Washing machine appliance and motor assembly therefor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional washing machine drive systems are complex, bulky, and inefficient due to the need for multiple parts and large motors to control the rotation of the agitator and wash basket, which are difficult to assemble and secure, leading to vibration-induced wear on traditional fasteners.
Innovation Solution
A simplified drive assembly with a motor connected to an agitator drive shaft and wash basket drive shaft, featuring a semi-circular profile and recessed face mounting portion, a clutch for selective engagement and disengagement, and a stator and rotor configuration that allows independent control of the agitator and wash basket rotation, reducing the need for complex linkages and large motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex linkages with multiple parts are used to control clutch movement, then the agitator and wash basket can be independently controlled, but the device complexity increases and assembly becomes difficult
Solution Approach 1:
The patent combines the clutch actuation mechanism with the drive shaft assembly by integrating the actuator directly onto the drive shaft. This merging eliminates the need for separate linkages and multiple control parts, reducing device complexity while maintaining the capability to independently control the agitator and wash basket through the clutch mechanism.
Solution Approach 2:
The drive shaft assembly is designed to serve multiple functions: it transmits power to the clutch, provides structural support, and enables independent control of both the agitator and wash basket. This multi-functionality reduces the need for additional specialized components, thereby simplifying the overall device structure.
2Power
If relatively large motors are used to rotate the wash basket and agitator, then sufficient power is available, but the device becomes bulky and assembly becomes difficult
Solution Approach 1:
The patent positions the motor within the wash tub structure, nesting it into the existing appliance framework. This nesting approach allows the motor to be integrated into the overall design without increasing the external dimensions of the washing machine, thereby providing sufficient power while avoiding a bulky appearance.
Solution Approach 2:
The motor is oriented and positioned to utilize vertical space within the wash tub rather than extending horizontally. By changing the dimensional arrangement from a horizontal layout to a vertical integration, the motor assembly provides adequate power output while maintaining a compact footprint that does not make the appliance bulky.
3Ease of manufacture
If traditional fasteners are used to secure the motor, then assembly is simple, but vibration-induced wear occurs rapidly
Solution Approach 1:
The patent replaces traditional mechanical fasteners with a splined coupling mechanism that engages the drive shaft with the motor rotor. This mechanical substitution eliminates the reliance on vibration-prone fasteners by using a positive engagement system with splines that inherently resist loosening under vibrational loads, thereby improving reliability while maintaining ease of assembly through the standardized spline interface.
4Power
If a spline is used to join the drive rod to the rotor, then power transmission is effective, but the component becomes bulky and difficult to machine
Solution Approach 1:
The patent modifies the spline geometry parameters, such as the number of splines, their depth, and spacing, to optimize the balance between power transmission capability and manufacturability. By adjusting these parameters, the design achieves effective torque transmission while reducing the overall size of the splined connection and simplifying the machining process compared to conventional spline designs.
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 enables efficient and independent control of the agitator and wash basket during different washing machine cycles, reducing assembly complexity, vibration-induced wear, and improving overall efficiency and reliability.
Implementation Method 1
The motor may include a rotor and a stator. The rotor may be fixed to the agitator drive shaft at the second end.
Data Source
AI summary
A washing machine appliance or drive assembly, as provided herein, may include an agitator drive shaft and a motor. The agitator drive shaft may extend along a drive axis from a first end to a second end defang a mounting portion about the drive axis. The motor may be operably connected to the agitator drive shaft to drive rotation thereof. The motor may include a rotor and a stator. The rotor may be fixed to the agitator drive shaft at the second end. The rotor may define a central aperture along the drive axis. The central aperture may define an interior profile complementary to the mounting portion of the agitator drive shaft. The stator may be rotationally fixed and positioned radially inward from the rotor.