Direct-Drive Washer Motor Stator Assembly for Lower-Cost Manufacturing
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Solution Overview
Problem
Existing direct drive motor systems for washing machines, particularly dual rotor types, face complexity and increased costs due to intricate assembly processes and the need for high-mechanical-characteristic polymers, which restrict the use of low-cost thermoplastics and pose risks during injection molding.
Innovation Solution
A direct drive motor system for washing machines featuring a stator assembly with stacked laminations, disc-shaped elements, and finger-shaped portions, where magnetic cores are secured to L-shaped tongues and wound with coils, allowing for a simpler assembly process and reduced material costs by using metal inserts for structural support and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high-mechanical-characteristic polymers are used to ensure dimensional stability of the stator, then dimensional stability is improved, but material cost increases and injection molding temperature must be raised
Solution Approach 1:
The patent extracts the structural support function from the polymer material and assigns it to metal inserts. The metal inserts are embedded in the polymer stator to provide dimensional stability and mechanical strength, allowing the use of lower-cost polymers without compromising stator stability.
Solution Approach 2:
The patent creates a composite structure combining metal inserts with polymer material. The metal inserts provide the necessary mechanical strength and dimensional stability, while the polymer provides insulation and structural form, achieving both stability and cost-effectiveness through material combination.
2Stability of the object's composition
If high-mechanical-characteristic polymers are used to ensure dimensional stability, then dimensional stability is improved, but the risk of damaging coil enamel and insulator material increases due to higher injection molding temperatures
Solution Approach 1:
The patent extracts the structural support function from the polymer material and assigns it to metal inserts. The metal inserts are embedded in the polymer stator to provide dimensional stability and mechanical strength, allowing the use of lower-cost polymers without compromising stator stability.
Solution Approach 2:
The metal inserts are pre-positioned in the stator before injection molding to protect the coil enamel and insulator materials from excessive heat. The inserts act as thermal barriers, cushioning the sensitive materials from the high temperatures that would otherwise be required for high-performance polymers.
3Strength
If a continuous helically wound metallic strip is used for the stator core, then mechanical continuity between teeth is ensured, but the weight of the motor system increases
Solution Approach 1:
The patent segments the stator core into discrete teeth rather than using a continuous helically wound metallic strip. Each tooth is independently formed, allowing for weight reduction while maintaining the necessary magnetic paths and mechanical structure through the laminated construction.
Solution Approach 2:
The patent changes the construction parameters of the stator core from continuous metallic strip to laminated stacked sheets. This parameter change reduces eddy current losses and allows for better weight management while maintaining mechanical and magnetic performance through the layered structure.
4Adaptability or versatility
If multiple single partition cores are assembled with insulators and wound with coils, then a stator for dual rotor type motor is achieved, but the assembly process becomes complex
Solution Approach 1:
The patent merges multiple discrete components (single partition cores, insulators, and coil windings) into an integrated stator structure. The metal inserts are embedded during the injection molding process, combining structural support and electrical insulation functions into a single manufacturing step, thereby reducing assembly complexity.
Solution Approach 2:
The patent performs preliminary positioning of metal inserts and core structures before the final injection molding process. This preliminary action ensures proper alignment and reduces the complexity of subsequent assembly steps, as the structural framework is already in place to guide the molding 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 solution simplifies the assembly process, reduces material costs, and ensures dimensional stability without the need for high-mechanical-characteristic polymers, enabling the use of lower-cost materials while maintaining mechanical integrity and efficiency.
Implementation Method 1
a direct drive motor including a rotor assembly fastened to the shaft and including magnets positioned in a circumferential direction, and a stator assembly with a plurality of magnetic cores of stacked laminations, a plurality of insulators, and a disc-shaped element including a plurality of finger-shaped portions. At least one of the plurality of insulators surrounds each of the plurality of magnetic cores, and a number of coils are wound on an outer surface of each of the plurality of insulators
Data Source
AI summary
A washing machine with a direct drive motor system including a tub, a drum rotatably mounted inside the tub, a shaft connected to the drum, and a direct drive motor comprising a rotor assembly fastened to the shaft and including magnets positioned in a circumferential direction, and a stator assembly. The stator assembly includes a plurality of magnetic cores and a disc-shaped element including a plurality of finger-shaped portions. Each of the finger-shaped portions has one of the plurality of magnetic cores secured thereto.