cycles to distribute laundry, the patent applies partial rotation adjustments during the spinning cycle. The transmission mechanism provides brief directional adjustments that are sufficient to redistribute laundry without requiring complete reverse rotation sequences, thereby reducing the time and energy required.
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
The solution simplifies the driving unit structure, reduces mechanical and electrical noise, enables direct spinning cycle initiation with small motors, shortens spinning time, and decreases power consumption by optimizing torque and rotation speed control.
Implementation Method 1
a first one way bearing between the bearing housing and the carrier shaft that holds the carrier shaft to the bearing housing only when the driving shaft is rotated in the first direction
Implementation Method 2
a reduction gear positioned between the ring gear shaft and the carrier shaft to reduce a rotation speed of the ring gear shaft
Implementation Method 3
The induction motor generates a rotation force by interaction of a rotating magnetic field generated by a current flowing through a line wound on a stator and a current induced at the rotor
Data Source
AI summary
A driving unit for a washing machine, and method for controlling the same. The driving unit includes a bearing housing fixedly secured to an outer tub. A motor is mounted on the bearing housing. A ring gear shaft is rotatably mounted to the bearing housing and is coupled to an inner tub. A carrier shaft is rotatably mounted in the ring gear shaft, with a driving shaft rotatably mounted in the carrier shaft. The driving shaft is coupled to the motor. A reduction gear is positioned between the ring gear shaft and the carrier shaft to reduce a speed of the ring gear shaft. A one directional holding device that holds the carrier shaft when the driving shaft rotates in a first direction, and holds two of the carrier shaft, the ring gear shaft, and the driving shaft when the driving shaft rotates in a second direction.