Washing Machine Motor Assembly for Independent Agitator Control
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Solution Overview
Problem
Conventional washing machine motor assemblies are complex, bulky, and inefficient, requiring large direct drive motors and complex linkages, which are difficult to assemble and expensive, and struggle to independently control the rotation of the agitator and wash basket across different modes of operation.
Innovation Solution
A compact motor assembly with a rotor, stator, support bushing, and linear fastener, where the rotor is fixed to the agitator drive shaft, and the stator is positioned radially inward, with a clutch that can be ultrasonically welded and a linear fastener extending through a support bushing to a stationary housing, allowing for efficient and independent control of the agitator and wash basket rotation during different cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex linkages with multiple parts are used to control clutch movement, then the washing machine can operate between wash, rinse, and spin modes, but the assembly becomes difficult and time-consuming
Solution Approach 1:
The clutch assembly is divided into modular components including a clutch body, clutch piston, and spring mechanism that can be assembled separately and then integrated, reducing overall assembly complexity and time
Solution Approach 2:
The clutch mechanism is extracted as a separate, pre-assembled unit from the overall drive system, allowing it to be manufactured and tested independently before integration into the washing machine, thereby improving assembly productivity
2Power
If large direct drive motors are used to rotate the wash basket and agitator, then sufficient power is provided, but the system becomes bulky and expensive
Solution Approach 1:
The clutch assembly is nested within the motor housing structure, with the clutch body positioned inside the motor assembly boundaries, effectively reducing the overall volume occupied by the motor system while maintaining full power capability
Solution Approach 2:
The motor and clutch mechanisms are merged into a single integrated assembly where the clutch is positioned directly within the motor housing, eliminating the need for separate mounting structures and reducing overall system volume
3Strength
If traditional fasteners are used to secure the motor to the wash tub, then the motor can be held in place, but vibrations rapidly wear out the fasteners
Solution Approach 1:
A vibration-dampening mounting bracket is introduced as an intermediary element between the motor and wash tub, absorbing vibrational forces and preventing them from being transmitted to the fasteners, thereby extending fastener life while maintaining secure motor attachment
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 solution provides a compact, efficient, and cost-effective motor assembly that can efficiently switch between wash, rinse, and spin modes by allowing independent control of the agitator and wash basket rotation, reducing assembly complexity and wear from vibrations.
Implementation Method 1
The support bushing may be ultrasonically welded within the stator
Data Source
AI summary
A washing machine appliance or drive assembly, as provided herein, may include an agitator drive shaft, a stationary housing, and a motor. The agitator drive shaft may extend along a drive axis. The stationary housing may be disposed about the agitator drive shaft. The motor may be operably connected to the agitator drive shaft to drive rotation thereof. The motor may include a rotor, a stator, a support bushing, and a linear fastener. The rotor may be fixed to the agitator drive shaft. The stator may be rotationally positioned radially inward from the rotor. The support bushing may be ultrasonically welded within the stator. The linear fastener may extend through the fastener to the stationary housing.