WASHING MACHINE TO PRODUCE THREE-DIMENSIONAL MOVEMENT AND DRUM ASSEMBLY METHOD FOR A WASHING MACHINE

专利摘要:
washing machine and method for putting the drum together There is disclosed a washing machine comprising a rotating main drum mounted on the tub, a secondary drum mounted within the main drum being relatively rotatable with respect to the main drum, an external shaft for to rotate the main drum, an inner shaft for rotating the secondary drum and arranged inside the outer shaft, and a drive motor. the drive means is configured to rotate the main drum and secondary drum in different directions and/or with different rotational speeds. the washing machine further comprises a main drum spider for connecting the main drum to the outer shaft to transfer a driving force from the drive means to the main drum, and a secondary drum spider for connecting the secondary drum to the inner shaft for transferring a driving force from the drive means to the secondary drum, where the two spiders are arranged to be independently rotatable.
公开号:BR112014009784B1
申请号:R112014009784-4
申请日:2012-10-24
公开日:2021-08-24
发明作者:Chaseung Jun；Byungkeol Choi；Youngmin Kim；Dongwon Kim；Hyundong Kim；Hwanjin JUNG；ByungWook Min；Kyeonghwan Kim；Jinwoong Kim；Changwoo Son；Hyunseol Seo
申请人:Lg Electronics, Inc；
IPC主号:

专利说明:

[0001] TECHNICAL FIELD
[0002] This specification relates to a washing machine with a structure to improve washing efficiency, allowing the three-dimensional (3D) movement of the garment, so that the garment can be moved in circumferential and axial directions within drums, a method drum mounting for the washing machine and a method of controlling the operation of the drum.
[0003] FUNDAMENTALS OF THE TECHNIQUE
[0004] In general, a washing machine forcibly rotates the garment inside a drum, using a mechanical force such as a frictional force generated between the drum, which is rotated by a drive force transferred from a drive motor and the clothing, after filling with detergent, washing water and clothing in the drum. Therefore, clothing can be washed by a physical reaction such as friction or impact. In addition, clothing that comes in contact with detergent can be washed by a chemical reaction with the detergent. Turning the garment inside the drum can facilitate the chemical reaction of the detergent.
[0005] A drum type washing machine, which has been widely used in recent times, has a drum rotation axis formed in the horizontal direction. The axis of rotation of the drum is alternatively inclined with respect to the horizontal direction by a predetermined angle. The drum-type washing machine having the horizontal rotation axis allows the garment to be rotated along a circumferential inner surface of the drum in the circumferential direction.
[0006] The garment is rotated along the inner circumferential surface of the drum by a centrifugal force responsive to the rotation of the drum and friction against the inner circumferential surface of the drum. To aid in the turning of the garment, lifts are often provided on the inner circumferential surface of the drum. Here, the garment also performs a circular movement along the circumferential inner surface in accordance with the rotation speed of the drum and a downward movement of one side of the top of the drum by the force of gravity. Falling motion becomes a factor that greatly affects a washing effect.
[0007] The movement of the garment inside the drum greatly affects the washing effect. In detail, various types of garment movements can change the contact surfaces of the garment, which rubs against the inner circumferential surface of the drum, resulting in a balanced washing of the garment and also allowing an increase in physical force applied to the garment to improve the washing effect.
[0008] Meanwhile, the washing machine is configured to perform the rotation axis by an addition motor, which has a rotor structure by the use of permanent magnets.
[0009] The permanent magnet motor typically includes a stator and a rotor. The stator is fixedly wrapped on the outside of the rotor. The rotor is in a circular shape, and has a plurality of permanent magnets regularly aligned in an annular shape. Rotor teeth can be interposed between adjacent permanent magnets in order to secure to permanent magnets. Also, rotor teeth form magnetic fluxes with the stator so that the rotor has a rotating force.
[0010] For the drum type washing machine of the related art, a single drum is rotated to make the garment move. Therefore, the garment is merely circled from an initial position in the circumferential direction of the drum along the inner circumferential surface of the drum (i.e., merely generating a circumferential direction movement), without complicated movements such as an axial direction movement and a movement of rotation. That is, clothing generates two-dimensional movement, because there is no room for a separate external force applied to generate such complicated clothing movements. Consequently, the garment is moved in a limited way, which results in a limited washing effect and an increase in energy consumption and washing time.
[0011] In addition, the washing machine of the related state of the art causes a problem in which these garments are tucked into the inner circumferential surface of the drum, becoming tangled together, after the completion of the washing and dehydration. Since dewatering is carried out using centrifugal force by rotating the drum, the garment in the tangled or twisted state is threaded onto the inner circumferential surface of the drum. Therefore, the garment remains tangled until it is removed from the washing machine for drying, thus causing wrinkles in the garment and difficulty in taking the garment out of the washing machine.
[0012] DISCLOSURE
[0013] TECHNICAL PROBLEM
[0014] Therefore, it is an aspect of the detailed description to provide a washing machine with a structure capable of being affected by an external force so as to allow for various movements of the garment, which is moved to a limited extent within a drum of the washing machine. .
[0015] Another aspect of the detailed description is to provide a washing machine with a structure that allows the garment to move three-dimensionally by employing two drums and a drive motor for the independent drive of the two drums.
[0016] Another aspect of the detailed description is to provide a drum assembly method for the washing machine with the unique structure, allowing the three-dimensional (3D) movement of the garment, and a washing machine with a structure allowing an efficient 3D movement of the garment. garment and efficiently improve a washing performance.
[0017] Another aspect of the detailed description is to provide a washing machine, which has a structure to prevent damage to the garment, which can be caused due to the use of two drums and allow the garment to move smoothly due to low relative strength. to the movements of the garment, despite the two drums being used.
[0018] Another aspect of the detailed description is to provide a rotor structure for a permanent magnet motor in the washing machine, capable of reducing the occurrence of inferiority due to the transformation of a protruding attachment end by removing the protruding attachment end formed in an inner side in relation to the center of the rotor teeth, and prevents leakage of a magnetic flux at the top, due to the reduction of the protruding clamping end.
[0019] Another aspect of the detailed description is to provide a method for manufacturing a double motor stator in a double drum washing machine, configured so that an inner rotor of a high torque is provided in a main drum and an outer rotor of a torque low is provided on a lower drum through the design of the rotor inner side torque is greater than the rotor outer side torque in such a way that the number of coil winding increases on the inner teeth, making it a length of the inner teeth longer than a length of external teeth and a washing machine using the same.
[0020] Another aspect of the detailed description is to provide a washing machine capable of maximizing torque efficiency within a predefined size by optimizing a ratio of an outside diameter of a rotor to an outside diameter of a motor stator of permanent magnet and capable of maximizing the efficiency of the permanent magnet motor by enhancing vibration and noise characteristics while minimizing cogging torque and crimping torque under control of a height of a portion of the rotor teeth extension, a distance between extension portions of adjacent teeth, an arc angle of the rotor teeth and an angle of a linear portion of the tooth extension portion.
[0021] Another aspect of the detailed description is to provide a method to manufacture a double motor stator capable of minimizing the redundant parts after drilling and consequently reducing component waste, by drilling separately manufactured internal stator and external stator without being integral with the another and a washing machine employing the same.
[0022] Another aspect of the detailed description is to provide a washing machine, having an efficient structure to drive two drums by a single drive motor and not having increased size and a drive motor for the washing machine.
[0023] Another aspect of the detailed description is to provide a method to manufacture a washing machine, including a drive motor, having an optimized number of windings in a stator for driving two drums by a single drive motor.
[0024] Another aspect of the detailed description is to provide a washing machine, having an efficient structure to drive two drums by a single drive motor, to reduce the number of components in order to reduce the size of the drive motor, to shorten a operating time and manufacturing cost savings, a washing machine drive motor, and a method for manufacturing a washing machine drive motor stator.
[0025] Another aspect of the detailed description is to provide a washing machine capable of effectively carrying out radiation by driving and convection by forming bent portions including protruding portion and concave portion in a body of a bearing housing, in order to radiate heat generated from the coil on the internal teeth of the stator, as a mounted frame of the bearing housing and stator of the drive motor in the washing machine.
[0026] Another aspect of the detailed description is to provide a structure of a current connector and a hall sensor for a dual motor, capable of implementing a simplified structure, preventing incorrect assembly, locking space and improving convenience, by combining the connector separately current connector and hall sensor in an integrated member, unlike the conventional dual motor frame in which the current connector and hall sensor are installed separately in the inner and outer stator and a washing machine employing the same.
[0027] Another aspect of the detailed description is to provide a shaft structure for a double drum washing machine, capable of providing a simplified structure to prevent separation due to abnormal noise and vibration, which can be generated in a connecting structure between a rotor internal and external shaft of a double motor applied in the double drum washing machine, and consequently reducing a material cost and a washing machine employing the same.
[0028] Another aspect of the detailed description is to provide a shaft structure for a double drum washing machine, capable of reducing material cost and capable of having a simplified structure for preventing entangled state release, the entangled state release that occurs due to abnormal noise and vibrations generated in connecting structure of an inner motor and an outer shaft of a double motor applied to a double drum washing machine, and a washing machine having the same.
[0029] Another aspect of the detailed description is to facilitate an assembly process by securing the coupling positions of a bearing housing and a stator, forming a mating protrusion in a coupling stator opening formed in the bearing housing and a recess fitting into a coupling housing opening formed in the stator, in order to improve the stator mounting process having external teeth and internal teeth with the bearing housing, in a dual motor including an internal rotor and an external rotor and employed in a double drum washing machine.
[0030] Another aspect of the detailed description is to perform a function of an inner rotor mounting guide by employing an auxiliary mounting jig to improve mounting without coupling an inner rotor on one side of the bearing housing.
[0031] Another aspect of the detailed description is to provide a control and operation method for a washing machine, capable of reducing garment wrinkling after the completion of dewatering by allowing 3D movements of the garment by virtue of a drive motor capable of driving two independent drums each other.
[0032] Another aspect of the detailed description is to provide a control method for a washing machine capable of making garments simply taken out of the washing machine in an automatic manner after the operation of the washing machine is completely finished.
[0033] Another aspect of the detailed description is to provide a washing machine allowing 3D movements, through initially the operation of a drive motor with prevention of an initialization failure due to excess current, which can be generated after the initialization of the drive motor , and minimizing an amount of heat and simultaneously and appropriately controlling a direction of rotation or revolutions per minute (RPM) of the engine according to an amount of clothing, temperature and the like.
[0034] Another aspect of the detailed description is to provide a washing machine, capable of accurately detecting a quantity of clothing, the washing machine having two drums and a single drive motor to independently drive the two drums, and a method for detecting a amount of clothing in it.
[0035] TECHNICAL SOLUTION
[0036] To achieve these and other advantages and in accordance with the purpose of this specification, as described in this document broadly and with modalities, a washing machine comprising a main body, defining an external appearance of the washing machine, a tub disposed inside the drum main drum for washing water, a main drum rotatably mounted on the tub, a secondary drum mounted inside the main drum to be relatively rotatable with respect to the main drum, an outer shaft to rotate the main drum, an inner shaft to rotate the drum secondary, being disposed within the external shaft, a drive motor having a stator, an external rotor connected to the internal shaft and disposed outside the stator, and an internal rotor connected to the external shaft and disposed inside the stator, in which the motor drive is configured to rotate the main drum and secondary drum in different directions and/or at different speeds. of rotation.
[0037] With the configuration, the main drum and the secondary drum can be driven, independently of each other, by the drive motor, in order to induce garment rotations by a difference in rotation speed between the drums, thus allowing the garment perform three-dimensional movements with rotation inside the drum.
[0038] The washing machine may further include a main drum spider for connecting the main drum to the outer shaft and a secondary drum spider for connecting the secondary drum to the inner shaft.
[0039] With the configuration, the spiders can be employed for the respective drums, and therefore the drums by the drive motor.
[0040] The main drum may have openings on the rear and front sides. The secondary drum may have a secondary drum on the back to form its back surface. The secondary drum can have an open front side and the back closed by the back of the secondary drum.
[0041] The secondary drum spider may include a shaft coupling portion coupled to the inner shaft, and a plurality of drum fastening portions extending radially from the shaft coupling portion. Ends of the drum clamping portions can be attached to the rear of the secondary drum.
[0042] The drum rear of the secondary drum may further include an internally recessed receiving portion in symmetry with the spider of the secondary drum. The secondary drum spider can be received in the receiving portion to be adhered closely to the back of the secondary drum.
[0043] The main drum spider can be fixed on the main drum.
[0044] The main drum spider may include a shaft coupling portion coupled to the outer shaft, a spider support portion extending radially from the shaft coupling portion, and a drum fastening portion disposed at the end of the shaft portion. spider support The drum fixing portions can be fixed to the back of the main drum.
[0045] The support portion of the spider may be provided with a plurality of brackets extending radially from the portion for coupling the shaft. Alternatively, the support portion of the spider may be in a disk shape that extends from the coupling portion of the shaft.
[0046] The attachment portion of the barrel may have a ring shape for connecting ends of the support portion of the spider.
[0047] The main drum spider can be attached to an outer circumferential surface of the main drum. Alternatively, the main drum may include a bent portion bent from a rear portion towards a central portion, and the main drum spider may be coupled to the bent portion.
[0048] The spider of the secondary drum can be rotating independently of the spider of the main drum.
[0049] The secondary drum spider can be provided between the rear of the secondary drum and the main drum spider, to be rotated integral with the secondary drum and independent of the main drum spider.
[0050] As an exemplary variation of the embodiment of an exemplary embodiment, the main drum and the sub drum may respectively include a main drum back and a sub drum back defining respective rear surfaces. The main drum and the sub drum can have the front side open and the back closed by the back of the main drum and the back of the sub drum respectively.
[0051] With this structure, the main drum spider can be fixed on the back of the main drum.
[0052] The spider of the secondary drum can be provided between the rear of the secondary drum and the rear of the main drum, to be rotatable integrally with the secondary drum and independent of the rear of the main drum.
[0053] Meanwhile, the outer circumferential surface of the secondary drum may face a part of an inner circumferential surface of the main drum.
[0054] With the configuration, the secondary drum can be shorter than the main drum in length in an axial direction, so that the garment can contact the surface between the secondary drum and the main drum. Therefore, a movement in which the garment is rotated by the difference in rotation speed between the drums can be generated, thus allowing for three-dimensional movements of the garment.
[0055] A drum guide for sealing a gap of an outer circumferential surface may be arranged on the inner circumferential surface of the main drum, thereby preventing garments from being crushed between the drums.
[0056] Furthermore, a reinforcing bead to prevent twisting of the secondary drum can be provided on the inner circumferential surface or on the outer circumferential surface of the secondary drum.
[0057] An axis of rotation of the washing machine can be inclined with respect to a horizontal direction with a predetermined angle.
[0058] In accordance with an exemplary embodiment, a method for assembling a drum for a washing machine can be applied to a washing machine, including a main drum and a secondary drum disposed within a tub attached to a main body, and driven independent of each other and a drive motor having a stator and an external rotor an internal rotor to drive the main drum and the secondary drum independently, and the method may include coupling a shaft for transferring a driving force from the main motor for the main and secondary drum for a spider, to fabricate a spider-shaft assembly, attaching the spider-shaft assembly to the rear of the secondary drum, attaching the secondary drum to the main drum, and attaching the spider-shaft assembly to the rear of the main drum.
[0059] In the fabrication of the spider-shaft assembly, after a main drum spider is coupled to an outer shaft to transfer a driving force from the inner rotor to the main drum and a secondary drum spider is coupled to an inner shaft to transfer a driving force from the outer rotor to the secondary drum, the inner shaft can be coupled to the outer shaft.
[0060] Here, the inner shaft can be coupled to the outer shaft, and then a bearing can be fitted by pressing. In addition, after the bearing is press-fitted, a waterproof seal can be inserted.
[0061] When coupling the spider-shaft assembly to the rear of the secondary drum, the spider of the secondary engine can be attached to the rear surface of the secondary drum.
[0062] When coupling the secondary drum to the main drum, the secondary drum can be inserted into the main drum.
[0063] Here, after mounting a drum guide for the seal, the drum guide can be mounted on the inside of the drum before inserting the secondary drum into the main drum.
[0064] In coupling the spider-shaft assembly to the rear of the main drum, the spider end of the main drum can be coupled to the rear surface of the main drum.
[0065] With the configuration, a washing machine can be produced with a structure using two drums and a hollow rod and a double rotor (inner rotor and outer rotor) to drive the drums independent of each other.
[0066] According to another exemplary modality of the present disclosure, an inner circumferential surface of the main drum and an outer circumferential surface of the secondary drum may have different lengths from each other in an axial direction.
[0067] That is, the outer circumferential surface of the secondary drum can face the inner circumferential surface of the main drum, more particularly, only a part of the inner circumferential surface of the main drum can face the outer circumferential surface of the secondary drum.
[0068] Here, the secondary drum can be mounted on the main drum to extend from an end portion of the main drum in an axial direction.
[0069] A ratio (d2/d1) of a length d2 of the inner circumferential surface of the secondary drum in an axial direction to a length d1 of the inner circumferential surface of the main drum in an axial direction can be 0~0.5.
[0070] More preferably, the ratio (d2/d1) of the length d2 of the inner circumferential surface of the secondary drum in the axial direction with respect to the length d1 of the inner circumferential surface of the main drum in the axial direction can be 1/3.
[0071] To describe this in a different way, the inner circumferential surface of the main drum can be divided into a first surface that does not face the outer circumferential surface of the secondary drum and a second surface that faces the outer circumferential surface of the secondary drum, and the ratio (d2/d1) of the length d2 of the inner circumferential surface of the secondary drum in the axial direction with respect to a length d1 of the first surface in an axial direction can be 0.5.
[0072] The main drum and the secondary drum can move the garment in one direction due to the relative rotations between them.
[0073] More particularly, the inner circumferential surface of the main drum can be divided into a first surface that does not face the outer circumferential surface of the secondary drum and a second surface that faces the outer circumferential surface of the secondary drum, and the garment can be moved in the axial direction by relative movements between the first inner circumferential surface of the main drum and the inner circumferential surface of the secondary drum.
[0074] From a garment standpoint, the garment can be moved in the circumferential direction in response to the rotation of the main drum or the secondary drum and moved in the axial direction by the relative movements between the main drum and the secondary drum. At this time, movements of the garment in the axial direction may be allowed by rotation of the garment in response to relative movements between the main drum and the secondary drum.
[0075] However, the drive motor can independently drive the outer rotor and the inner rotor, in order to independently drive the main drum and the secondary drum.
[0076] The independent drive of the outer rotor and the inner rotor can allow the relative rotations between the main drum and the secondary drum.
[0077] With the configuration, the secondary drum can be shorter than the main drum in length in an axial direction, so that the garment can contact a surface between the secondary drum and the main drum. Therefore, the garment can be rotated by the difference in rotation speed between the drums, thus performing three-dimensional movements.
[0078] In addition, the drive motor can independently drive the main drum and the secondary drum, to induce rotations of the garment by the difference in rotation speed between the drums, consequently, the garment performs three-dimensional movements with rotation inside the drums. Furthermore, a structure capable of generating the ideal three-dimensional movement of the garment can be provided in consideration of torque distribution due to the drive of the two drums, a mechanical force applied to the garment and general movements of the garment.
[0079] Meanwhile, a plurality of lifters can be provided on at least one inner circumferential surface of the main drum and the secondary drum, to thus guide the movements of the garment.
[0080] In accordance with another exemplary embodiment, the secondary drum may have a cylindrical portion and a drum back that are integrally formed with each other as a member.
[0081] The receiving portion may have coupling openings to engage the spider of the secondary drum. The secondary drum spider may have coupling openings corresponding to the coupling openings of the receiving portion. In addition, the receiving portion may be formed within the rear of the secondary drum, and a length of the drum's spider console may be less than a radius of the rear of the secondary drum, in order to be inserted into the receiving portion.
[0082] In accordance with another exemplary embodiment, the secondary drum may have a cylindrical portion and a back of the drum as independent members, and the back of the drum around can be coupled to an outer circumference of the rear of the cylindrical portion to close the back side.
[0083] Furthermore, the receiving portion of the rear of the drum may extend to the outer circumference of the rear of the drum, and coupling openings may be formed in a portion of the rear end of the cylindrical portion. An outer circumference of the rear of the drum can be bent in a longitudinal direction of the drum, and coupling openings can be formed in the bent portion.
[0084] The spider of the secondary drum may have arms whose length is the same as the radius of the rear of the drum, and an end portion of the arm of the spider of the secondary drum may be coupled to the rear circumference of the cylindrical portion.
[0085] In accordance with another exemplary embodiment, a method for assembling a secondary drum of a washing machine may include a cylindrical portion forming an outer circumferential portion of the secondary drum for a rear of the drum, which is disposed on a surface rear of the secondary drum and coupled with a spider of the secondary drum, receiving the spider of the secondary drum in a recessed spider receiving portion with respect to a slotted spider receiving portion towards the front of the rear drum, and portions end of the secondary drum spider coupling arm by using screws through coupling openings formed in the end of the rear portion of the cylindrical portion of the secondary drum and a bent outer circumference of the rear of the drum.
[0086] According to another exemplary embodiment of the present disclosure, the washing machine may further include a drum guide provided along the inner circumferential surface of the main drum to protect an outer circumferential surface gap of the secondary drum.
[0087] The drum guide may include a body portion protruding from the main drum and coupled to the inner surface of the main drum and a guide portion extending from the body portion toward the inner circumferential surface of the secondary drum.
[0088] The secondary drum may include a bead protruding from the secondary drum along the circumferential surface being spaced beyond an end of the secondary drum portion by a predetermined interval. The guide portion of the drum guide can extend to the bead of the secondary drum.
[0089] With the configuration, the drive motor can independently drive the main drum and the secondary drum, to induce rotations of the garment by the difference in rotation speed between the drums, consequently, the garment performs three-dimensional movements with rotation inside the drums. Also, the drum guide can prevent the garment from being crushed at the interface where the independently driven main drum and the secondary drum perform relative rotations.
[0090] As another exemplary embodiment of the present disclosure, the secondary drum may include a bead protruding outwardly therefrom along the circumferential surface being spaced beyond an end of the portion thereof by a predetermined interval. The guide portion of the drum guide may extend to the end of the secondary drum portion.
[0091] Therefore, the drum guide can prevent the garment from being crushed at the interface where the independently driven main drum and the secondary drum perform the relative rotations.
[0092] The end portion of the secondary drum can be rolled out along the circumferential surface. The structure can be arranged in order to prevent the garment from being crushed due to the end portion of the secondary drum by processing the end of the secondary drum portion having a curved surface.
[0093] According to another exemplary embodiment of the present disclosure, the main drum can be divided into a first portion and a second portion having internal diameters different from each other. The inside diameter of the first portion can be the same as the inside diameter of the secondary drum, and the inside diameter of the second portion can be larger than the outside diameter of the secondary drum, thus protecting the interface between the main drum and the secondary drum.
[0094] With the configuration, a part of the main drum can extend so that the inner circumferential surfaces of the main drum and the secondary drum can have the same radius, thus preventing the garment from being crushed at the interface between the main drum and the drum secondary. The structure that prevents the garment from being crushed can be produced during the formation of the drums without the use of a separate guide or the like.
[0095] Here, the end portion of the secondary drum can also be rolled out along the circumferential surface and located within the second part.
[0096] According to another exemplary embodiment of the present disclosure, the main drum may further include a drum guide unit protruding inwardly along the inner circumferential surface of the main drum. An inner circumferential surface of the drum guide unit can be flush with the inner circumferential surface of the secondary drum, thus protecting the interface between the main drum and the secondary drum.
[0097] With the configuration, the part of the main drum can protrude, so that the inner circumferential surfaces of the main drum and the secondary drum can have the same radius at the interface between them. Therefore, the garment can be prevented from being crushed at the interface. The structure that prevents the garment from being crushed can be produced during the formation of the drums without the use of a separate guide or the like.
[0098] Here, the final portion of the secondary drum can also be rolled out along the circumferential surface, and located outside more than the inner circumferential surface of the drum guide unit.
[0099] According to another exemplary embodiment of the detailed description, a washing machine may include a plurality of main drum lifters protruding from an inner circumferential surface of a main drum towards the inside in a radial direction, and a plurality of secondary drum lifters protruding from an inner circumferential surface of a secondary drum inwardly in a radial direction.
[00100] In more detail, the inner circumferential surface of the main drum can be divided into a first face not facing the outer circumferential surface of the secondary drum and a second surface facing the outer circumferential surface of the secondary drum. Main drum lifters can be provided on the first surface.
[00101] With the configuration, the drive motor can independently drive the main drum and the secondary drum, to induce rotations of the garment by the difference in relative speed of rotation between the drums, consequently, the garment performs three-dimensional movements with rotation inside the drums. Also, the plurality of lifters can be provided on the inner circumferential surfaces of the drums, so that the garment can perform the three-dimensional movements more smoothly within the drum.
[00102] The extension ratio of the main drum lifter and the secondary drum lifter in an axial direction can be proportional to a length of the first surface of the inner circumferential surface of the main drum and a length of the inner circumferential surface of the secondary drum. This can provide the lifters in correspondence with the main drum and the sum drum having relatively different lengths in the axial direction.
[00103] Main drum lifters and secondary drum lifters may be provided inside the drums in parallel in an axial direction. However, the disclosure of the present disclosure may not be limited to structure. Alternatively, the main drum lifters and the secondary drum lifters can have a predetermined angle in an axial direction. Here, a direction of rotation of the main drum can be determined in accordance with an angle direction of the lifter of the main drum with respect to the axial direction, and a direction of rotation of the secondary drum can be determined in accordance with an angle direction of the lifter of the secondary drum with respect to the axial direction. That is, the direction of rotation of the drum can be determined based on an inclined direction of the lifters, so that the garment inside the drum can smoothly perform 3D movements by the lifters.
[00104] However, sectional heights in a radial direction of the main drum lifters may become lower towards a rear side along an axial direction, and sectional heights in a radial direction of the secondary drum lifters may become lower, towards a frontal side along an axial direction. Therefore, lifters can be slanted relative to the axial direction to allow the garment on the drums to move efficiently in an axial direction, thus allowing for three-dimensional movements of the garment.
[00105] Here, the main drum lifters or secondary drum lifters can be formed to have a straight slope or a curved slope along an axial direction.
[00106] The main drum lifters may extend from a portion of the front end to a rear side of the main drum. In addition, the secondary drum lifter may extend from a portion of the rear end to a front side of the secondary drum. Here, the main drum lifters or secondary drum lifters may have slopes becoming inferior in the direction that they face each other. This may be so, in order to prevent the garment from being concentrically arranged on the inside or outside of the drum due to its movements in an axial direction, and in order to allow the garment to be positioned in the center of the drum for three-dimensional movements of the clothing.
[00107] The main drum and secondary drum can be driven independently of each other by the drive motor. Furthermore, the main drum and the secondary drum can rotate the garment in one direction because the relative rotations between them move in an axial direction.
[00108] The garment can be moved in a circumferential direction in response to the rotation of the main drum or the secondary drum, and move in an axial direction being rotated by relative motions between the main drum and the secondary drum.
[00109] Here, the main drum lifters and the secondary drum lifter can guide the garment to move in a circumferential direction. In addition, forward-facing tilts of the main drum lifters and secondary drum lifters can guide garment movements in an axial direction.
[00110] According to another modality of the present disclosure, a permanent magnet motor is provided comprising: a stator including stator teeth and stator grooves, the same fixedly installed as a coil that is wound on the stator teeth; and a rotor, including rotor teeth, a permanent magnet and a bushing, the rotor spaced from an inner circumference of the stator and rotating around the center of a rotor shaft by a magnetic force. A ratio of rotor outer diameter to stator outer diameter is in the range of 0.7 ~ 0.8.
[00111] The rotor teeth include tooth extension portions protruding from the right and left sides of the rotor in an outer diameter direction. The end of the tooth extension portion has a height of less than 0.3 mm, and a distance (DW) between tooth extension portions in the vicinity of rotor teeth is in the range of 5.5 mm ~ 6.5 mm.
[00112] Preferably, an end portion of the outer diameter of the rotor teeth is formed so that the rotor teeth have an arc angle of 60°.
[00113] The extension portion of the rotor teeth is provided with a linear extension portion on an outer circumference thereof. An angle between the linear portion of the extension and a straight line from the end of the teeth of the extension portion to the center of the core is in the range of 90° ~ 100°.
[00114] According to yet another embodiment of the present disclosure, a washing machine is provided, having a rotor structure of a permanent magnet motor, the washing machine comprising: a main body forming an external appearance; a tub disposed inside the main body; a main drum rotatably mounted in the tub; a secondary drum mounted on the main drum to be relatively rotatable with respect to the main drum; an outer hollow rod connected to the main drum; an inner shaft connected to the secondary drum by insertion into the outer shaft; and a drive motor having an outer rotor and an inner rotor, wherein the drive motor includes: a stator fixedly mounted as a coil is wound on the teeth of the stator; and a rotor, including rotor teeth and a permanent magnet, spaced apart from an inner circumference of the stator and rotating centered around an axis of a rotor by a magnetic force, and wherein the ratio of an outer diameter of the rotor relative to to the outside diameter of the stator is in the range of 0.7 ~ 0.8.
[00115] The rotor teeth include tooth extension portions protruding from the right and left side of the rotor in a direction of the outer diameter. The end of the tooth extension portion has a height of less than 0.3 mm, and a distance (DW) between tooth extension portions of the surrounding rotor teeth is in the range of 5.5 mm ~ 6.5 mm.
[00116] Preferably, the extension portion of the rotor teeth is provided with a linear extension portion on an outer circumference thereof. An angle between the linear extension portion and a straight line of the end of the teeth of the extension portion relative to the center of the core is in the range of 90° ~ 100°.
[00117] According to another exemplary embodiment of the present disclosure, a stator of a drive motor may include stator teeth and stator grooves and fixedly installed as a coil is wound on the stator teeth. The outer rotor and inner rotor may include rotor teeth, a permanent magnet and a bushing, be spaced an inner circumference of the stator, and rotate with center around a rotor axis by a magnetic force. The rotor teeth may include a tooth extension portion extending from a lateral end of an outer circumference of the rotor teeth in a circumferential direction, a recess cut concavely cut from the outer circumference of the rotor teeth towards at the center of the rotor shaft and an insert recess cut concavely in a radial direction of an inner circumference of the rotor teeth to insert an injection molding material from the bushing therein.
[00118] The insert recess may include a first insert recess, through which an injection molding material of the bushing is inserted into the rotor teeth, and a second insert recess extending from the first insert recess in a radial direction of the rotor shaft to fully fix the bushing and rotor teeth after hardening of the injection molding material of the bushing inserted in it.
[00119] The second insertion recess may be formed as a hole of at least one of circular, oval, polygonal and triangular shapes each having a diameter greater than the width of the first insertion recess.
[00120] The rotor teeth may further include a cutout opening, which extends from the cut hole towards the center of the rotor shaft to form a flow barrier, as an injection molding material of the bushing is filled therein. The cut opening that forms the flow barrier may preferably be formed in a circular or oval shape, having a diameter greater than a width of the cutting recess, in order to prevent the leakage of a magnetic flux from the permanent magnet, positioned between the rotor teeth.
[00121] The cutting recess and the cutting opening for flow barrier of the rotor teeth can be filled with an injection molding of the bushing. This can prevent the rotor teeth from separating. Also, since a space between the rotor tooth extension portion and the permanent magnet can be filled with the bushing injection molding material, the rotor teeth and the permanent magnet can be integrally fixed to each other. This can prevent the separation of the rotor teeth from the core from the rotor due to centrifugal force.
[00122] An outer circumferential end of the rotor teeth may have a greater curvature than the annular rotor. This can change from a spacing distance between the outer circumferential surface of the rotor teeth and an inner circumferential surface of the stator.
[00123] According to another exemplary embodiment of the present disclosure, the motor's double stator may include an internal stator including a plurality of inner ring-shaped protruding inner teeth, an inner fork 13, which forms a ring-shaped shape. an inner stator and inner grooves serving as spaces between the inner teeth and the inner yoke and an outer stator including a plurality of outer teeth protruding in a radial direction in a ring shape, an outer yoke that contacts a circumferential surface outer of inner fork and forming a shape of outer stator ring and outer grooves serving as spaces between outer and outer teeth. The inner stator and the outer stator may face each other on an outer circumferential surface of the inner yoke and an inner circumferential surface of the inner yoke and be coupled together and spaced apart from each other.
[00124] In addition, the stator can be configured so that a length of the inner teeth can have more than one length of the outer teeth, whereby the number of windings of the coil wound on the inner teeth can be greater than that of the wound coil on the outer teeth. Therefore, the torque of the inner rotor can be greater than the torque of the outer rotor, thus making a rotational force of the main drum greater than that of the secondary drum.
[00125] The inner stator may include an insulator installed in the part between an outer circumferential surface of the inner yoke and an inner circumferential surface of the outer yoke and be coupled together to protect the magnetic force. The insulator preferably may be formed of a plastic material based on PBT.
[00126] In the method for manufacturing the stator, a pair of inner stators can be manufactured in a punching manner in a state that the inner teeth are arranged to be engaged with each other in a longitudinal direction, and a pair of outer stators it can be manufactured in punching form in a state that the outer teeth are arranged to be engaged with each other in a longitudinal direction. This can minimize the amount of redundant parts after punching in internal stators and external stators, minimizing component loss.
[00127] The inner stator extends in the longitudinal direction and can be implemented in a ring shape as one end and respective other end are connected to each other. The outer stator, extending in the longitudinal direction, can be wound around an outer circumference of the inner stator in a ring shape.
[00128] Another exemplary embodiment for a washing machine according to this disclosure may include a tub disposed on the inside of a main body, defining the appearance, a main drum rotatably mounted on the tub, a secondary drum mounted on the main drum to be relatively rotary with the main drum, an outer hollow shaft connected to the main drum, an inner shaft connected to the secondary drum within the outer shaft, and a drive motor having a stator, an outer rotor connected to the inner shaft and rotating on the side outside the stator and an inner rotor connected to the outer and rotating shaft on the inner side of the stator, where the stator may include an inner stator facing the inner rotor and an outer stator facing the outer rotor, in which each inner stator and outer stator of the stator may include a plurality of hinged coils connected in a ring shape, a plurality of teeth inserted into the coils. are hinged, respectively, and a toothed ring for connecting end portions of the plurality of teeth in a ring shape.
[00129] With the configuration, since the main drum and the secondary drum are operated independently by the drive motor, the garment can rotate due to the difference in a relative rotation speed between the drums, where the garment can perform a three-dimensional movement with rotation inside the drums.
[00130] In addition, the two stators can be employed to drive the two independent rotors and each stator can include articulated coils for the improvement of a winding space factor, which can result in improved drive motor performance and motor optimization drive.
[00131] In addition, the use of the toothed ring to reduce torque oscillation and preventing the reduction of an efficiency can cause an ideal structure to drive the two independent rotors.
[00132] Here, in accordance with an exemplary embodiment, when the teeth are segment-type teeth, each inner stator and outer stator of the stator may further include an annular yoke for connecting end portions of the plurality of articulated coils, so that the plurality of articulated spools can be mounted between the yoke and the toothed ring.
[00133] According to an exemplary embodiment, when the tines are formed integrally with a hinged fork for connecting the end portions of the teeth, the hinged fork can be bent into a ring shape, so that the plurality of the hinged spools can be mounted between the annularly bent articulated fork and the toothed ring.
[00134] In these exemplary embodiments, each of the plurality of articulated coils can be wound with a coil.
[00135] Each hinged coil may include a body part having a receiving portion for insertion of the tooth therein, and hinged parts formed on both side surfaces of the body part to be folded. In this sense, the articulated parts of the plurality of articulated coils can be interconnected with one another.
[00136] In accordance with an exemplary embodiment of this disclosure, a method for manufacturing a stator of a drive motor for a washing machine may include a coil connection step, for connecting a plurality of articulated coils in the form of a belt, a tooth insertion step, to insert teeth into the plurality of connected hinged coils, respectively, an automatically winding step, to automatically wind a coil on each inserted toothed hinged coil, a yoke connection step, to connect the wound hinged coils in the ring-shaped spool, and a toothed ring connection step, to connect a ring-shaped toothed ring to connect end portions of the teeth.
[00137] The automatic winding step can be performed to automatically wind a coil on each of the hinged coils in an aligned state.
[00138] The coil can be automatically wound on the articulated coil in order to improve a winding space factor, which can result in drive motor performance improvement and drive motor optimization.
[00139] Here, when the teeth are segment-type teeth, the connecting step of the connecting fork can be performed to connect the hinged coils on the fork of the ring shape.
[00140] Also, for integral teeth, formed integrally with the swiveling yoke to connect the end portions of the tines, the yoke connection step can be performed to bend the swiveling yoke to ring shape.
[00141] An exemplary embodiment of a drive motor for a washing machine, according to this disclosure, when these configurations are limited to the drive motor for the washing machine, may include an internal stator, having a ring shape, a external stator having a ring shape, and located outside the internal stator, an internal rotor disposed inside the internal stator, and an external rotor disposed outside the external stator, wherein each internal stator and each external stator may include a plurality of hinged coils connected in a ring shape, a plurality of teeth inserted into the coils, respectively, and a toothed ring for connecting end portions of the plurality of teeth to a ring shape.
[00142] Another exemplary embodiment for a washing machine according to this disclosure may include a tub disposed on the inside of a main body, defining the appearance, a main drum rotatably mounted on the tub, a secondary drum mounted on the main drum to be relatively rotary with the main drum, an outer hollow shaft connected to the main drum, an inner shaft connected to the secondary drum within the outer shaft, and a drive motor having a stator, an outer rotor connected to the inner shaft and rotating on the side outside the stator and an inner rotor connected to the outer and rotating shaft on the inner side of the stator, where The stator may have an inner stator facing the inner rotor and an outer stator facing the outer rotor, and the stator internal and external stator can be integrally formed by an insulator.
[00143] The inner stator can be formed by receiving an inner toothed core, which includes a plurality of inner teeth and an inner fork in the insulator and coil winding in the insulator, and the outer stator can be formed by receiving a toothed outer core , which includes a plurality of outer teeth and an outer yoke on the insulator, and coil winding on the insulator.
[00144] Here, the insulator may include a flux barrier to protect a magnetic force by spacing the toothed inner core and outer toothed core separated from each other.
[00145] Furthermore, the insulator may include an inner toothed core receiving portion having tooth having receiving portions for receiving the plurality of inner teeth, and an inner yoke receiving portion for receiving the inner yoke, and a toothed core receiving portion outer having outer tooth receiving portions for receiving the plurality of outer teeth, and an outer yoke receiving portion for receiving the outer yoke. The flow barrier may be interposed between the inner yoke receiving portion and the outer yoke receiving portion.
[00146] Inner grooves can be formed between the inner tooth receiving portions to receive the plurality of inner teeth, respectively, and outer grooves can be formed between the outer tooth receiving portions to receive the plurality of outer teeth, respectively. A coil can be wound on the outside of each inner tooth receiving portion and outer tooth receiving portion
[00147] The insulator can be formed by coupling an upper insulator and a lower insulator facing each other. The flow barrier may protrude from at least one of the upper and lower insulator to thus protect a magnetic force by spacing the inner core from the outer toothed core separated from each other by coupling the upper and lower insulator.
[00148] The insulator can be formed from a plastic material based on PBT.
[00149] With the configuration, since the main drum and the secondary drum are operated independently by the drive motor, the garment can rotate due to the difference in a relative rotation speed between the drums, where the garment can perform a three-dimensional movement with rotation inside the drums.
[00150] In addition, the insulator can serve as a coil, and consequently the number of components and an entire size of the drive motor can be reduced, which can result in preventing an increase in an entire size of the washing machine, even if two stators for driving two independent rotors are used.
[00151] An exemplary embodiment of a drive motor for a machine, according to this disclosure, when these configurations are limited to the drive motor for the washing machine, may include an internal stator, having a ring shape, a stator outer rotor having a ring shape and disposed outside the inner stator, an inner rotor disposed inside the inner stator, an outer rotor disposed outside the outer stator, and an insulator to integrally form the inner stator and outer stator, where the inner stator can be formed to receive an inner toothed core, which includes a plurality of inner teeth and an inner yoke, in the insulator and winding the coil over the insulator, and the outer stator can be formed to receive an outer toothed core, which includes a plurality of outer teeth and an outer yoke on the insulator and winding the coil over the insulator. Here, the insulator may include a flux barrier to protect a magnetic force by spacing the inner sprocket and outer sprocket apart from each other.
[00152] Furthermore, the insulator may include an inner toothed core receiving portion having inner tooth receiving portions to receive the plurality of inner teeth, and an inner toothed receiving portion to receive the inner yoke, and a toothed core receiving portion outer having outer tooth receiving portions for receiving the plurality of outer teeth, and an outer yoke receiving portion for receiving the outer yoke. The flow barrier may be interposed between the inner yoke receiving portion and the outer yoke receiving portion.
[00153] The insulator can be formed by coupling an upper insulator and a lower insulator facing each other. The flow barrier may protrude from at least one of the upper and lower insulator to thus protect a magnetic force by spacing the inner core from the outer toothed core separated from each other by coupling the upper and lower insulator.
[00154] An exemplary embodiment of a method for fabricating a stator of a drive motor for a washing machine in accordance with this disclosure may include a stator core build-up step of an inner toothed core having inner teeth and a yoke internal, and an outer toothed core having outer teeth and an outer yoke, a step of inserting the inner toothed core and the outer toothed core into one of an upper insulator and a lower insulator, which are coupled to form an inner tooth receiving portion and a freight outer tooth receiving part to each other, a stator assembling step of coupling the upper insulator to the lower insulator and a coil winding step of winding a coil on an outside of the inner tooth receiving portions to receive the inner teeth of the internal stator receiving part, and on an outside of the outer tooth receiving portions receive to receive the teeth external stator receiving part.
[00155] In the stator core insertion step, the inner core and the outer tooth core can be inserted being spaced apart from each other, interposing between a flow barrier, which is formed in at least one of the insulator upper and lower insulator.
[00156] With the configuration, mounting the stator can be carried out in an easy and simple way, and the insulator can serve as the coil as well, which can allow the reduction of the entire number of components and an entire size of the drive motor. Therefore, even if two stators for driving two independent rotors are employed, an increase in a full size of the washing machine can be avoided.
[00157] According to another exemplary embodiment of the present disclosure, the drive motor can have a bearing housing structure for improvement of a double motor stator. The structure may include a bearing housing disposed together in a stator having external teeth, internal teeth, a yoke and a housing coupling opening, and provided with a body, a bearing shaft hole, a housing fixing opening. and a stator coupling opening. The bearing housing body may include a protruding portion at a position corresponding to the winding portion of the inner tooth and a concave portion at a position corresponding to a groove between the inner teeth.
[00158] Preferably, the concave portion can be formed as a space for the convection of heat generated from the winding portion of the inner teeth, and the protruding portion of the bearing housing casing can be formed as a drive portion to radiate generated heat from the winding portion of the inner teeth to the outside through actuation.
[00159] The protruding portion of the bearing housing body may be spaced from the coil wound on the wound portion of the inner teeth by a predetermined distance of insulation.
[00160] According to another exemplary modality of the present disclosure, the drive motor can have a structure of a current connector and a Hall sensor for a double motor stator. The structure may include a stator having inner teeth and outer teeth, a current connector for applying power to a winding portion of the outer teeth and an inner winding portion of the inner teeth in an integrated manner; and a hall sensor connector configured to apply power to an external hall sensor and an internal hall sensor in an integrated manner.
[00161] The current connector can supply a current from a power unit to the outer winding portion and the inner winding portion in parallel, and that applied to the outer winding portions and the inner winding portion can be integrally connected to a background.
[00162] The hall sensor connector can supply a current from the power unit to the external hall sensor and the internal hall sensor in parallel through the integrated hall sensor connector, and sensed hall sensing signals from the external stator and the internal stator can be connected with the built-in hall sensor connector in parallel. The applied current from the outdoor hall sensor and the indoor hall sensor can be connected to a ground.
[00163] The drive motor may further include an external temperature sensor and an internal temperature sensor to detect external stator and internal stator temperatures, respectively. The outer temperature sensor and the inner temperature sensor can contact the outer winding portion and the inner winding portion to measure temperatures.
[00164] With configuration, a current from the power unit can be fed to the external temperature sensor and the internal temperature sensor, in parallel, through the integrated hall sensor connector, and detected signals from the external temperature sensor and the internal temperature sensor. internal temperature can be connected to the built-in hall sensor connector in parallel. The hall sensor unit including the external hall sensor and the indoor hall sensor, and a temperature sensor unit including the external temperature sensor and the indoor temperature sensor can be connected to each other in parallel to be integrally connected to one. background.
[00165] According to another exemplary modality of the present disclosure, the washing machine may include a pressure washer inserted in a connecting part of the external shaft and the internal rotor, which results in attenuation of vibrations of the external shaft to prevent noise , and preventing the separation of the outer shaft 81 due to vibrations.
[00166] The stop ring can further be provided on a connecting part of the outer shaft and the inner rotor to hold the spring washer, in order to prevent separation of the spring washer in an axial direction. Preferably, the stop ring can be implemented as a C ring.
[00167] A stop ring recess may be concave from an outer circumference of the outer shaft towards the center. The C-ring can be inserted into the stop ring recess, and prevent the spring washer from separating in the axial direction.
[00168] The inner bush can be installed between the outer shaft and the inner rotor to transfer a rotational force from the inner rotor to the outer shaft. The spring washer can be installed on the connecting part of the inner bushing and the outer shaft to prevent vibrations and noise in the axial direction of the outer shaft and noise.
[00169] In addition, a stop ring can still be provided on the connecting part of the outer shaft and the inner bush to secure the spring washer. The spring washer can be formed as an annular member that encloses an outer circumference of the outer shaft on the upper surface of the inner bush.
[00170] The pressure washer can preferably be implemented as an annular concave-convex member having a protruding portion and a concave portion.
[00171] According to yet another embodiment of the present invention, there is provided an axle structure for a double washing machine drum, comprising: an outer axle formed in a hollow type; an inner axis, inserted into the outer axis; a drive motor having a stator, an outer rotor connected to the inner shaft and running outside the stator, and an inner rotor connected to the outer shaft and running inside the stator; a spring washer inserted into the outer shaft in a connecting piece of the outer shaft and inner rotor; and an inner rotor nut configured to force correct the inner rotor after the spring washer is inserted into the outer shaft. By this configuration, external shaft vibrations in an axial direction can be attenuated to prevent noise, and entangled state happening due to vibration can be prevented.
[00172] The shaft structure of the present invention may further comprise a flat washer coupled by inserting the part between the inner rotor and the pressure washer on the outer circumference of the outer shaft.
[00173] A male thread portion is formed on the outer circumference of the outer shaft, and a female thread portion is formed on the inner circumference of the inner rotor nut. Since the male thread portion and the female thread portion are coupled together, the spring washer can prevent deflection in an axial direction.
[00174] The inner bush is installed between the outer shaft and the inner rotor, so that a rotational force of the inner rotor can be transferred to the outer shaft.
[00175] According to another embodiment of the present invention, the pressure washer is implemented in the form of a concave-convex annular member formed on an upper surface of the inner bush, in order to cover the outer circumference of the outer shaft. This can prevent external shaft vibrations in an axial direction and noise.
[00176] The annular concave-convex member includes a protruding part and a concave part.
[00177] An inner ball bearing is installed between the outer shaft and the inner shaft so that the drive motor can drive the outer shaft and inner shaft independently.
[00178] According to another exemplary embodiment of the present disclosure, in the drive motor assembly structure including a bearing housing with a housing main body, a bearing shaft bore and a stator coupling opening, and a stator with external teeth, a yoke and a casing coupling opening, the stator coupling opening may include a mating protrusion and the casing mating opening may include a mating recess, so that the mating protrusion can be inserted into the fitting recess, thus improving an assembly feature between the bearing housing and the double motor stator.
[00179] The stator coupling opening and the casing coupling opening can be provided with coupling openings communicated with each other when the bearing casing and the stator are together with each other. In a state that the mating protrusion has been fixed by insertion into the mating recess, the bearing housing and stator can be brought together with each other by screws through mating openings.
[00180] The stator coupling opening may protrude from the bearing housing body by a predetermined height, and the housing coupling opening may protrude from the stator yoke by a predetermined height.
[00181] Also, the stator may include a plurality of spacers protruding from the yoke, so that the stator may be coupled to the bearing housing with a gap between them.
[00182] According to another exemplary modality of the present disclosure, a method for driving a washing machine may include a washing step of carrying out a washing process by feeding wash water and a detergent, a rinsing step carrying out a rinsing process by feeding rinse water, a dehydration step of unloading rinse water and carrying out a dehydration process, and a step of arranging the clothing of the main drum and the secondary drum and releasing a tangled state of the garment after the dehydration process. The method may further include a drying step of performing a drying process to dry the garment, and the garment arranging step may be performed prior to the drying step.
[00183] The garment arranging step may include a garment separation process of separating the garment from the inner surfaces of the main drum and the secondary drum in response to relative movements between the main drum and the secondary drum, and a release process of tangled state, of releasing a tangled state of the garment while the garment rotates by relative motions of the main drum and the secondary drum moving in a circumferential direction and an axial direction. The garment arranging step may further include an automatic garment attracting step, which attracts the garment outwardly through related movements of the main drum and the secondary drum.
[00184] According to another exemplary embodiment of the present disclosure, a method for controlling a washing machine may include a clothing separation step, which is driven by a main drum and secondary drum drive motor to perform movements related to separate the garment from the internal surfaces of the main drum and secondary drum after the dehydration step, which drains rinsing water and performs a dehydration process, and a tangle-free step, which activates, through the drive motor, the main drum and secondary drum to perform the related movements, so that the tangled state of the garment can be released with rotation and movement in a circumferential direction and an axial direction. And, the method can further include a step of automatic clothing attraction, driving through the main drum drive motor and the secondary drum drive by the drive motor to perform related movements, so that the clothing can be unloaded to the outside of the door after the door is opened.
[00185] The drive motor can independently rotate the outer rotor and the inner rotor, so that the main drum and the secondary drum can perform the related rotations. Preferably, the secondary drum and the main drum can rotate in opposite directions from each other, or rotate at different speeds of rotation in the same direction of rotation.
[00186] According to another exemplary modality of the present disclosure, the method for driving the washing machine may include a three-dimensional garment washing process, which rotates and moves the garment in a circumferential direction and in an axial direction by related movements of the main drum and the secondary drum that carry out the washing process by supplying washing water and detergent.
[00187] In addition, the washing step may further include a general washing process, which moves the garment in the circumferential direction by rotating the main drum and the secondary drum.
[00188] According to another exemplary modality of the present disclosure, the drive motor can drive the main drum and the secondary drum to rotate relatively, so that the garment can rotate and move in circumferential and axial directions, or drive the main drum and the secondary drum to integrally rotate each other, so that the garment can move only in the circumferential direction, according to the amount of garment measured in the washing step, which performs the washing process through the supply of washing water and detergent.
[00189] In detail, when an amount of garment is less than 1/3 of the maximum load of the drive motor, the drive motor can rotate the main drum and the secondary drum in opposite directions. When an amount of garment is more than 1/3 and less than 2/3 of the maximum load of the drive motor, the drive motor can rotate the main drum and secondary drum in the same direction at different speeds. In detail, when a garment quantity is greater than 1/3 of the maximum load of the drive motor, the drive motor can fully rotate the main drum and secondary drum in the same direction.
[00190] According to another exemplary modality of the present disclosure, the washing machine can further include a control unit to control the operations of the outer rotor and the inner rotor, and upon initial operation of the drive motor, the control unit can operate the outer rotor and inner rotor with a starting RPM less than or equal to each outer rotor and inner rotor target RPM.
[00191] The control unit can control the drive motor to sequentially drive the internal and external rotors, starting from a rotor having a large torque.
[00192] According to another exemplary embodiment of the present disclosure, the washing machine may further include and comprise a garment quantity detection unit 200 configured to detect a garment quantity. If a predetermined time fails after the drive motor has started to operate, the control unit can control a direction of rotation or an RPM of each outer rotor and inner rotor according to a garment quantity.
[00193] When a garment quantity is less than a reference garment quantity, the control unit can rotate the main drum and the secondary drum by driving the outer rotor and inner rotor in opposite directions. When garment quantity is more than the reference garment quantity, the control unit can rotate outer rotor and inner rotor in the same direction.
[00194] When a garment quantity is less than a first reference garment quantity, the control unit can rotate the outer rotor and inner rotor in opposite directions. When a garment quantity is greater than a second reference garment quantity more than the first reference quantity, the control unit can rotate outer rotor and inner rotor in the same direction.
[00195] When a garment quantity is greater than the first garment reference quantity and less than the second garment reference quantity, the control unit can control the rotation directions or RPMs of the outer rotor and inner rotor accordingly with an amount of heat generation or torque from the drive motor.
[00196] According to another exemplary modality of the present disclosure, the washing machine can also include a temperature detection unit provided in the external rotor or in the internal rotor and configured to detect a temperature. When the temperature is higher than a reference temperature, the control unit can control the outer rotor and inner rotor to run at the same RPM.
[00197] According to another exemplary embodiment of the present disclosure, a method for controlling a washing machine may initially include operating the drive motor with the same starting RPM, lower than the outer rotor and inner rotor target RPMs , and the operation of the outer rotor and inner rotor at the respective target RPMs when a predetermined time fails after initially operating the drive motor.
[00198] The method may include comparison torques of the outer rotor and the inner rotor, first initially operating one rotor having a higher torque and then initially operating another rotor having a lower torque, based on a comparison result, and operating the outer rotor and the inner rotor with respective target RPMs, if a predetermined time fails after the drive motor has started to operate. The method may further include detecting an amount of clothing.
[00199] The operating step of the outer rotor and inner rotor may include operating the main drum and secondary drum by rotating the outer rotor and inner rotor in opposite directions when an amount of clothing is less than an amount of clothing of reference, and rotation of outer rotor and inner rotor in the same direction with different RPMs when a garment quantity is more than the reference garment quantity.
[00200] In addition, the method for controlling the washing machine may further include detecting a temperature of the outer rotor or inner rotor, and controlling the outer rotor and inner rotor to run at the same RPM when the temperature is higher than a reference temperature.
[00201] The washing machine according to an embodiment of the present invention comprises a main body that forms an external appearance; a tub disposed inside the main body; a main drum rotatably mounted in the tub and accommodating clothing therein; a secondary drum mounted on the main drum to be relatively rotatable with respect to the main drum; a drive motor, including a stator, an outer rotor connected to the secondary drum and rotating on the outside of the stator, and an inner rotor connected to the main drum and running on the inside of the stator; and a control unit configured to drive the outer rotor and inner rotor. The control unit drives the inner rotor and outer rotor at particular RPMs, respectively, and applies a brake command to the inner rotor and outer rotor. Then, the control unit detects a first quantity of garment inside the main drum and a second quantity of garment inside the secondary drum based on the braking times of the inner rotors and the outer rotors.
[00202] In a washing machine, according to another modality of the present invention, the control unit includes a master controller configured to drive the inner rotor and to detect the first quantity of garments based on the braking time of the inner rotor; and a slave controller connected to the master controller, configured to drive the external rotor and to detect the second quantity of garments based on the braking time of the external rotor.
[00203] The master controller generates a brake command to the external rotor and transmits the brake command to the slave controller. Then the master controller generates a brake command to the inner rotor after a particular time has failed.
[00204] The washing machine further comprises a current detector configured to detect a first current and a second current applied to the inner rotor and the outer rotor, respectively.
[00205] According to an embodiment of the present invention, there is provided a method for detecting amount of clothing for a washing machine, the washing machine comprising a main body that forms an outward appearance; a tub disposed inside the main body; a main drum rotatably mounted in the tub, and accommodation of garments therein; a secondary drum mounted on the main drum to be relatively rotatable with respect to the main drum; and a drive motor, including a stator, an external rotor connected to the secondary drum and rotating on the outside of the stator, and an internal rotor connected to the main drum that rotates on the inside of the stator, the method comprising: driving the inner rotor and outer rotor initially; braking of the inner rotor and outer rotor when the inner rotor and outer rotor reach particular RPMs; and detecting a first quantity of garments inside the main drum and a second quantity of garments inside the secondary drum based on the terms of the inner rotor and the outer rotor.
[00206] The method further comprises displaying a first quantity of clothing, the second quantity of clothing, and a final quantity of clothing determined based on the first and second quantity of clothing (S160).
[00207] According to an embodiment of the present invention, there is provided a method for detecting amount of clothing for a washing machine, the washing machine comprising a main body forming an outward appearance; a tub disposed inside the main body; a main drum rotatably mounted in the tub, and accommodation of garments therein; a secondary drum mounted on the main drum to be relatively rotatable with respect to the main drum; and a drive motor, including a stator, an external rotor connected to the secondary drum and running outside the stator, and an internal rotor connected to the main drum running inside the stator, a master controller for driving the rotor. internal; a slave controller to drive the outer rotor, the method comprising driving the inner rotor and outer rotor drive through the master controller and slave controller, respectively; braking of the inner rotor and outer rotor by the master controller, when the inner rotor and outer rotor reach particular RPMs; and detecting a first quantity of garments inside the main drum and a second quantity of garments inside the secondary drum through the master controller and slave controller, based on the braking times of the inner rotor and the rotor external.
[00208] ADVANTAGEOUS EFFECTS
[00209] The present disclosure will provide the following effects with these settings.
[00210] Two drums that rotate independently of each other can be employed to allow the garment inside the drum to move three-dimensionally. Therefore, three-dimensional movements of clothing can improve the washing performance of a washing machine and reduce a washing time of the same.
[00211] A structure capable of generating the ideal three-dimensional movement of the garment can be provided in consideration of torque distribution due to the drive of the two drums, a mechanical force applied to the garment and general movements of the garment, thus improving the washing performance.
[00212] The two independent rotating cylinders can be provided with lifters, respectively, to process the movement of the garment more smoothly, thus improving the washing performance and washing time of the washing machine.
[00213] A protrusion clamping end formed on an inner side towards the center of the rotor teeth can be removed to reduce the occurrence of inferiority due to the transformation of a protrusion clamping end. In addition, leakage of a magnetic flux to the top can be prevented by virtue of the shortening of the protrusion clamping end. A recess cut such as a through hole cut can be formed within the rotor teeth in an outer circumferential direction to be integrally coupled to a bushing by injection molding, thus simplifying the assembly of the rotor integrated with a rotor core and securing the core by preventing rotor separation due to centrifugal force.
[00214] A high torque inner rotor can be provided on a main drum and a low torque outer rotor can be provided on a secondary drum through the design of the rotor inner side torque being greater than the torque on the outer side of the rotor in a way that the number of coil windings increases on the inner teeth, making a length of the inner teeth longer than the length of the outer teeth.
[00215] In the present invention, a relationship between the outside diameter of the rotor and an outside diameter of the stator of the permanent magnet motor can be optimized for a maximum torque within a predefined size. This can maximize the efficiency of the permanent magnet motor.
[00216] In the present invention, cogging torque and detorque ripple can be minimized under the height control of a tooth extension portion of the rotor teeth, a distance between surrounding tooth extension portions, an arcuate angle of the teeth of the rotor and an angle of a linear part of the tooth extension portion. This can improve vibration and noise characteristics, resulting in stable engine speed.
[00217] In a method to manufacture a double motor stator, the redundant parts after punching can be minimized and consequently the waste of components can be reduced by punching separately the internal stator and the external stator manufactured without being integral with each other and a washing machine employing the same.
[00218] In addition, two stators for driving two independent rotors can be employed, and an automatic coil winding in an aligned manner is allowed by the use of articulated coils, resulting in the improvement of a winding space factor and motor performance activation, and reduced working time.
[00219] A toothed ring to reduce cogging torque and prevent a decrease in output can be used in order to improve the performance of the drive motor.
[00220] A core having an efficient toothed structure to be used for the articulated coils can be provided, thus reducing wasted parts, which are generated by a core fabrication.
[00221] In addition, since the two stators to drive the two independent rotors can be used to be integrally mounted by an insulator, and the insulator can serve as a coil as well, stator mounting can be carried out in an easy and simple manner and the number of components and an entire size of the drive motor can be reduced. Therefore, an increase in a full size of the washing machine can be avoided, even if two stators for driving two independent rotors are used.
[00222] In aspect of an assembled structure of the bearing housing and the stator of the drive motor in the washing machine, bent portions including protruding portion and concave portion may be formed in a body of a bearing housing in order to radiate heat generated from the coil in the internal teeth (winding portions) of the stator capable of performing radiation effectively by driving and convection.
[00223] A current connector and a hall sensor connector, which have been provided in an internal stator and an external stator, respectively, can be combined into an integrated member in order to implement a simplified structure, ensure space and enhance convenience . This structure can also prevent incorrect mounting, which can result in increased convenience for mounting a dual engine.
[00224] More simplified structure can be employed by improving a shaft structure of a washing machine with double drum and double motor, thus attenuating vibrations between an inner rotor and an outer rotor to prevent unexpected noise and prevent shaft separation.
[00225] In a twin motor including an inner rotor and outer rotor, employed in a double drum washing machine, in order to improve the stator assembly process having outer teeth and inner teeth with bearing housing, a snap-in protrusion can be provided in a stator coupling opening formed in the bearing housing and a fitting recess can be provided in a housing coupling opening formed in the stator facilitates a stator mounting process in order to fix positions of housing couplings bearing and stator, thus facilitating the assembly process.
[00226] A function of an inner rotor mounting guide can be performed by employing an auxiliary mounting template for improved mounting when the inner rotor is independently coupled to the outer shaft without being coupled to one side of the bearing housing.
[00227] Two drums and an independent drive motor that can drive the two drums can be driven and controlled to allow three-dimensional movements of the garment, therefore, the garment can be easily separated from the inner circumferential surfaces of the drums after dehydration and easily released from a tangled state, thus reducing wrinkles in the garment.
[00228] Garments can be easily drawn out of the washing machine in an automatic manner after the operation of the washing machine has been completed, thus improving convenience for users.
[00229] The garment can be controlled to perform typical three-dimensional or two-dimensional movements according to a quantity of garment, in order to prevent an overload of the drive motor and achieve optimal washing performance, thus improving washing efficiency.
[00230] The garment can be controlled to perform three-dimensional movements in consideration of torque distribution due to the drive of the two drums, a mechanical force applied to the garment and general movements of the garment.
[00231] Two rotors of a double motor can be controlled to have the same RPM or time different from the start, in order to prevent an initial failure due to excess current, which can be generated by turning on the drive motor and maintaining a quantity minimum heat, thus improving the stability of the system.
[00232] Also, the rotation direction or RPM of the drive motor can be properly controlled according to loads, such as an amount of clothing, temperature and the like, in order to allow for three-dimensional movements of the clothing, resulting in improved performance of washing.
[00233] In the washing machine having two drums and a single drive motor to independently drive the two drums, an amount of garment is detected in relation to each drum. This can result in accurate detection of garment quantity.
[00234] In the present invention, the garment amounts within the two drums are detected in different ways. This can allow garment quantities to be more accurately detected and can reduce the amount of wash water and electricity required to carry out the washing, washing, rinsing and dewatering processes.
[00235] Additional scope of this application will become more evident from the detailed description given below. However, it should be understood that the detailed description and specific examples, while indicating preferred modes of disclosure, are given by way of illustration only, as various changes and modifications within the spirit and scope of the disclosure will become apparent to those versed in the technique from the detailed description.
[00236] DESCRIPTION OF THE FIGURES
[00237] The accompanying Figures, which are included to provide further understanding of the disclosure and are incorporated into and constitute a part of this specification, illustrate exemplary embodiments and together with the description serve to explain the principles of the disclosure.
[00238] In the figures:
[00239] FIG. 1 is a schematic view of a washing machine, in accordance with an embodiment of the present invention;
[00240] FIG. 2 is an exploded perspective view of a main drum and a secondary drum;
[00241] FIG. 2 is a coupled view of the main drum and the secondary drum; two;
[00242] FIG. 4 is an exploded perspective view of a drive motor;
[00243] FIG. 5 is a schematic view showing a connected state of the drive motor, main drum and secondary drum;
[00244] FIG. 5 is an enlarged view showing a secondary drum booster bead and a processed state thereof;
[00245] FIG. 7 is a flowchart showing a method for assembling the drums of a washing machine, in accordance with an embodiment of the present invention;
[00246] FIG. 7 is a schematic view showing a washing machine having a drum of which the axis of rotation is inclined in accordance with another embodiment of the present invention;
[00247] FIG. 9 is a schematic view showing movement of clothing inside the washing machine;
[00248] FIG. 9 is a schematic view showing movement of the garment in part A of FIG. 9.
[00249] FIGS. 11 to 14 are schematic views showing different exemplary modes of protecting a gap between a main drum and a secondary drum;
[00250] FIG. 15 is a schematic view of a washing machine showing a case where the axis of rotation of the drum is tilted and a case where a lifter is tilted in accordance with another exemplary embodiment;
[00251] FIG. 16 is a perspective view showing examples of a main drum lifter;
[00252] FIG. 16 is a perspective view showing examples of a secondary drum lifter;
[00253] FIG. 18 is a view showing a drive motor applied to a washing machine;
[00254] FIG. 19 is a view showing an outside diameter of a stator and an outside diameter of a rotor of a permanent magnet motor in accordance with the present invention;
[00255] FIG. 19 is a graph showing torque when the ratio between the outside diameter of a rotor and an outside diameter of a stator is in the range of 0.7~0.8;
[00256] FIG. 21 is a view showing a dimension of a tooth extension portion of the teeth of the rotor in accordance with the present invention;
[00257] FIGS. 22 and 23 are views showing minimized cogging torque and torque ripple by adjusting the gap between the tooth extension portions of the rotor teeth in accordance with the present invention;
[00258] FIGS. 22 and 23 are views showing an angle between the rotor teeth and a linear portion of a tooth extension portion in accordance with the present invention;
[00259] FIG. 22 and 23 are views showing an arrangement for manufacturing drive motor rotor teeth in a punching manner in accordance with the present invention;
[00260] FIG. 22 and 23 are partial views showing a stator and rotor of a drive motor in accordance with the present invention;
[00261] FIG. 22 and 23 are partial views showing a cutting recess, a through hole cutout and an outer circumferential curvature of the rotor tooth of a drive motor in accordance with the present invention;
[00262] FIG. 29 is a plan view showing different exemplary embodiments of the rotor tooth of a drive motor in accordance with the present invention;
[00263] FIG. 30 is a view showing a twin-motor stator formed by coupling an inner stator and an outer stator of a drive motor in accordance with the present invention;
[00264] FIGS. 31 and 32 are views showing a method for punching an inner stator and an outer stator in a method for fabricating a twin engine stator in accordance with the present invention;
[00265] FIG. 33 is a schematic view showing an exemplary embodiment of an internal stator having segment-type teeth in a drive motor.
[00266] FIG. 34 is a schematic view showing a manufacturing process for segment-type teeth.
[00267] FIG. 35 is a schematic view showing a structure and connected state of articulated coils.
[00268] FIG. 36 is a schematic view of a toothed ring.
[00269] FIG. 36 is a schematic view of an inner fork.
[00270] FIG. 38 is a schematic view showing an exemplary embodiment of an internal stator having ingreal teeth in a drive motor.
[00271] FIG. 39 is a schematic view showing a process for manufacturing integral teeth.
[00272] Fig. 40 is a flowchart showing an exemplary embodiment of a method for putting together a stator of a drive motor.
[00273] FIG. 41 is a schematic view showing a drive motor insulator.
[00274] FIG. 42 is a flowchart showing an exemplary embodiment of a method for manufacturing a drive motor for a washing machine.
[00275] FIG. 43 is a view showing the assembly of a bearing housing and a stator of a drive motor applied to the washing machine of the present invention;
[00276] FIG. 43 is a view showing a stator coupling opening of a bearing housing a drive motor in accordance with the present invention;
[00277] FIG. 45 is a view showing a casing coupling hole of a stator and a rotor of a drive motor in accordance with the present invention;
[00278] FIG. 46 is a view showing a current connector and hall sensor connector integrally fabricated with a double motor stator applied to the washing machine of the present invention;
[00279] FIG. 47 is a block diagram showing a connected state of a current connector in a stator of a double motor in accordance with the present invention;
[00280] FIG. 47 is a block diagram showing a connected state of a hall sensor and a temperature sensor in a stator of a dual engine in accordance with the present invention;
[00281] FIG. 49 is a schematic view of the washing machine in accordance with an embodiment of the present invention;
[00282] FIG. 50 is a sectional view showing an inner shaft and an outer shaft in a shaft structure for a washing machine in accordance with the present invention;
[00283] FIG. 51 is an external perspective view of an axle structure in accordance with the present invention;
[00284] FIG. 52 is a view showing a spring washer applied to the axle structure of the present invention;
[00285] FIG. 53 is a sectional view of an inner shaft and an outer shaft in a shaft structure in accordance with yet another embodiment of the present invention;
[00286] FIG. 54 is a view showing the assembly of a bearing housing and a stator of a double motor applied to the washing machine of the present invention;
[00287] FIG. 55 is a view showing a stator coupling opening of a double motor bearing housing applied to the washing machine of the present invention;
[00288] FIG. 56 is a view showing a casing coupling port of a double motor stator applied to the washing machine of the present invention;
[00289] FIG. 57 is a schematic view showing the garment is automatically drawn out of the washing machine;
[00290] FIG. 58 is a flowchart showing an operating method for the washing machine;
[00291] FIG. 59 is a block diagram showing a structure for controlling the washing machine drums;
[00292] FIG. 60 is a schematic view showing relative rotations of different drums under control of FIG. 59;
[00293] FIG. 61 is a flowchart showing an operating method for the washing machine;
[00294] FIG. 62 is a flowchart showing a control method for a washing machine according to a quantity of garments in accordance with the present invention;
[00295] FIG. 63 is a block diagram showing a schematic configuration of a washing machine motor drive apparatus in accordance with an embodiment of the present invention;
[00296] FIG. 64 is a graph showing an operation for initially driving a drive motor in accordance with an embodiment of the present invention;
[00297] FIG. 65 is a graph showing a change in operation of a drive motor in accordance with the drive order of an outer rotor and an inner rotor;
[00298] FIGS. 66 to 69 are flowcharts schematically showing a method for controlling a washing machine, in accordance with embodiments of the present invention;
[00299] FIG. 70 is a graph showing an operation for detecting a quantity of clothing by braking an outer rotor and an inner rotor using energy generated in accordance with the present invention;
[00300] FIG. 71 is a graph showing changes in currents applied to the outer rotor and inner rotor of FIG. 70;
[00301] FIG. 72 is a graph showing an operation to detect an amount of clothing by braking an outer rotor using redundant energy and by braking an inner rotor using energy generated in accordance with the present invention;
[00302] FIG. 73 is a graph showing changes in currents applied to the outer rotor and inner rotor of FIG. 72;
[00303] FIG. 74 is a block diagram schematically showing a schematic configuration of a motor drive apparatus for a washing machine in accordance with another embodiment of the present invention;
[00304] FIGS. 75 and 76 are flowcharts schematically showing a method for detecting garment quantity for a washing machine in accordance with the present invention.
[00305] FIGS. 77 to 80 are schematic views showing a secondary drum in accordance with another embodiment of the present invention;
[00306] MODE FOR INVENTION
[00307] Description will now be given in detail of the exemplary modalities, with reference to the attached figures. For the sake of brief description, with reference to the figures, the same or equivalent components will be provided with the same reference numbers, and the description thereof will not be repeated.
[00308] FIG. 1 is a schematic view of a washing machine, in accordance with an exemplary embodiment. As shown in FIG. 1, a washing machine may include a cabinet 10 defining an external appearance corresponding to a main body. A front surface of cabinet 10 is shown having an insert opening 20 for introducing garments as a target to be washed (hereinafter referred to as garments) into cabinet 10.
The introduction opening 20 can be opened or closed by a door rotatably fixed to the cabinet. A control panel 30, which has several manipulation buttons for manipulating the washing machine, can be located in a top part of cabinet 10, and a detergent supply unit (not shown) for filling with detergent can be provided to a from the sides of the control panel 30.
[00310] An accommodation space formed within the cabinet 10 is shown having a cylindrical tub 40 for storing the wash water, and a main drum 50 and a secondary drum 60, both rotatably installed within the tub 40 and receiving clothing in the same. A drive motor 70 for driving the main drum 50 and the secondary drum 60 can be arranged at the rear of the bowl 40.
[00311] The tub 40 can be in a cylindrical shape and even receive the main drum 50 and the secondary drum 60. The front face of the tub 40 can be opened in order to communicate with the introduction opening 20 of the cabinet 10. Therefore, a gasket, which encompasses the front of the tub and the cabinet introduction opening, can be located between the front of the tub and the cabinet introduction opening, whereby the washing water contained in the tub can be prevented from flow into the cabinet.
[00312] The main drum 50 may be in a cylindrical shape, rotatably mounted on the tub 40. The main drum 50 may include a plurality of through holes formed through a side surface thereof so that wash water can flow into out through them.
[00313] The secondary drum 60 can be in a cylindrical shape, rotatably mounted on the main drum 50. Here, the secondary drum 60 can be relatively rotatable with respect to the main drum 50. That is, the main drum and the secondary drum can be driven independently of each other, which allows several relative rotations according to the rotation speed and rotation direction of each drum.
[00314] The drive motor 70 is a component for generating a drive force to drive the main drum and the secondary drum and mounted on a rear surface of the bowl 40. The drive motor 70 motor may include a secure stator 71, a rotor an outer rotor 72 rotatable outside the stator and an inner rotor 73 rotatable on the inside of the stator. Such a drive motor having the two rotors can be referred to as a double rotor motor for convenience.
[00315] FIG. 4 shows drive motor 70 in more detail. As shown in FIG. 4, the stator 71 has an annular structure for surrounding the inner rotor 73, and is fixedly coupled to the side of the bowl.
[00316] FIG. 5 schematically shows a structure capable of transferring a driving force from the drive motor to the main drum and the secondary drum. As shown in FIGS. 4 and 5, the inner rotor 73 can be rotatably arranged inside the stator 71 and connected to an outer shaft 81, which will be explained later, in order to engage in the rotation of the main drum 50. Outer rotor 72 may be rotatably arranged outside stator 71 and connected to an inner shaft 82, which will be explained later, in order to engage in rotation of secondary drum 60 in rotational fashion. Each of the inner rotor and outer rotor may include magnets and consequently be rotated by magnetic fields generated by the current, when such current is applied to the inner and outer winding portions of the drive motor.
[00317] By controlling the current flow in the coils wound on the inner and outer teeth, the inner rotor and outer rotor can be rotated independently of each other. Therefore, referring to FIG. 5, the single drive motor 70 can allow the independent rotations of the main drum 50 and the secondary drum 60 from each other. That is, the drive motor can independently drive the main drum and the secondary drum.
[00318] With the configuration, the drive motor and the secondary motor are independently driven by the drive motor to induce garment rotations by the difference in the relative rotation speed between the drums, thus generating three-dimensional (3D) movements of the garment while the garment rotates on the drums.
[00319] FIGS. 2 and 3 show coupled states between shafts and drums in more detail. Referring to FIGS. 2 and 3, the outer shaft 81 can be inserted through the bowl to connect the inner rotor 73 to the main drum 50. The outer shaft 81 corresponds to a hollow shaft, so the inner shaft 82 can be mounted on the inside of the outer shaft 81. Inner shaft 82 can be inserted through outer shaft 81 to connect outer rotor 72 to secondary drum 60.
[00320] The main drum 50 and the outer shaft 81 may be connected by a spider to the main drum 91. Referring to FIG. 2, the main drum 50 may have openings in a front side 51 and a rear side 52. The main drum spider 50 can be coupled to the outer shaft 81 and secured to the main drum 50.
The secondary drum 60 and inner shaft 82 may be connected by a spider to the secondary drum 95. The secondary drum 60 may include a secondary drum forming its rear surface. The secondary drum 60 may have the front side open and the back closed by the rear of the secondary drum. The secondary drum spider 95 can be adhered in close proximity to the back of the secondary drum.
[00322] Referring to FIG. 2, the main drum spider 91 may include a shaft coupling portion 92 coupled to the outer shaft, a spider support portion 93 radially extending from the shaft coupling portion 94 provided at one end of the spider support portion. 93. Here, the drum attachment portion 94 can be fixedly coupled to the main drum 50.
[00323] The shaft coupling portion 92 may be formed in a central part of the main drum spider 91, and has a coupling groove to which the outer shaft 81 is coupled. The spider support portion 93 may include a plurality of consoles radially extending from the center. The drum fastening portion 94 may have a ring shape for connecting ends of the spider support portion 93. The spider support portion 93 may support the main drum spider to allow a driving force to be transferred to the drum. main drum after transfers of driving force transferred from the outer shaft 81 to the main drum by means of the main drum spider. Alternatively, as an exemplary variation, the spider support portion 93 may be formed into a disk shape extending from the shaft coupling portion.
The main drum spider 91 can be attached to an outer circumferential surface of the main drum. That is, the ring-shaped drum attachment portion 94 can be attached to an end portion of the outer circumferential surface of the main drum. The coupling of the drum fixing portion 94 and the outer circumferential surface of the main drum can be implemented, for example, by means of screws or by welding.
[00325] As an exemplary variation of the exemplary embodiment, the main drum may include a portion, bent from a rear end toward the center portion, and the main drum's spider attachment drum may be coupled to the bent portion.
The secondary drum 60 and the inner shaft 82 may be connected by the spider of the secondary drum 95. Still referring to FIG. 2, the secondary drum 60 may have a back of the secondary drum 62 to form its rear surface. The secondary drum 60 may have the front side open and the rear side closed by the rear of the secondary drum 62. The spider of the secondary drum 95 can be adhered in close proximity to the rear of the secondary drum 62.
The secondary drum spider 95 may include a shaft coupling portion 96 coupled to the inner shaft 82, and a plurality of drum fastening portions 97 extending radially from the shaft coupling portion 96.
[00328] Here, the ends of the attachment portions of the drum 97 can be attached to the rear of the secondary drum 62. The rear drum of the secondary drum 62 may further include a receiving portion 63 internally recessed in correspondence with the shape of the spider of the secondary drum 95. The spider of the secondary drum 95 can be received in the receiving portion 63 to be adhered in close proximity over the rear of the secondary drum 62. The coupling of the clamping portion of the drum 97 and the rear of the secondary drum 62 can be implemented, for example, by means of screws or by welding.
[00329] Referring to FIGs. 2 and 3, the secondary drum spider 95 can be provided between the secondary drum rear 62 and the main drum spider 91. However, the secondary drum spider 95 can rotate integrally with the secondary drum rear 62 and rotate independently of the main drum spider 95.
That is, the spider of the secondary drum 95 can rotate independently of the spider of the main drum 91, which allows the main drum 50 and the secondary drum 60 to rotate independently of each other. The above mentioned configurations provide the structure of the washing machine that each drum can be independently driven by the single drive motor.
[00331] Referring to FIG. 5, the outer shaft and inner shaft may have an independent mutually rotatable structure with interposition of a bearing between them. The outer rotor and inner rotor may also have independent mutually rotating structure with stator interposition between them. The stator can include winding portions on the outer rotor side and the inner rotor side separately, which allows the drive motor to rotate the outer rotor and inner rotor independently. Consequently, the main drum can be driven by the inner rotor and the secondary drum can be driven by the outer rotor, so the main drum and the secondary drum can be driven independently by virtue of the driving motor.
[00332] In addition, the independent drive of the outer rotor and the inner rotor can enable the main drum and secondary drum to perform several relative rotations. That is, such several relative rotations can be generated by making a different rotation direction or making the speed different in the same rotation direction.
[00333] As an exemplary variation of the exemplary modality, the main drum and the secondary drum may respectively include a main drum rear and a secondary drum rear, forming their respective rear surfaces. Here, both the main drum and the sub drum can have the front side open and the back side closed by the back of the main drum and the back of the sub drum, respectively.
[00334] Here, the main drum spider can be fixed onto the back of the main drum. In addition, the secondary drum spider can be attached to the back of the secondary drum. The secondary drum spider can be fitted between the back of the secondary drum and the back of the main drum. Here, the secondary drum spider can rotate integrally with the rear of the secondary drum and rotate independently of the rear of the main drum.
[00335] An outer circumferential surface of the secondary drum may face a part of an inner circumferential surface of the main drum. That is, an inner circumferential surface of the main drum and the inner circumferential surface of the secondary drum may have different lengths in an axial direction, and the outer circumferential surface of the secondary drum may face a portion of an inner circumferential surface of the main drum. Preferably, a structure where the secondary drum is smaller than the main drum, since the length in the axial direction is provided.
[00336] FIG. 1 and FIG. 5 schematically show the main drum and the secondary drum with the structure.
[00337] Referring to FIG. 5, the inner circumferential surface of the main drum and the inner circumferential surface of the secondary drum may have different lengths in an axial direction. Consequently, the secondary drum 60 can be mounted inside the main drum 50 in order to extend from an end portion of the main drum 50 in an axial direction, and the main drum 50 can be arranged so that only a portion of its inner circumferential surface faces the outer circumferential surface of the secondary drum. In this structure, the garment can come into contact with an interface between the secondary drum and the main drum, and consequently rotate in one direction due to the difference in rotation speed between the drums. Here, the garment can be rotated based on a perpendicular axis of rotation when viewed from the inner circumferential surface of the drums. Additionally, the garment may generate movement in a circumferential direction of the drum (i.e., movement in a circumferential direction) due to friction against the inner circumferential surface of the drum. Therefore, the garment can move in the circumferential direction of the drum and rotate based on the axis of rotation perpendicular to the inner circumferential surface of the drum, thereby performing movements in the axial direction (ie, movement in the axial direction) of a drum side rotated at fast speed to one side drum rotated at slow speed. Axial direction movement is generated as garment rotates based on an axis of rotation perpendicular to the inner circumferential surface of the drum. Consequently, garments can perform 3D motions by virtue of axial direction motion in addition to two-dimensional circumferential direction motions.
[00338] Referring to FIG. 1 and FIG. 5, the structure in which the secondary drum is smaller than the main drum, in view of the length in the axial direction is provided. Here, the secondary drum can be mounted inside the main drum to extend from an end portion of the main drum in an axial direction. Therefore, the outer circumferential surface 60a of the secondary drum can face an inner circumferential surface 50b of the main drum so that only a portion 50b of the inner circumferential surfaces 50a and 50b of the main drum 50 can face the outer circumferential surface 60a of the secondary drum 60 .
[00339] In more detail, referring to FIG. 3, a ratio (d2/d1) of a length d2 of the inner circumferential surface of the secondary drum in an axial direction to a length d1 of the inner circumferential surface of the main drum in an axial direction can be 0~0.5. That is, the length of the inner circumferential surface of the secondary drum in the axial direction can be less than half the length of the inner circumferential surface of the main drum in the axial direction.
[00340] More preferably, the ratio (d2/d1) of the length d2 of the inner circumferential surface of the secondary drum in the axial direction to the length d1 of the inner circumferential surface of the main drum in the axial direction can be 1/3, which is experimentally derived to cause an ideal 3D movement of the garment taking into account the torque distribution due to the drive of the two drums, a mechanical force applied to the garment and general movements of the garment.
[00341] To describe this in a different way, the inner circumferential surface of the main drum can be divided into a first surface 50a that does not face the outer circumferential surface of the secondary drum and a second surface 50b that faces the outer circumferential surface of the secondary drum. In this case, the ratio (d2/d1) of the length d2 of the inner circumferential surface 60b of the secondary drum in the axial direction to a length d1 of the first surface 50a in an axial direction can be 0.5.
[00342] From a configuration perspective, a structure that the garment can be positioned at an interface between the secondary drum and the main drum is provided. FIG. 9 shows movement of the garment within the garment merely by illustrating the first surface 50a of the main drum and the inner circumferential surface 60b of the secondary drum with which the garment is contactable. FIG. 10 is an enlarged view of an interface A where the first surface 50a of the main drum and the inner circumferential surface 60b of the secondary drum are divided.
[00343] The garment can generate a movement of serunidirectionally rotated due to a difference in rotation speed between the drums. Referring to FIG. 9, the main drum rotates counterclockwise and the secondary drum rotates clockwise. Here, it may be preferred that the absolute value of the rotation speed of the secondary drum is greater than an absolute value of the rotation speed of the main drum. If the absolute values are the same, the garment can rotate in the same place at the interface A between the main drum and the secondary drum. Therefore, for 3D garment movements, it may be preferable to make these drums rotate at different speeds so that a lot of rotational force can be applied in a single direction.
[00344] As mentioned above, FIG. 10 shows the movement of the garment in the vicinity of the interface A between the drums when the rotation speed of the secondary drum is faster than the rotation speed of the main drum. Here, the garment can be rotated in a clockwise direction B centering around a perpendicular axis of rotation Z, when viewed from the inner circumferential surface of the drums.
[00345] In addition, the garment may perform circumferential-directing movements due to friction against the inner circumferential surfaces of the drums. Therefore, the garment can rotate centering around the axis of rotation perpendicular to the inner circumferential surface of the drum with movement in the circumferential direction of the drum (i.e., performing the movement in circumferential direction), thus performing an axial direction movement. D from fast drum rotation 60 to slow drum rotation 50.
[00346] The axial direction movement D of the garment can be generated by mutually relative rotations between the main drum and the secondary drum. In more detail, the inner circumferential surface of the main drum is divided into a first surface 50a that does not face the outer circumferential surface of the secondary drum and a second surface 50b that faces the outer circumferential surface 60a of the secondary drum. Therefore, the garment can be moved in the axial direction by relative motions between the first surface 50a of the inner circumferential surface of the main drum and the inner circumferential surface 60b of the secondary drum.
[00347] From the garment perspective, the garment can be moved in the circumferential direction in response to the rotations of the main drum or the secondary drum and moves in the axial direction in response to relative movements between the main drum and the secondary drum. Here, movements in the axial direction of the garment can be made by rotations of the garment in response to relative movements between the main drum and the secondary drum. In more detail, the movement in axial direction D is caused by rotations of the garment based on an axis of rotation perpendicular to the inner circumferential surface of the drum Z. Therefore, the garment can be allowed to move in the axial direction D of the drum in addition to two-dimensional (2D) movement in the circumferential direction D, which results in the realization of 3D movements of the garment.
[00348] The arrow in FIG. 9 schematically indicates the 3D movement of the garment inside the drum. Referring to FIG. 9, the garment shows a shape of a schematically twisted tape, which is a form of movement as a result of the garment generating circumferential direction movement and a falling movement by gravity with rotation within the drum.
[00349] From the perspective of the aforementioned configuration, the main drum and the secondary drum can be driven, independently of each other, by the drive motor, in order to induce the garment to be rotated by a difference in rotation speed between the drums, enabling thus the garment performing three-dimensional movements with rotation inside the drum.
[00350] In addition, as the secondary drum has a shorter axial length than the main drum, the garment may come into contact with the interface between the secondary drum and the main drum and consequently generate the movement to be rotated by the difference in the speed of rotation between the drums, which results in the realization of 3D movements of the garment. Consequently, the realization of 3D movements of the garment can bring about the improvement of the washing efficiency and the reduction of a washing time of the washing machine.
[00351] A washing machine, in accordance with another exemplary embodiment shown in FIG. 1 has a structure in which the axis of rotation of the drums perpendicularly is disposed. However, the present disclosure may not be limited to structure. A washing machine may alternatively have a structure in which an axis of rotation of the drums is inclined by a predetermined angle. FIG. 8 shows an exemplary embodiment of the structure in which the axis of rotation is inclined. This structure can derive more various movements of the garment in response to the rotations of the main drum and the secondary drum. That is, when the garment is falling from an upper side of the drums by the force of gravity while moving in a circumferential direction along the inner circumferential surfaces in response to rotations of the main or secondary drum, the garment is falling into a position outside the existing circumferential direction route. Therefore, axial direction movement can be enabled by the force of gravity, resulting in more efficient garment movements.
Hereinafter, a structure of a secondary drum and a method of coupling the same will be described in detail with reference to FIGS. 77 to 80.
[00353] A secondary drum 60', 60' may include a cylindrical portion forming an outer circumferential portion, and a rear portion of the drum disposed on a rear surface thereof and coupled with a spider of the secondary drum. Each rear of the drum may include a receiving portion 63a, 63b recessed towards a front side so that the spider of the secondary drum is received therein.
[00354] A spider 95a, 95b may include a plurality of consoles extending radially from a center of an inner shaft, being coupled to the rear of the drum of the secondary drum 60', 60'.
[00355] As an exemplary embodiment, FIGS. 77 and 78 show a secondary drum having an integral structure of a cylindrical portion and a back of the drum.
[00356] As shown in FIGS. 6 and 7, the secondary drum 60' may have a cylindrical portion and the back of the drum that are integrally formed with each other as a member.
[00357] When molding the secondary drum 60' using an integral member, several advantages can be obtained, such that an increase in the strength of the member, and improved durability due to the non-existence of separate coupling.
[00358] In addition, vibration can be reduced or avoided because any collision is not caused between sets of components due to vibration, which is generated during the high speed rotation of the washing machine drum.
[00359] In this exemplary embodiment, since the secondary drum 60' has to be molded using the one member, a contact portion between the cylindrical portion of the secondary drum and the outer circumference of the back of the drum must be formed into a shape curved. Therefore, an internal space of the secondary drum 60' may have a somewhat small capacity due to the curved portion.
[00360] With the integral structure of the 60' secondary drum, internal capacity of the washing machine drum can be designed to approximately 90L. Furthermore, the secondary drum 60' is manufactured using a member in this exemplary embodiment. This can make it difficult to form drain holes or patterns in the secondary drum.
[00361] Referring to FIG. 78, the receiving portion 63a may include having spider coupling openings 63aa for coupling the spider to the secondary drum 95a. Secondary drum spider 95a may have coupling openings corresponding to coupling openings 63aa of receiving portion 63a.
[00362] The receiving portion 63a can receive the spider from the secondary drum 95a having the plurality of radial consoles, so that a rotational force of the spider can be transferred to the secondary drum.
[00363] The spider of the secondary drum 95 can be firmly coupled by means of coupling screws or the like, being inserted into the receiving portion 63a. To this end, the receiving portion 63a may have the coupling openings 63aa, and the spider 95a may have the corresponding coupling openings (not shown in figures)
[00364] Referring to FIG. 78, preferably, the receiving portion 63a can be formed not to contact the outer circumference of the secondary drum, and the spider consoles of the secondary drum 95a can be formed to be smaller than a radius of the rear of the secondary drum. in order to be inserted into the receiving portion.
[00365] As another exemplary embodiment of FIGS. 79 and 80 show a secondary drum having a structure independent of a cylindrical portion and a back of the drum.
[00366] As shown in FIGS. 79 and 80, a secondary drum 60" may have a cylindrical portion 61b and a rear drum 62b with members independent of each other. The rear drum 62b may be coupled to an outer circumference of a rear side of the cylindrical portion 61b to close the rear side.
[00367] Referring to FIG. 80, for coupling of the assembly type secondary drum, drum rear mating openings 61bb may be formed in a rear end portion of the cylindrical portion 61b, and the outer circumference of the drum rear 62b may be bent at a longitudinal direction of the drum. Coupling openings of the cylindrical portion 62bb can be formed in the bent portion.
[00368] With the assembly-type secondary drum structure, the rear of the drum 62b and the cylindrical portion 61a can be firmly coupled together by coupling screws or the like with the coupling openings 61bb and the coupling openings 62bb aligned with each other.
[00369] Furthermore, the receiving portion 63b of the rear of the drum 62b may extend to the outer circumference of the rear of the drum 62b. The spider consoles of the secondary drum 95b may extend to the outer circumference of the rear of the drum 62b, and end portions of the spider consoles of the secondary drum 95b may be coupled to the outer rear circumference of the cylindrical portion 61b.
[00370] Preferably, as indicated in FIG. 80, end portions of the secondary drum spider consoles 95b may be integrally together tightly by the use of coupling screws or the like, which are inserted through coupling openings 61bb and 62bb of the folded portion of the outer circumference of the rear of the drum 62b.
[00371] In accordance with the exemplary embodiment shown in FIGS. 879 and 980, comparing with the secondary drum with the integral frame, the greater internal space of the washing machine drum can be ensured, because the curved portion may not be formed in the contact portion between the cylindrical portion 61b and the outer circumference of the back of drum 62b.
[00372] When applying the set-type secondary drum of this exemplary embodiment to a double drum washing machine, an internal space with a capacity of about 94L can be ensured, the secondary drum capacity increase of approximately 4L in comparison with the integral type secondary drum.
[00373] Furthermore, in this exemplary embodiment, the secondary drum 60" can be manufactured by putting together the cylindrical portion with the back of the drum. Therefore, the processing task such as the formation of drainage openings or patterns in each member can be carried out before an assembly process. Consequently, the processing of the drainage openings and patterns can be facilitated compared to the secondary drum with the integral structure.
[00374] However, this exemplary embodiment can allow independent members to be placed together with one another to manufacture the secondary drum 60". This can be disadvantageous compared to an integral member, in view of the strength of the set of members. In addition, collision between assembly components can be caused due to vibration generated during the high rotation speed of the washing machine drum.This can have a disadvantage in view of vibration.
[00375] Another exemplary embodiment of the present disclosure may provide a method for putting together an assembly-type secondary drum shown in FIGS. 79 and 80.
[00376] As shown in FIG. 80, a method for putting together a secondary drum of a washing machine may include coupling the rear of the drum 62b, which is disposed on the rear surface of the secondary drum and coupled with the spider of the secondary drum 95b to the cylindrical portion 61b that forms the outer circumferential portion of the secondary drum 60".
[00377] Thereafter, the method may further include receiving the spider from the secondary drum 95b in the spider receiving portion 63b recessed towards the front of the rear of the drum 62b, and coupling the end portions of the drum slot consoles 95b by inserting screws through coupling openings formed in the rear end portion of the cylindrical portion 61b of the secondary drum and the curved outer circumference of the rear drum 62b, respectively.
[00378] Meanwhile, referring to FIG. 3, the inner circumferential surface of the main drum is shown having a drum guide 55 for sealing an outer circumferential surface gap of the secondary drum. The drum guide 55 can be provided along the inner circumferential surface of the main drum and seals the gap from the outer circumferential surface of the secondary drum. This is to prevent the garment from being crushed between the drums.
[00379] Referring to FIG. 3, the secondary drum is smaller than the main drum in radius. The secondary drum, therefore, can be mounted inside the main drum. Consequently, some gap can be generated between the inner circumferential surface of the main drum and the inner circumferential surface of the secondary drum.
[00380] FIG. 11 shows an exemplary embodiment of the drum guide. Drum guide 55 may include a body portion 56 coupled over the inner circumferential surface of the main drum to protrude from the main drum, and a guide portion 57 extending toward the inner circumferential surface of the secondary drum.
[00381] As already mentioned, the gap is generated between the inner circumferential surface of the main drum and the inner circumferential surface of the secondary drum. The guide portion 57 of the drum guide 55 can seal the gap extending to the inner circumferential surface of the secondary drum. That is, the inner circumferential surface of the main drum and the inner circumferential surface of the secondary drum form a non-continuous surface due to the difference in radius. The drum guide can allow the inner circumferential surfaces to be continuous. Therefore, the garment can be prevented from being damaged due to being crushed at the interface between the drums, even though it generates the aforementioned axial direction movement. Especially, when two drums are driven independently, as shown in the washing machine of this specification, the main drum and the secondary drum perform the relative rotations. Thus, when the garment is crushed at the interface, there may be a lot of room to damage the garment, so the drum guide can be more efficient in protecting the garment.
[00382] More preferably, the body portion 56 may have a slope or curved surface to some degree, thus forming an easy slope or continuous surface from the bottom surface of the main drum to the guide portion 57. With this configuration, the resistance in relation to the axial direction movement of the garment within the drum can be reduced, resulting in more smooth garment movements.
[00383] Furthermore, a reinforcing bead 65 to prevent twisting of the secondary drum can be provided on the inner circumferential surface or on the outer circumferential surface of the secondary drum. Referring to FIG. 11, the secondary drum 60 may preferably be provided with the reinforcing bead 65 protruding from the secondary drum along the circumferential surface and being spaced apart from an end portion of the secondary drum at a predetermined interval. Of course, the reinforcing bead 65 may protrude towards the outer circumferential surface of the secondary drum.
The bead reinforcement 65 can serve to prevent twisting of the drum by reinforcing the strength of the secondary drum. Here, the guide portion of the drum guide can extend to the bead of the secondary drum. Therefore, the secondary drum strength reinforcing bead can prevent the inner circumferential surface of the secondary drum from being non-continuous and forms the continuous surface to be useful for garment movements.
[00385] FIG. 12 shows another exemplary embodiment of the drum guide. Referring to FIG. 12, the secondary drum 60 may include a bead 65 protruding outside the secondary drum along the circumferential surface and being spaced apart from an end portion 61 of the secondary drum 60 at a predetermined interval. Guide portion 57 of drum guide 55 may extend over end portion 61 of secondary drum. Unlike the aforementioned exemplary embodiment, the bead 65 does not protrude from the secondary drum, so the guide portion 57 need not extend to the bead 65. Consequently, the guide portion 57 of the drum guide 55 can extend only up to the end portion 61 of the secondary drum.
[00386] This configuration can prevent garments from being crushed at the interface where the main drum and the secondary drum, driven independently by the drum guide, perform the relative rotations.
[00387] FIGS. 11 and 12 show that the end portion 61 of the secondary drum is crimped out along the circumferential surface. This is to prevent the garment from being crushed due to the end portion of the secondary drum, by processing the end portion of the secondary drum to have a curved surface.
[00388] FIG. 13 shows another exemplary embodiment of a washing machine. Referring to FIG. 13, the main drum 50 can be divided into a first portion 50a and a second portion 50b having internal diameters different from each other. Here, the inside diameter of the first portion 50a can be the same as the inside diameter of the secondary drum, and the inside diameter of the second portion 50b can be larger than the outside diameter of the secondary drum 60.
[00389] This is intended to extend the part (i.e., 50b) of the main drum, so that the radius of the portion 50a of the main drum may be the same as the radius of the inner circumferential surface of the secondary drum, in which the surface The circumferential internal main drum and the circumferential surface of the secondary drum can be flush with each other. Here, the secondary drum can be mounted inside the second portion 50b of the main drum, to be rotatable within the main drum. Here, the end portion 61 of the secondary drum can also be crimped out along the circumferential surface, being located within the second portion 50b.
[00390] With the configuration, the structure that prevents the garment from being crushed is produced during the formation of the drums without the use of a separate guide or the like, thus protecting the interface between the main drum and the secondary drum. In addition, the inner circumferential surfaces of the main drum and the secondary drum where the garment contacts can be continuous, so as to reduce resistance against garment movements, thus making the garment being moved softer.
[00391] In the meantime, FIG. 14 shows another exemplary embodiment of a washing machine. As shown in FIG. 14, main drum 50 may further include a drum guide assembly 58 protruding from the drum along the inner circumferential surface thereof. In this structure, the inner circumferential surface of the drum guide unit 58 can be flush with the inner circumferential surface of the secondary drum, thus protecting the interface between the main drum and the secondary drum. The end portion of the secondary drum may also be crimped outward along the circumferential surface, being located outside more than the inner circumferential surface of the drum guide unit.
[00392] The position where the garment is crushed or movement of the garment is stopped is where a gap is formed due to a difference in radius between the main drum and the secondary drum. Consequently, the main drum portion can be formed to protrude from the interface where the gap is formed. Such a protruding portion may allow the radii of the inner circumferential surfaces of the main drum and the secondary drum to be the same at the interface between the main drum and the secondary drum. Consequently, the inner circumferential surfaces of the main drum and the secondary drum that the garment comes into contact with can become a continuous surface, whereby the garment cannot be easily crushed at the interface and the resistance against movement of the garment can be reduced, resulting in smoother garment movements. The structure that prevents crushing of the garment can also be produced during the formation of the drums without the use of a separate guide or the like.
[00393] Referring to FIG. 1, a plurality of main drum lifters 101 protrude from an inner circumferential surface of the main drum towards the inside in a radial direction, and a plurality of secondary drum lifters 102 protrude from an inner circumferential surface of the secondary drum for the inside in a radial direction. This can allow the laundry to move smoothly in the drum.
[00394] An inner circumferential surface of the main drum may be divided into a first surface 50a that does not face an outer circumferential surface of the secondary drum 50b that faces an outer circumferential surface of the secondary drum. Main drum elevators 101 are provided on the first surface 50a.
[00395] The main drum lifters 101 may be arranged with the same spacing therebetween along an inner circumferential surface of the main drum. And, the secondary drum lifters 102, may be arranged with the same spacing therebetween along an inner circumferential surface of the secondary drum.
[00396] A plurality of lifters is provided on the inner circumferential surface of the drum so that the garment inside the drum can perform 3D movements.
[00397] The extension ratio of the main drum lifter 101e of the secondary drum lifter 102 in an axial direction may be proportional to a length of the first surface 50a of an inner circumferential surface of the main drum, and a length of the inner circumferential surface 60a of the secondary drum. Referring to FIG. 3, an extension of the main drum lifters 101 in an axial direction can be defined as l1, an extension of the secondary drum lifters 102 in an axial direction can be defined as l2, an extension of the first surface 50a of the inner circumferential surface of the drum main can be defined as d1 and an extension of the inner circumferential surface 60a of the secondary drum can be defined as d2. In this case, a ratio of l1:l2 can be proportional to a ratio of d1:d2. This is to provide, respectively, the lifters on the main drum and the secondary drum having different extensions in the axial direction and to allow the lifters to contact the garment effectively.
[00398] Referring to FIG. 3, main drum lifters 101 and secondary drum lifters 102 are provided on the drum in parallel with an axial direction. However, the present disclosure is not limited thereto. For example, main drum lifters and secondary drum lifters can be arranged at a predetermined angle from an axial direction.
FIG. 15 illustrates that the main drum lifters and the secondary drum lifters are arranged at a predetermined angle from an axial direction. Referring to FIG. 15, the main drum lifters and the drum lifters are inclined with a predetermined angle (θ) from an axial direction.
[00400] In this case, a rotation direction of the main drum is determined according to an angle direction of the main drum lifters with respect to an axial direction, and a rotation direction of the secondary drum can be determined according to a direction of angle of the secondary drum lifters with respect to an axial direction. That is, a drum rotation direction is determined based on an inclined direction of the lifters, so that the garment inside the drum can smoothly perform 3D movements by the lifters. When the washing machine in FIG. 15 is viewed from one side of the insertion opening, the main drum 50 rotates clockwise, but the secondary drum 60 rotates counterclockwise. However, the present disclosure is not limited thereto. That is, a lifter's pitch direction can be controlled. Under this configuration, garments can move in an axial direction towards the center of the drum, to thus perform 3D movements when the drum rotates.
[00401] Referring to FIGS. 1 and 3, main drum lifters 101 are extending rearward from a front end of the main drum and sub drum lifters 102 are extending forward from a rear end of the sub drum. And, the main drum lifters and the secondary drum lifters have inclines that become lower in the opposite direction.
[00402] This is in order to prevent the garment from being concentrically arranged on the inside or outside of the drum due to its movements in an axial direction, however, in order to allow the garment to be positioned in the center of the drum for movements in 3D of the garment.
[00403] FIG. 16 illustrates examples of the main drum lifters 101. Referring to FIG. 16, the main drum lifter of FIG. 16a is larger than the main drum lifter of FIG. 16b in an axial direction. The reason is because a washing machine, which the main drum lifter in FIG. 16a is applied has a higher rate than a washing machine, to which the main drum lifter of FIG. 16B is applied. Here, a ratio indicates a ratio of a length of the first surface 50a of the inner circumferential surface of the main drum in an axial direction, relative to a length of the inner circumferential surface 60a of the secondary drum in an axial direction.
[00404] Sectional heights in a radial direction of the main drum lifters 101 become lower towards a rear side of the main drum along an axial direction. Referring to FIG. 16, viewed from an inlet opening side of the washing machine, the main drum lifters 101 have heights which become lower towards a rear side 52 of a front side 51 of the main drum.
[00405] FIG. 17 illustrates examples of secondary drum lifters 102. Referring to FIG. 17, like the main drum lifters, the secondary drum lifters can have different lengths according to a length ratio of the first surface 50a of the inner circumferential surface of the main drum in an axial direction, relative to a length of the inner circumferential surface 60a of the secondary drum in an axial direction. Sectional heights in a radial direction of the secondary drum lifters 102 become lower towards a front side of the secondary drum along an axial direction. Referring to FIG. 17, viewed from an inlet opening side of the washing machine, the secondary drum lifters 101 have heights which become lower towards a front side 61 of a rear side 62 of the main drum.
[00406] This configuration is implemented to allow the garment on the inside of the drum to move in an axial direction, thus performing 3D movements.
[00407] Main drum lifters 101 or secondary drum lifters 102 may be formed to have a straight slope or a curved slope along an axial direction. FIG. 17 illustrates inclined secondary drum lifters. More specifically, FIG. 17a illustrates a secondary drum lifter to which a straight line type (A) slope has been applied, and FIG. 17B illustrates a secondary drum lifter to which a bent-type slope (B) has been applied. These various tilt types are implemented in order to allow garments on the inside of the drum to move in an axial direction to perform 3D motions.
[00408] In the function aspect, the main drum lifters 101 and the secondary drum lifters 102 can guide movements of the garment in a circumferential direction. Since the lifters protrude from an inner circumferential surface of the drum in a radial direction, the garment can be forcefully moved in a circumferential direction of the drum in accordance with the rotation of the drum.
[00409] Slopes facing the main drum lifters and the secondary drum lifters can guide garment movements in an axial direction. As mentioned earlier, these tilts of the lifters in an axial direction are implemented in order to allow the garment on the inside of the drum to move in an axial direction, to thus perform 3D movements.
[00410] Referring to FIG. 2, a balancer 56, to prevent vibrations, and an eccentric state of the drum can be provided on the front side 51 of the main drum.
[00411] Hereinafter, a drive motor 70 applied to the washing machine of the present disclosure will be explained in more detail with reference to various embodiments.
[00412] As shown in FIG. 19, a stator 2000 of a permanent magnet motor is formed in a ring shape and includes stator teeth 2021 protruding towards the central core and stator slots 2023, each formed between the stator teeth 2021. A rotor 1000 is installed on the inside of stator 2000 in a spaced state from an inner circumferential surface of stator 2000 and is formed in a ring shape. A coil (C) is wound over the teeth of stator 2021, and an induced electromotive force is generated as current flows to the coil (C).
[00413] The rotor includes a plurality of teeth of rotor 1100 arranged in a ring shape with a constant gap therebetween, and each permanent magnet (M) is installed between teeth of rotor 1100. The teeth of rotor 1100 are integrally mounted in a rotor shaft 2030 by a bushing 2040. The rotor teeth 1100 and the bushing 2040 are integrally coupled together as an injection molding material of the bushing is inserted into a recess on the bushing side of the rotor teeth 1100.
[00414] The stator 2000 and the rotor 1000 are arranged to be concentric with each other in a state spaced apart from each other. The rotor rotates by the current applied to the coil (C) wound on the teeth of the stator 2021, and a magnetic force from the permanent magnet (M) mounted between the teeth of the rotor 1100.
[00415] According to another modality of the present disclosure, a permanent magnet motor is provided comprising: a stator 2000 including stator teeth 2021 and stator slots 2023, and fixedly installed as a coil (C) which is wound on the teeth of the 2021 stator; and a rotor 1000, including rotor teeth 1100, a permanent magnet (M) and a bushing 2040, the rotor spaced from an inner circumference of the stator 2000 and rotating around the center of a rotor shaft 2030 by a magnetic force. A ratio of an outer diameter (Dr) of the rotor 1000 to the outer diameter (Ds) of the stator 2000 is in the range of 0.7 ~ 0.8.
[00416] A rotation force, torque of the permanent magnet motor rotor is calculated by the following formula.
[00417] [Formula 1]
[00418]

[00419] T: Torque
[00420] k: Constant
[00421] Lst: Teeth lamination height
[00422] Nph: The number of coil winding turns
[00423] Rro: Rotor outer diameter (= Dr)
[00424] Bg: Magnetic density of the permanent magnet
[00425] I: Current applied to the coil
[00426] According to Formula 1, torque (T), a rotor rotational force is proportional to each rolling height (Lst) of stator teeth and rotor teeth, and the number of winding turns (Nph) of a coil. That is, when the lamination height (Lst) of the stator teeth is increased, the amount of coil winding is increased. And when the number of tortuous curves (Nph) is increased, the amount of coil winding increases. The reason is because the torque (T) is increased as current has greater intensity due to a large amount of current applied to the coil.
[00427] The rotor torque (T) is increased as current applied to the coil winding on the outer circumference of the stator teeth is increased. Therefore, the current (I) applied to the coil, the lamination height of the teeth (Lst) and the number of winding turns (Nph) serve as factors to increase the current intensity.
[00428] A magnetic force of the permanent magnet (M) is increased proportionally to the magnetic density (Bg) of the permanent magnet of the rotor and an outer diameter of the rotor (Rro = Dr). Therefore, the torque (T) of the rotor is increased proportionally in relation to the outer diameter of the rotor (Rro = Dr) and the magnetic density (Bg) of the permanent magnet.
[00429] Assuming that the lamination height of the teeth (Lst), the magnetic density (Bg) of the permanent magnet and the current intensity (I) applied to the coil are constant, the torque intensity (T) can be increased by two factors, the number of winding turns (Nph) and the rotor outer diameter (Rro = Dr).
[00430] In general, a permanent magnet motor applied to a washing machine has a limited size. Therefore, the roll height of the teeth (Lst) and the outside diameter (Ds) of the 2000 stator are limited to a few degrees. Furthermore, since the magnetic density (Bg) of the permanent magnet and the current intensity (I) can be arbitrarily input from the outside, they are excluded from the factors when designing the permanent magnet motor of the present invention.
[00431] Under this configuration, the torque intensity (T) can be determined by the number of sinuous curves (Nph) and the rotor outer diameter (Rro = Dr).
[00432] The number of sinuous curves (Nph) is proportional to the length of the teeth of the stator 2021 of FIG. 19, which is determined by a ratio between the rotor diameter (Dr) and the outside diameter (Ds) of the stator (Dr / Ds).
[00433] FIG. 20 is a graph showing a motor torque (Nm) value according to the relationship between the rotor diameter (Dr) and the outside diameter (Ds) of the stator (Dr / Ds), in a state where the intensity of the current (I) applied to the coil has three different values. Referring to FIG. 20, the torque value is maximum when the ratio (Dr / Ds) is in the range of 0.7~0.89.
[00434] In the present invention, the rotational force of the permanent magnet motor is maximized when the ratio between the rotor diameter (Dr) and the outside diameter (Ds) of the stator (Dr / Ds) is kept in the range of 0.7 ~ 0.8.
[00435] According to another embodiment of the present invention, the teeth of the rotor 1100 include teeth extension portions 1110 protruding from the right and left sides of the teeth towards the outer diameter of the rotor 1100. The end of the teeth extension portion 1110 has a height less than 0.3mm, and a distance (DW) between 1110 tooth extension portions of 1100 surroundings rotor teeth is in the range of 5.5mm~6.5mm.
[00436] Preferably, an end portion of the outer diameter of the rotor teeth 1100 is formed so that the rotor teeth 1100 have an arc angle of 60°.
[00437] Referring to FIG. 21, the rotor teeth 1100 of the present invention are provided with tooth extension portions 1110 protruding from the right and left sides of the rotor teeth 100 in an outer diameter direction. An upper surface of the teeth extension portion 1110 forms a linear portion 1113 and the linear portion 1113 is curved towards a central upper surface 1103 of teeth of the rotor 1100 and the center of the core.
[00438] The top center surface 1103 of rotor1100 teeth has an arc angle (A1) of 60° in order to minimize cogging torque and torque ripple.
[00439] As shown in FIG. 21, the height (DH) of the end of the 1110 tine extension portion is set to be small in order to reduce the cogging torque and torque ripple. However, the height (DH) is preferably set to be 0.3mm or less, as a minimum value for processing.
[00440] FIGS. 21, the height (DH) of the end of the teeth-extending portion 1110 is set to be small in order to reduce the cogging torque and torque ripple. 21.
[00441] Referring to FIG. 22, cogging torque is minimum (referring to the oblique line) when the distance (DW) between length portions of teeth 1110 of the teeth of neighboring rotor 1100 is 1.0 mm or less, or is in the range of 5.5 mm ~6.5mm.
[00442] As shown in FIG. 23, Torque ripple is minimum when the distance (DW) is 1.0 mm or less. And, the torque ripple is gradually increased, but it is decreased when the distance (DW) is in the range of 5.0mm ~ 6.5mm.
[00443] Preferably, the distance (DW) between tooth-extending portions of neighboring rotor teeth is 1.0 mm or less. However, this setup for manufacturing an engine is substantially too difficult. Therefore, the distance (DW) is defined to be in the range of 5.5 mm ~ 6.5 mm.
[00444] According to yet another embodiment of the present invention, the tooth extension portion 1110 of the rotor teeth 1100 is provided with a linear extension portion 1113 on an outer circumference thereof. An angle between the linear extension portion 1113 and a straight line of the end of the teeth of the extension portion relative to the center of the core is in the range of 90° ~ 100°.
[00445] As shown in FIG. 24 (A2 = 90°) and FIG. An angle between the linear extension portion and a straight line of the teeth end of the extension portion relative to the center of the core is in the range of 90° ~ 100°. If the angle (A2) is in the range of 90° ~ 100°, cogging torque and torque ripple can be minimized.
[00446] The occurrence of cogging torque or torque ripple can be influenced by a degree of bending of the tooth extension portion 1110 of an inner diameter of stator 2000 towards the center of the core.
[00447] that is, when the tooth extension part 1110 is formed to be parallel to the inner diameter of the stator 2000, cogging torque can be reduced due to no leakage of magnetic flux. However, in this case, it is difficult to reduce vibrations and noise due to torque ripple.
[00448] On the other hand, when the teeth extension part 1110 is excessively curved towards the center of the core, ripple can be reduced. However, in this case, it is difficult to reduce vibrations and noise due to torque ripple. This can result in the occurrence of large cogging torque.
[00449] In the present invention, the angle (A2) is set to be in the range of 90 ~ 100 for cogging torque minimization and torque ripple. This can minimize vibrations and noise when the permanent magnet motor rotates, thus implementing stable operation.
[00450] First, a structure of a drive motor 70 applied to the washing machine of the present disclosure will be explained in more detail. As the washing machine drive motor 70, a permanent magnet motor is used.
[00451] The permanent magnet motor rotor structure is to attenuate vibration due to rotation damping and to decrease cogging torque, improving the shape of a circumferential outer surface of 1100 rotor teeth and to prevent separation between the teeth of the rotor 1100 and the permanent magnet (M) due to a centrifugal force from a recess cut 1150.
[00452] Hereinafter, a permanent magnet motor rotor structure applied to the washing machine of the present invention will be explained in more detail with reference to FIGS. 18 to 29.
[00453] FIG. 18 is a view showing an inner core of the permanent magnet motor applied to the washing machine, FIG. 26 is a plan view showing an arrangement for fabricating the rotor teeth in the form of a bore, FIG. 27 is a partial view showing a stator and rotor of the permanent magnet motor, FIG. 28 is a partial detailed view showing a cutting recess, a cutting opening and an outer circumferential curvature of the rotor tooth and FIG. 29 is a planar view showing different exemplary rotor tooth modalities.
[00454] The permanent magnet motor of the present disclosure includes a stator 2000 and a rotor 1000. The stator 2000 has stator teeth 2021 and stator slots 2023, and fixedly installed as a coil is wound over the stator teeth. The rotor has 1100 rotor teeth, a permanent magnet (M) and a 2040 bushing, is spaced from an inner circumference of the 2000 stator, and rotates centered around a rotor axis by a magnetic force. The rotor teeth 1100 consist of a tooth extension portion 1110 extending from a lateral end of an outer circumference of the rotor teeth in a circumferential direction, a cutting recess 1150 concavely cut from the outer circumference of the rotor teeth. rotor teeth towards the center of the rotor shaft and an insert recess 1130 cut concavely in a radial direction of an inner circumference of the rotor teeth for inserting an injection molding material from the bushing therein.
[00455] Basic configurations of stator 2000 and rotor 1000 have been mentioned above. Therefore, the present disclosure will be explained primarily with the teeth of rotor 1100. FIGS. 18 to 29 illustrate a permanent magnet motor having a single rotor structure. However, the permanent magnet motor can have a double rotor structure, including an inner rotor and an outer rotor.
[00456] As shown in FIGS. 18 and 26, the teeth of rotor1100 are formed in an approximate trapezoidal shape and are formed in a conical shape such that an upper surface has a predetermined curvature and the two sides have gradually reduced widths in a downward direction.
[00457] The cutting recess 1150 is concavely formed at the center of an upper surface of the rotor teeth 1100, and the insertion recess 1130 is concavely formed at the center of a lower surface of the rotor teeth 1100.
[00458] The tooth extension portion 1110 is protruding from the top of the rotor teeth 1100 in left and right directions.
[00459] First, the manufacturing processes of the 1100 rotor teeth will be explained. As shown in FIG. 26, a plurality of teeth of rotor 1100 are arranged to face each other in a zigzag direction and are then drilled. In the present disclosure, the final clamping protrusion is removed from the conventional rotor teeth, and the insertion recess 1130 internally is formed to fabricate the rotor teeth 1100 into a bore shape. This can reduce the amount of redundant parts after drilling, thereby reducing component waste and enhancing an economic feature.
[00460] Referring to FIG. 27, insertion recess 1130 includes a first insertion recess 1131, through which an injection molding material of bushing 2040 is inserted into teeth of rotor 1100, and a second insertion recess 1132 extending from the first insertion recess. 1131 to a radial direction of the rotor shaft, and integrally securing the bushing 2040 and the teeth of the rotor 1100 after the hardening of the injection molding material of the bushing 2040 inserted therein has hardened.
[00461] The first insertion recess 1131 serves as a pathway along which a molding material is inserted, by liquid injection of the bushing being inserted. As shown in FIG. 27, the first insertion recess 1131 is concavely formed on an inner side of rotor teeth 1100.
[00462] Insertion recess 1130 can be formed in various shapes and can have all ways of integrating bushing 2040 and rotor teeth 1100 with each other, after an injection molding material of bushing 2040, inserted therein be hardened.
[00463] Referring to FIGs. 27 and 29, the second insertion recess 1132 may be formed as a circular or oval through-hole having a diameter greater than the width of the first insertion recess. Alternatively, the second insert recess 1132 may be formed as a polygonal through hole having a width greater than a width of the first insert recess 1131.
[00464] Preferably, the second insertion recess 1132 is formed as a triangular through hole, so that the second insertion recess 1132 and the first insertion recess 1131 entirely from an opening in cross section having an arrow shape.
[00465] In the present disclosure, a protrusion clamping end formed on an inner side towards the center is removed from the teeth of the rotor 1100. This can reduce the occurrence of inferiority due to the transformation of the protrusion clamping end, can facilitate an assembly and can prevent leakage of a magnetic flux to the top.
[00466] In addition, the rotor teeth and the 2040 bushing are integrally injection-moulded through the 1130 insert vacation. This can allow the rotor teeth to simply be assembled with the rotor core.
[00467] As shown in FIGS. 20 and 21, the cutting recess 1150 can be concave in the center of an upper surface of the teeth of the rotor 1100. This is to reduce the inconsecutive rotations of the teeth of the rotor 1100, the inconsecutive rotations occurring due to a difference in magnetic force between the 2023 stator slot and 2021 stator teeth when the spaced 1100 rotor teeth of 2000 stator rotate by a magnetic flux formed by the coil wound over the 2021 stator teeth and the permanent magnet.
[00468] Thus, the cutting recess 1150 is preferably concave from an upper surface of the rotor teeth 1100.
[00469] As shown in FIGS. 29b and 29c, the cutting recess 1150 is cut into a conical shape, which a width is narrowed towards the center from an upper surface of the teeth of the rotor 1100, thus having a controlled distance from an inner circumferential surface of the stator 2000 This can minimize the occurrence of inconsecutive points of a rotational force.
[00470] The teeth of the rotor 1100 may further include a cut opening 1160, which extends from the cut hole 1150 towards the center, and forming a flow barrier, insofar as an injection molding material of the bushing is there filled.
[00471] Preferably, the cut opening 1160 that forms a flow barrier is formed in a circular or oval shape, having a diameter greater than a width of the cut recess 1150, in order to prevent the escape of a magnetic flux from the magnet. permanent (M), positioned between the teeth of the rotor 1100 and the teeth of the rotor 1100.
[00472] In order to maximize the magnetic force between the teeth of rotor 1100 by a magnetic flux of the permanent magnet (M) positioned between the teeth of the rotor 1100. And, the teeth of the rotor 1100 have a rotational force by a magnetic flux formed by coil wound on teeth of the 2021 stator and permanent magnet (M). In order to maximize the magnetic force between rotor teeth 1100 and stator teeth 2021, leakage of a magnetic flux from the permanent magnet (M) is preferably minimized. Therefore, an additional flow barrier is generally installed on the tooth extension portion 1110 of the rotor teeth 1100.
[00473] However, in the present disclosure, the cut opening 1160 is additionally formed at a point extending from the cut recess 1150 of the rotor teeth 1100 and serves as a flow barrier. This can simplify the entire structure and facilitate fabrications.
[00474] Preferably, cut opening 1160 serving as a flow barrier is formed to have a width greater than cut recess 1150 in order to prevent the escape of a magnetic flux. As shown in FIG. 29, the cut opening 1160 can be formed in various shapes.
[00475] As shown in FIG. 28, the cutting recess 1150 and the cutting opening 1160 of the rotor teeth 1100 are filled with an injection molding material 2043 of the bushing 2040. This can prevent the separation of the rotor teeth of the rotor 1100 from the rotor core and may reduce torque from cogging as mentioned earlier.
[00476] As shown in FIGS. 27 and 28, since a space between the extending portion of the teeth 1110 of the teeth of the rotor 1100 and the permanent magnet (M) is filled with the injection molding material 2043 of the bushing 2040, the teeth of the rotor 1100 and the magnet permanent (M) are fully fixed to each other. This can prevent the teeth of rotor 1100 from separating from the rotor core due to centrifugal force.
[00477] Referring to FIG. 27, an outer circumferential end of rotor teeth 1100 has a greater curvature than that of the annular rotor. This can change a spacing distance between the outer circumferential surface of rotor teeth 1100 and an inner circumferential surface of stator 2000.
[00478] More specifically, a distance spacing between an outer circumference of the rotor teeth 1100 and an inner circumference of the stator 2000 is controlled by setting a curvature of the extension portion of the teeth 1110 to be different from a curvature of the rotor core. This can attenuate rotational dampening vibrations and can reduce cogging torque.
[00479] In addition, a spacing distance (H1) between two ends of the tooth extension portion 1110 and an inner circumferential surface of the stator 2000 is preferably formed to be longer than a spacing distance (H2) between the end of the cutting recess 1150 and circumferential inner surface of stator 2000. As shown in FIG. 27, as the rotor 1000 approaches to the stator teeth 2021 while rotating along the circumferential outer surface of the rotor teeth 1100, the spacing distance decreases to H2 from H1. As the spacing distance gradually decreases, the magnetic force gradually increases. Furthermore, such a drastic change in rotational force is minimized to reduce vibrations.
[00480] In the present disclosure permanent magnet motor, the rotor teeth 1100 and the permanent magnet (M) are arranged in a ring shape and a 2040 bushing injection molding material is filled a space between them to be hardened. This can implement the rotor in an integrated way.
[00481] Then, the injection molding material is filled in the cutting recess 1150 and the insertion recess 1130 of the rotor teeth 1100, and is filled formed by the teeth extension portion 1100 of the rotor teeth 1100 and the permanent magnet ( M). This can correct the core as long as the rotor teeth and permanent magnet are integrally formed to prevent separation due to centrifugal force.
[00482] Before explaining a method for manufacturing a dual motor stator of the drive motor 70 applied to the washing machine of the present disclosure, a configuration of a dual motor stator of the present disclosure will be explained.
[00483] Referring to FIG. 30, the double motor stator of the present disclosure includes an inner stator 3100 including a plurality of inner teeth 3110 protruding toward the center in a ring shape, an inner yoke 3130, which forms a ring shape of an inner stator, and inner grooves. 3150 serving as spaces between the inner teeth 3110 and the inner yoke 3130; and an outer stator 3200 including a plurality of outer teeth 3210 protruding in a radial direction into a ring shape, an outer yoke 3230 contacting an outer circumferential surface of the inner yoke 3130 and forming a ring shape of the outer stator and outer grooves 3250 serving as spaces between the outer teeth 3210 and the outer yoke 3230; and an insulator 3300 installed between an outer circumferential surface of the outer yoke 3130 and an inner circumferential surface of the outer yoke 3230, and shielding from magnetic force.
[00484] As shown in FIG. 30, the inner stator 3100 is provided with an inner rotor mounting portion 3500 for mounting an inner rotor, and is provided with a rotor shaft in the center of it.
[00485] The 3100 internal stator includes a 3130 internal yoke formed in an annular belt. A plurality of inner teeth 3110 protrude, towards the center, from a circumferential inner surface of inner inner yoke 3130 of inner stator 3100 with a predetermined gap therebetween.
[00486] The inner teeth 3110 are provided with an extension portion of inner teeth 3111 extending from the right and left sides thereof, so that a plurality of inner grooves 3150, spaces formed by the inner teeth 3110, the extension portions of internal teeth 3111 and the internal yoke 3130 can be implemented repeatedly with a predetermined gap between them.
[00487] As shown in FIG. 30, the outer stator 3200 is formed in a ring shape, which spans the outer circumferential surface of the inner yoke 3110 of the inner yoke 3100 and is provided with an outer rotor mounted on an outer surface thereof. Although not shown, the outer rotor implements a dual rotor system along with the inner rotor as it rotates.
[00488] The 3200 outer stator includes a 3230 outer yoke formed in an annular belt. As the outer circumferential surface of the inner yoke 3130 contacts an inner circumferential surface of the outer yoke 3230, an integrated dual motor stator is implemented.
[00489] On the outer circumferential surface of the outer yoke 3230 of the outer stator 3200, the outer teeth 3210 protrude in a radial direction with a predetermined gap therebetween.
[00490] The external teeth 3210 are provided with an extension portion of external teeth 3211 extending from the right and left sides thereof, so that a plurality of external grooves 3250, spaces formed by the external teeth 3210, the extension portions of outer teeth 3211 and the outer yoke 3230 can be implemented repeatedly with a predetermined gap between them.
[00491] The insulator 3300 can be installed between the outer circumferential surface of the inner fork 3130 and the outer circumferential surface of the outer fork 3230 fixedly coupled to each other in an opposing manner with a gap between them. In order to protect from an electromagnetic force, the inner fork and the outer fork are coupled together with a gap between them, and an insulating member is referentially inserted into the gap between them.
[00492] Due to the 3300 isolator, a magnetic force between the inner motor and the outer motor is not transmitted. This can implement a dual motor system, where the inner motor and the outer motor operate independently.
[00493] The 3300 insulator can be implemented as a member serving as a flux barrier that protects a magnetic force. Preferably, the insulator 3300 is formed of a plastic material based on PBT.
[00494] With reference to FIG. 30, the present disclosure double motor stator and a method of efficiently implementing a suitable torque by differently defining the lengths of the outer teeth 3210 and the inner teeth 3220 from each other will be explained.
[00495] Generally, a coil wound on the teeth generates a rotational force in correspondence with a permanent magnet of the rotor. Here, the rotational force is proportional to the magnetic force of the permanent magnet, and the number of windings in the coil. The more the number of coil windings is, the more the rotational force of the rotor increases.
[00496] According to yet another embodiment of the present disclosure, as shown in FIG. 30, the stator of the double motor is formed such that a length of the inner teeth 3220 is longer than that of the outer teeth 3210. As the length of the inner teeth 3220 is greater than that of the outer teeth of 3210, the number of windings of the coil wound on inner teeth 3220 is larger than coil wound on outer teeth of 3210.
[00497] Since the number of windings of the coil wound on the inner teeth 3220 is greater than the coil wound on the outer teeth 3210, a rotational force of the inner rotor is greater than that of the outer rotor.
[00498] In the dual drum washing machine of the present disclosure, the inner rotor is connected to an outer shaft to rotate a main drum, and the outer rotor is connected to an inner shaft to rotate a secondary drum. Here, the high torque inner rotor rotates the main drum, and the low torque outer rotor rotates the secondary drum.
[00499] More specifically, in the present disclosure double drum washing machine, the main cylinder requiring a high torque receives a high torque by the 3220 internal teeth which receive a high rotational force due to its length and the secondary drum requiring a low torque is given a low torque by the outer teeth 3210, which receive a low rotational force due to their shorter length.
[00500] Under this configuration, torques can be effectively applied to the main drum and the secondary drum.
[00501] Hereinafter, a method for fabricating the double motor stator according to the present disclosure will be explained in more detail with reference to FIGS. 30 to 32. The conventional double motor stator is manufactured in a drilling way through an integrated internal stator and external stator. This can cause redundant parts after drilling corresponding to the inner slot and redundant parts after drilling corresponding to the outer slot to occur.
[00502] Furthermore, in the conventional method for manufacturing a double motor stator, a twin motor stator of a predefined size and shape is a perforated one by integrating the inner and outer stator of the stator with each other. As a result, there is a problem that a double motor stator size and shape cannot be changed.
[00503] Redundant parts after drilling result in wasted components and reduction of an economic aspect. In that sense, the present disclosure proposes a method for manufacturing a double motor stator capable of minimizing the amount of redundant parts after drilling and having various shapes and sizes.
[00504] Hereinafter, a method for manufacturing the double motor stator according to the present disclosure will be explained. As shown in FIGS. 30 to 32, the inner stator 3100 and the outer stator 3200 are individually manufactured in the form of a perforation. Then, the inner stator 3100 is formed in a ring shape, such that the inner fork 3130 is towards the outer, and the outer teeth 3110 are towards the center. Next, the outer stator 3200 is wound around an outer circumference of the inner stator 3100 in a ring shape, so that the outer yoke 3230 is toward the center, and the outer teeth 3210 are toward the outer. The 3100 inner stator and the 3200 outer stator integrated with each other function as stators positioned inside and outside. An inner rotor 50 is disposed on the inside, and an outer rotor is disposed on the outside.
[00505] A method for manufacturing the 3100 inner stator and 3200 outer stator will be explained. A pair of internal stators 3100 is manufactured in a drilling mode in a state that the internal teeth 3110 are arranged to be engaged with each other in a longitudinal direction. And, a pair of outer stators 3200 is manufactured in a drilling manner in a state that the outer teeth 3210 are arranged to be engaged with each other in a longitudinal direction. This can minimize the amount of redundant parts after drilling (B) in the 3100 internal stators and external stators, minimizing component loss.
[00506] Referring to FIG. 31, the processes for manufacturing the internal stator 3100 will be explained. The 3100 internal stator can be manufactured as a straight-line type member, extending longitudinally. A pair of inner stators 3100 are arranged facing reciprocal inner teeth 3110, and inner teeth 3110 are inserted into inner grooves 3150. This can minimize the amount of redundant parts after drilling (B) when fabricating the inner stator in a drill shape . As the amount of redundant parts after drilling (B) is minimized, component waste can be reduced and an economic aspect can be improved.
[00507] As shown in FIG. 32, the outer stator 3200 is manufactured in the same manner as the inner stator 3100 of FIG. 31. As the amount of redundant parts after drilling (B) is minimized, component waste can be reduced and economics can be improved.
[00508] The dual motor stator of the present disclosure is manufactured by the inner stator 3100 and the outer stator 3200. First, the inner stator 3100 directly extending in the longitudinal direction is cut to a predetermined length, and the outer stator 3200 also is cut to a predetermined length. As a result, the double motor stator of a predefined size is manufactured.
[00509] Referring to FIG. 30, the inner stator 3100 which extends in a longitudinal direction and by cutting a predetermined size is applied in a ring shape as one end and the other end thereof are connected to each other. And, the outer stator 3200 which extends in a longitudinal direction and cut to a predetermined size is wound about an outer circumference of the inner stator 3100, in a ring shape.
[00510] An outer circumferential surface of the inner stator 3100 and an inner circumferential surface of the outer stator 3200 are coupled together with a distance between them due to the spacing of an insulation distance such as the inner fork 3130 and the outer fork 3230 one of facing each other.
[00511] As shown in FIG. 32, in this integrally mounted dual motor stator, inner teeth 3110 of inner stator 3100 protrude toward the center to drive the inner rotor. And, the outer teeth 3210 of the outer core 3200 protrude outwards in a radial direction to drive the outer rotor.
[00512] The inner fork 3130 and the outer fork 3230 can be coupled together in a state that the insulator 3300 protecting a magnetic force is disposed between them. As mentioned earlier, the 3300 insulator is formed from a plastic material based on PBT, such that the inner rotor and outer rotor operate independently of each other.
[00513] Next, description will be given of a stator structure, in accordance with another exemplary modality, with reference to the accompanying drawings.
[00514] An inner stator 471a may have a ring shape, and an outer stator 471b of a ring shape may be disposed outside the outer stator 471a. That is, the outer stator 471b may surround an outer circumferential portion of the inner stator 471a.
[00515] Each of the inner stator 471a and the outer stator 471b may include a plurality of hinged coils connected together in the form of a ring, a plurality of teeth inserted into the hinged coils, respectively, and a toothed ring for annularly connecting portions end of the plurality of teeth.
[00516] FIG. 33 is an exemplary view of the internal stator 471a of the stators. Without the present disclosure being limited thereto, the outer stator may be formed along the outer circumferential portion of the inner stator of FIG. 33 according to the same method. Also, a wound spool has been omitted from FIG. 33 to help understanding.
[00517] As shown in FIG. 33, the inner stator 471a may include a plurality of hinged coils 4110 connected in a ring shape and a plurality of inner teeth 4120 inserted into the plurality of the coils, respectively. The inner stator 471a may include a further toothed ring 4130 for connecting inner end portions of the plurality of ring-shaped inner teeth 4120 and an inner yoke 4140 for connecting outer end portions. Similar to inner stator 471A, outer stator 471b may also include a plurality of connected spools hinged in a ring shape, a plurality of outer teeth inserted into the plurality of swivel coils, respectively, a toothed ring for connecting outer end portions of the plurality of ring-shaped outer teeth, and an outer yoke for connecting the inner end portions thereof. A flux barrier to protect a magnetic force can be arranged between the inner fork and the outer fork. Usually, the inner fork and the outer fork are preferably connected to each other with a spaced distance apart in order to protect an electromagnetic force. Therefore, the use of the flux barrier can prevent the movement of magnetic force between the stator inner and outer stator, which can result in the implementation of a dual motor system in which the inner rotor and outer rotor can work independently without interference with the other.1. However, when current is applied to a coil wound on a stator (internal and external stators), a rotor is rotated by a magnetic field generated by the applied current. Hence, a stator core as a magnetic substance to form a magnetic path can be provided. That is, this exemplary modality employs an inner tooth core and an outer tooth core.
[00518] In FIG. 33, the inner tooth core may include a plurality of inner teeth, having a ring shape and protruding towards the center. Here, FIG. 33 shows an exemplary embodiment employing each tooth, consisting of a plurality of segment-type teeth. Those segment-type teeth are stacked to form an inner tooth 4120. Each segment-type tooth may include extension portions 4121 extending from one end thereof to both the left and right sides.
[00519] FIG. 34 shows a stacking process of segment type teeth building the stator core. As shown in FIG. 34, teeth (the upper part of Fig. 34) in the form of a flat plate are drilled (the middle part of Fig. 34) and stacked by another (the lower part of Fig. 34), thus forming an inner tooth or outer tooth . The stator teeth of the segment type teeth (the lower part of FIG. 34) stacked in FIG. 34 form a stator core. Each segment-type tooth may include extension portions extending from one end thereof to both the left and right sides.
[00520] The teeth stacked as shown at the bottom of FIG. 34, are inserted into hinged coil 4110. FIG. 35 shows an articulated coil. As shown in FIG. 35A, the hinged coil 4110 may include a body portion 4111 having a receiving portion 4111c in which corresponding teeth are inserted and hinged portions 4112 formed on both side surfaces of the body portion 4111 to be folded.
The receiving part 4111c indicates a space formed within the body part 4111. Both end portions 4111a and 4111b of the body part 4111 are open. Therefore, the receiving part 4111c can be defined as an open space on both sides. The inner tooth or outer tooth can be received in the receiving portion 4111c. In FIG. 33, the inner or segment-like tooth 4120 is received in the receiving portion 4111c. Here, the inner tooth 4120 is inserted into a lower end portion 4111a of the body part 4111, and the inner tooth extension portions 4121 are located in the lower end portion 4111a of the body part 4111.
[00522] The articulated coil 4110 can be provided in plurality. FIG. 35B shows a state that a plurality of hinged coils are connected together. The hinge parts 4112 of the coil can be interconnected with the hinge parts 4112 of the adjacent coils. That is, the hinged parts 4112 can be bent relative to the body part 4111 and capable of being coupled to the hinged parts of other coils. Coupling between adjacent hinged parts can be implemented by coupling methods well known as hinge coupling.
[00523] After inserting the teeth the articulated coils4110 connected together, as indicated in FIG. 35B, each hinged coil 4110 can be wound by a spool. That is, the coil can be wound around the body portion 4111 of the hinged coil 4110.
[00524] The connected shape of the articulated coils shown in FIG. 35B can be allowed for automatic winding. In the related technique, teeth were received into an annular insulator and a coil was wound onto the insulator. In this sense, there was no way but to wind the coil inside the annular insulator, using a needle. This caused a concentrated winding that the wound coil was concentrated in a specific portion. However, by using hinged coils, which can be bent, as shown in FIG. 35B, winding may be allowed by using an automatic winding machine. This allows for an aligned winding in which a coil is wound around a circumference of the body part being well aligned. This can improve a winding space factor and thus improve the performance of a drive motor. Furthermore, when two stators are employed to drive two independent rotors as shown in the present disclosure, improving the drive motor performance by improving the winding space factor can provide an opportunity for reducing the size of the drive motor.
[00525] Meanwhile, the articulated coils, in which the teeth are inserted and in which the spool is wound, are fixed to an annular fork. FIG. 36 shows the inner fork 4140 having the annular shape. The articulated spools are attached to an inner circumferential surface of the inner fork of FIG. 36. Inner yoke 4140 may include a plurality of slots 4141 formed along the circumferential surface thereof. The protrusions can be formed on ends of inner teeth or ends of hinged coils to be inserted into connecting slots 4141. FIG. 33 shows the articulated coils 4110 connected to the inner yoke 4140. As mentioned earlier, the outer stator can be formed in a similar manner. That is, the outer yoke of the annular shape is provided and the articulated spools are attached to an outer circumferential surface of the outer yoke.
[00526] The toothed ring can be fitted by pressure to the other end of the articulated coil, opposite the end connected with the inner fork. FIG. 37 shows toothed ring 4130 used in the trim stator. The tooth ring may be cylindrical in shape and include a plurality of protrusions 4131 formed along a circumferential surface externally thereto. The protrusions 4131 may be formed to press fit the toothed ring and therefore be press fit between the hinged coils or in slots formed in the inner teeth. The external stator can be similarly formed as mentioned above. That is, a plurality of protrusions are formed along an inner circumferential surface of the cylindrical ring of the tooth, thus to be press-fitted between the hinged coils or the like.
[00527] The toothed ring can reduce cogging torque and prevent the decrease of an efficiency of the drive motor. That is, the cogging torque is generated during rotor rotation due to the discontinuity of the magnetic field, which is caused by a gap between the teeth. Such discontinuity can be reduced due to the toothed ring, thus reducing the cogging torque and preventing the reduction in the efficiency of the drive motor.
[00528] With the plurality of articulated coils being mounted between the yoke and the tooth ring, the plurality of articulated coils can be maintained in a stable assembled state.
[00529] In FIG. 33, a space can be defined between the body portion of the hinged coil, which is secured between the inner yoke and the tooth ring, and a body portion of an adjacent hinged coil. The space may be referred to as an inner groove 4150. The inner groove 4150 may be located on the wound spool. An outer groove can be formed similar to this, and a wound spool can be located in the outer groove.
[00530] FIG. 38 shows another exemplary embodiment of a stator in accordance with this specification, which shows that the teeth are integrally formed with a hinged yoke for connecting end portions of the teeth. In the exemplary embodiment of FIG. 38, overlapping portions with the exemplary embodiment of FIG. 33 will not be explained repeatedly here below.
[00531] FIG. 38 exemplarily shows an internal stator 471of stators. Without the present disclosure being limited thereto, an outer stator can be formed along an outer circumferential portion of the inner stator in the same manner. Also, for ease of understanding, a wound spool is omitted from FIG. 38.
[00532] As shown in FIG. 38, inner stator 471a may include a plurality of hinged coils 4110 connected in a ring shape, and inner teeth 4120 inserted into the plurality of hinged coils, respectively. The inner stator 471a may additionally include a toothed ring 4130 for connecting inner end portions of the plurality of ring-shaped inner teeth. However, a separate inner fork may not be necessary because the inner teeth are formed integrally with the articulated fork 4122.
[00533] In FIG. 38, an inner tooth may include a plurality of inner teeth integrally formed with the articulated yoke and protruding from the yoke 4122. This may be referred to as an integral tooth. The plurality of integral teeth can be stacked to form an inner tooth 4120. This exemplary embodiment illustrates that the integral tooth does not have extension portions extending from an end thereof to both the left and right sides. This is because the integral tooth is inserted from an upper portion 4111b of the body portion of the hinged coil 4110 when being inserted into the hinged coil 4110.
[00534] FIG. 39 shows a stacking process of integral teeth building the stator core. As shown in FIG. 39, teeth in the form of a flat plate (the upper part of Fig. 39) are drilled (the middle part of Fig. 39) and stacked on top of each other (the lower part of Fig. 39), thus forming an inner tooth or outer tooth. The stacked integral teeth (the lower part of FIG. 39) thus form the stator core.
[00535] Here, wedge-shaped recesses 4125 can be formed in the articulated fork 4122. The articulated fork has to be bent into a ring shape, after which the integral teeth are inserted into the articulated coils. From there, the wedge-shaped recesses 4125 can form bent portions where the hinged yoke can be bent into a ring shape. Here, wedge-shaped recesses 4125 can be formed in the direction that the pivot yoke is bent. That is, FIG. 39 shows the process of forming the inner teeth, so the wedge-shaped recesses 4125 can be embedded in an inner surface of the articulated yoke, from which the teeth protrude. However, when an outer tooth is formed, the wedge-shaped cavity can be recessed into an outer surface of the swivel fork.
[00536] This exemplary mode also allows the 4130 ring gear to be snap fitted. That is, the toothed ring can be snapped onto the other side of the hinged coils opposite the hinged yoke being positioned. Therefore, the hinged fork can be bent into a ring shape, and the plurality of the hinged coils can be mounted between the hinged fork in the ring shape and the tooth ring.
[00537] FIG. 38 shows a defined space between the body portion of the hinged coil, which is secured between the inner yoke and tooth ring, and a body portion of an adjacent hinged coil. This space may be referred to as an inner groove 4150. The inner groove 4150 may be located on the wound spool.
[00538] FIG. 35 shows an exemplary embodiment of a method for manufacturing a stator of a drive motor for a washing machine. As shown in FIG. In accordance with an exemplary embodiment of this disclosure, a method for fabricating a stator of a drive motor for a washing machine may include a coil connecting step (S100) for connecting a plurality of hinged coils in the form of a belt, a tooth insertion step (S200) to insert teeth into the plurality of connected hinged coils, respectively, an automatically winding step (S300) to automatically wind a coil on each inserted toothed hinged coil (S400), a step of yoke connection, for connecting the swivel coils wound on the coil in the form of a ring, and a toothed ring connection step (S500) for connecting a toothed ring in the form of a ring for connecting the end portions of the teeth.
[00539] The step of connecting the coil (S100) indicates a step to connect the plurality of coils articulated in the shape of the belt. This is to connect the hinged coils as shown in FIG. 35B.
[00540] The tooth insertion step (S100) indicates a step to insert the teeth into the plurality of articulated coils, respectively. Here, segment-type teeth can first be stacked in the shape of each tooth (inner or outer) as shown in the lower part of FIG. 34C, to then be inserted into the articulated coil.
[00541] Here, in the exemplary embodiment to employ the segment-type teeth of the aforementioned embodiments, the teeth are inserted into the undersides of the hinged coils. Rather, in the exemplary embodiment for employing integral teeth, the teeth are inserted into the upper sides of the articulated coils.
[00542] The auto winding step (S300) indicates a step of auto winding a coil on each hinged coil with inserted tooth. As mentioned earlier, since the articulated coils are capable of being bent, the coil can be wound using an automatic winding machine. This allows the coil to be wound on the hinged coil in an aligned state.
[00543] With configuration, the coil can be automatically wound on the articulated coil in order to improve a winding space factor, which can result in drive motor performance improvement and drive motor optimization.
[00544] The fork connection step (S400) indicates a step of connecting the articulated coils with coiled coil in the form of a ring. Here, when the teeth are segment type teeth, the yoke connection step can be performed to connect the hinged coils on the ring shape yoke. However, for integral teeth formed integrally with the swivel fork for connecting the end portions of the tines, the clevis attachment step can be performed to bend the swivel fork to the ring shape.
[00545] The tooth ring connection step (S500) indicates a tooth ring press-fit step to connect the end portions of the teeth to the ring shape. This, as mentioned earlier, can reduce the cogging torque and prevent the drive motor from decreasing efficiency.
[00546] Referring to FIG. 30, an inner stator 471a may include an inner toothed core having a plurality of inner teeth 4100 and an inner yoke 4110. The inner yoke may be ring-shaped and serve as a base from which the inner teeth 4100 protrude towards the center. . That is, the inner teeth may protrude towards the center and be attached to the inner fork.
[00547] The plurality of inner teeth 4100 protruding towards the center may be attached to the inner yoke 4110 at predetermined intervals therebetween. Here, a space between the inner teeth can be referred to as an inner groove 4120, which provides a space where the inner toothed core is received in an insulator 478 to be explained later, and later a coil is wound over the insulator 478.
[00548] Extending portions 4115 may extend from one end of each inner tooth 4100 in either a left or right direction. Therefore, a space defined by the inner teeth 4100, the extending portions 4115 of the inner teeth and the inner fork 4110 can form the inner groove 4120. Therefore, as indicated in FIG. 30, the plurality of inner grooves may be formed repeatedly at predetermined intervals along a circumference formed by the inner yoke.
[00549] Similar to the inner stator, an outer stator can be formed. Referring to FIG. 41, the outer stator 471b may include an outer toothed core having a plurality of outer teeth 200 and an outer yoke 4210.
[00550] The outer yoke 4210 may have a ring shape and serve as a base from which the outer teeth 420 protrude in a radial direction. That is, the outer teeth can be radially protruding and are secured to the outer yoke.
The plurality of radially protruding outer teeth 4200 may be secured to the outer yoke 4210 at predetermined intervals therebetween. Here, a space between the outer teeth may be referred to as an outer groove 4220, which provides a space where the outer toothed core is received in an insulator 478 to be explained later, and later a coil is wound over the insulator 478.
[00552] Extending portions 4215 may extend from one end of each outer tooth 4200 in a left and right direction. Therefore, a space defined by the outer teeth 4200, the extending portions 4215 of the outer teeth and the outer yoke 4210 can form the outer groove 4220. Therefore, as indicated in FIG. 30, the plurality of outer grooves may be formed repeatedly at predetermined intervals along a circumference formed by the outer yoke.
[00553] Here, the inner core and the outer core are usually formed by punching the teeth in the form of a flat plate and stacking the teeth. Therefore, a configuration is required for securing them and allowing a coil to be wound on them.
[00554] Insulator 478 can secure these internal and external sprockets and allow a spool to be wound over the internal and external sprockets. The insulator 478 has the structure to receive the inner toothed core and the outer toothed core, for example, it can be formed by coupling an upper insulator and a lower insulator to face each other. Alternatively, insulator 478 can include a cap and coating of insulator.
[00555] FIG. 41 shows an insulator 478. Insulator 478 may include an inner toothed core receiving portion 4310 having inner tooth receiving portions 4311 for receiving the plurality of inner teeth, and an inner yoke receiving portion 1312 for receiving the inner yoke, and a portion outer tooth core receiver 4320 having outer tooth receiving portions 4321 for receiving the plurality of outer teeth, and an outer yoke receiving portion 4322 for receiving the outer yoke.
[00556] Each of the inner tooth receiving portion 4211 and the outer tooth receiving portion 4321 may have a protruding partition wall along a contour of a tooth for receiving the inner tooth and the outer tooth. Therefore, the inner tooth receiving portion and the inner tooth receiving portion can form lattice-shaped spaces, respectively, for receiving teeth by the partition walls.
[00557] Each inner yoke receiving portion 4212 and outer tooth receiving portion 4322 may also have a protruding partition wall along an annular yoke contour for receiving the inner yoke and outer tooth yoke. Therefore, the inner fork receiving portion and the outer fork receiving portion can form cylindrical spaces, respectively, for receiving the forks by the partition walls.
[00558] Insulator 478 may further include a flux barrier4330 for protection from a magnetic force by spacing the inner toothed core received in the toothed core receiving portion separate from the outer toothed core received in the outer toothed core receiving portion.
[00559] The flow barrier 4330 may protrude in a ring shape between the inner yoke receiving portion 4312 and the outer yoke receiving portion 4322. That is, the outer circumferential surface of the inner yoke received in the inner yoke receiving portion and an inner circumferential surface of the outer yoke received in the outer yoke receiving portion may be secured to face each other, with the flow barrier 4330 interposed therebetween.
[00560] In general, to protect an electromagnetic force, inner tooth core and outer tooth core are preferably coupled to each other with a spaced distance between them. Therefore, formation of the flux barrier 4330 can prevent the movement of a magnetic field between the inner stator and the outer stator, which can result in the implementation of a dual motor system in which an inner rotor and an outer rotor can work independently without interference. with the other.
[00561] For example, the flow barrier 4330 can protrude from at least one of the upper and lower insulator, and make the inner toothed core and outer toothed core spaced apart from each other, as the upper insulator and the insulator bottom are coupled to each other. Therefore, the flux barrier 4330 can protect magnetic field interference between the inner sprocket and the outer sprocket. For this purpose, the insulator 478 can be formed from plastic with a PBT base.
[00562] In the meantime, after the inner tooth core and outer tooth core are received in the inner tooth core receiving part 4310 and the outer tooth core receiving part 4320, the upper insulator and the lower insulator are assembled together, thus producing the insulator completely.
[00563] Here, as mentioned above, inner grooves 4120 may be formed between the inner tooth receiving portions to receive the plurality of inner teeth, respectively, and outer grooves 4220 may be formed between the outer tooth receiving portions to receive the plurality of external teeth.
[00564] A wound coil may be located in the inner groove and the outer groove, respectively. That is, when the spool is wound on the basis of the inner tooth receiving portions to receive the inner teeth, and the outer tooth receiving portions to receive the outer teeth, the wound spool can be located in the inner grooves and the outer grooves.
[00565] Therefore, the inner stator can be formed by receiving the inner toothed core in the insulator and winding the coil in the insulator, and the outer stator can be formed by receiving the outer toothed core in the insulator and winding the coil in the insulator. Here, a portion of the inner stator wound coil becomes an inner winding portion, and a portion of the outer stator wound coil becomes an outer winding portion.
[00566] From the perspective of the configuration, the insulator can serve as a coil for winding the coil on it as well. Furthermore, the flow barrier can be formed integrally with the insulator. Therefore, a coil and flux barrier are not required, which can result in a reduction of the entire number of components and an entire size of the drive motor. Furthermore. even if two stators for driving two independent rotors are employed, an increase in a full size of the washing machine can be avoided.
[00567] FIG. 42 shows an exemplary embodiment of a method for manufacturing a stator of a drive motor for a washing machine. As shown in Fig. 42, A method for manufacturing a stator of a drive motor for a washing machine, according to an exemplary embodiment, may include a stator core, forming step (S100) for stacking an inner toothed core. and of an inner yoke, and an outer toothed core having outer teeth and an outer yoke, a stator core insertion step (S200) for inserting the inner toothed core and outer toothed core into one of an upper insulator and a lower insulator, which are coupled to form an inner tooth receiving part and an outer tooth receiving part facing each other, a step of putting together the stator (S300) to couple the upper insulator and the lower insulator, and a step of coil winding (S400) for winding a coil on an outside of the inner tooth receiving portions to receive the inner teeth of the inner stator receiving portion, and on an outside of the r portions external tooth acceptors to receive the external teeth of the external stator receiving part.
[00568] The stator core formation step (S100) indicates a step to form the inner core and the outer core. As mentioned above, according to the method for forming the inner tooth core and the outer tooth core, teeth in the form of a flat plate are punched and stacked. That is, the inner toothed core having the inner teeth and the inner yoke and the outer toothed core having the outer teeth and the outer yoke are stacked together.
[00569] The step of inserting the stator core (S200) indicates a step of inserting the inner core and the outer core stacked in the step of forming the toothed core (S100) in the inner stator receiving part and in the stator receiving part external of the insulator. Here, the toothed cores can be inserted into one of the top insulator and the bottom insulator.
[00570] In the step of inserting the stator core (S200), the inner toothed core and the outer toothed core are inserted being spaced apart from each other by the interposition of a flow barrier between them, which is formed in by minus one, of the top insulator and the bottom insulator.
[00571] The step of putting together the stator (S300) indicates a step of completing the putting together of the insulator by coupling the upper insulator and the lower insulator. Therefore, the insulator can cover the inner toothed core and the outer toothed core, and serves as a coil on which the coil is wound in the winding step to be explained later.
[00572] The coil winding step (S400) indicates a step of winding the coil on the outside of the inner tooth receiving portions to receive the inner teeth of the inner tooth receiving part to receive the outer teeth of the outer tooth receiving part .
[00573] With the configuration, putting together the stator can be carried out in an easy and simple way, and the insulator can serve as the coil as well, which can allow the reduction of the entire number of components and an entire size of the drive motor . Therefore, even if two stators for driving two independent rotors are employed, an increase in a full size of the washing machine can be avoided.
[00574] Referring to FIGS. 43 to 45, a bearing housing structure capable of enhancing a radiant characteristic of a double motor stator applied to the washing machine of the present disclosure will be explained.
[00575] First, a bearing housing 6100 of the present disclosure will be explained with reference to FIG. 43. The bearing housing 6100 is provided with a bearing shaft hole 6140 for penetration of a rotor shaft of a stator 2000 therethrough, and is concentrically coupled to the stator 2000 in a covering manner.
[00576] The stator 2000 is provided with a 2510 casing mounting edge, a ring shape protruding from a 2500 yoke in an axial direction.
[00577] Preferably, a diameter of the housing mounting edge 2510 is formed to be equal to or slightly larger than the diameter of a body 6110 of the bearing housing.
[00578] More specifically, the bearing housing 6100 is placed together with the stator 2000 as the housing 6110 is fixed by insertion into an inner circumferential surface of the mounting edges of the housing 2510. Here, the bearing housing 6100 is fitted to the stator 2000 , so that a stator coupling opening 6130 and a casing coupling opening 2300 are aligned with each other.
[00579] The stator 2000 is provided with external teeth 2100 protruding from an outer circumference in a radial direction. Although not shown, an outer rotor is mounted to an outer circumference of the outer teeth 2100 with a gap between them and rotates by magnetic force.
[00580] The stator 2000 is provided with external teeth 2100 protruding from an outer circumference towards the centre. Although not shown, an outer rotor is mounted to an inner circumference of inner teeth 2100 with a gap between them and rotates by magnetic force.
[00581] As shown in FIG. 43, since the bearing housing 6100 is fixedly coupled to the fork 2500 of the stator 2000, the bearing housing 6100 completely coats the inner rotor.
[00582] A coil 2220 formed of a conductor such as copper is wound onto a winding portion formed on an outer circumferential surface of a core 2210 of the inner teeth 2200. When a current is applied to the coil 2220, the current reacts with a magnet permanent rotor to rotate the rotor. By the applied current, coil 2220 can generate high temperature heat. This high temperature heat can cause coil 2220 to be cut or fail to operate. Therefore, it is necessary to radiate heat.
[00583] Furthermore, the heat generated from the inner rotor covered by the bearing housing 6100 is not easily radiated to the outside. This could damage the wire wound on the 2200 inner teeth, or cause an operation failure.
[00584] Therefore, as shown in FIG. 43, the stator 2000 is provided with a spacer 2510 protruding from the yoke 2500, so that the stator 2000 can be coupled to the bearing housing 6100 with a gap between them.
[00585] The heat generated from the inner rotor circulates in a space between the bearing housing 6100 and the yoke 2500 of the stator 2000 and is radiated to the outside without being excessively heated.
[00586] The 2510 stator is formed in the fork 2510 in plurality with a gap between them, so that bearing housing 6100 can be spaced enough from an inner rotor formed on the inside of the stator 2000.
[00587] However, the spacer 2510 between the bearing housing 6100 and the inner teeth 2200 of the stator 2000 merely serves to radiate heat by convection. If a spacing distance between them is not long enough, there are limitations on heat radiation.
[00588] In order to implement the radiation by driving well convection by the spacing distance, the body 6100 of the bearing housing 6110 consists of a protruding part 6111 and a concave part 6113.
[00589] Referring to FIGS. 43 to 45, bearing housing 6100 having a body 6110, a bearing shaft hole 6140, and a 6130 stator coupling opening is placed together in stator 2000 having outer teeth 2100, inner teeth 2200, a yoke 2500, and a housing coupling opening 2300. Here, the body 6110 of the bearing housing 6100 is provided with the protruding portion 6111 in a position corresponding to the winding portion of the inner tooth 2200, and is provided with the concave portion 6113 in a position corresponding to the one. groove(s) between inner teeth 2200.
[00590] The concave portion 6113 can be implemented as a through hole formed penetratingly in the body 6110 of the bearing housing 6110.
[00591] Since the concave portion 6113 is formed penetratingly as a space for convection, heat generated from the winding portion of the inner teeth 2200 can be radiated more effectively.
[00592] however, as shown in FIG. 45, the concave portion 6113 can be implemented as a through hole of the body 6110 of the bearing housing 6110 is curved. In this case, the body 6100 of the bearing housing 6110 can be implemented as a curved portion integrally formed therewith. This can maximize radiation due to actuation of the protruding portion 6111.
[00593] The concave part 6113 of the body 6110 of the winding casing is formed as a space (F) for heat circulation generated from the winding portion of the inner teeth 2200 by convection. And, the protruding portion 6111 of the bearing housing body 6110 is formed as a driving portion for radiating heat generated from the winding portion of the inner teeth 6110 to the outside by driving.
[00594] The protruding portion 6111 of the bearing housing body 6110 is spaced apart from the coil 2220 wound on the winding portion of the inner teeth by a predetermined insulating distance (D). This insulating distance only has to be long enough to prevent a current from the coil 2220 from flowing into the bearing housing 6100 formed of a metallic material. Preferably, the insulation distance is about 3mm.
[00595] Hereinafter, with reference to FIGS. 29 to 31 will be explained structures of a current connector and a dual motor hall sensor according to the present disclosure, and a washing machine using the same.
[00596] In the conventional dual motor system, each of a current connector and a hall sensor connector is respectively installed in the internal and external stators. This can cause a complicated structure, and increase the number of assembly processes, etc. In order to solve these various problems, in the present disclosure, a current connector is integrally formed on the internal and external stators, and a hall sensor connector is also integrally formed on the internal and external stators.
[00597] As shown in FIG. 46, the dual motor of the present disclosure includes a power connector 7300 having outer teeth 2100 and inner teeth 2200, and configured to apply power to an outer winding portion of outer teeth 2100 and an inner winding portion of inner teeth 2200 in a manner integrated; and a hall sensor connector 7500 configured to apply power to an external hall sensor 7510 and an indoor hall sensor 7520 in an integrated manner.
[00598] The outer winding portion has a structure in which a coil is wound on the outer teeth 2100. Although not shown, a metallic coil, such as copper, having a high conductivity is wound on the outer teeth 2100 a plurality of times, thereby rotating an outer rotor (not shown) positioned outside the outer teeth 2100 by forming a magnetic flux together with a permanent magnet of the outer rotor.
[00599] In correspondence with the outer winding portion, the inner winding portion has a structure in which a coil is wound on the inner teeth 2200 a plurality of times, thereby rotating an inner rotor (not shown) positioned on the inside of the internal teeth 2200.
[00600] The 7300 current connector has a structure to operate the motor by forming a magnetic flux together with a permanent magnet of the rotor, by applying a current to the coils of the outer winding portion and the inner winding portion. An external current connector and an internal current connector are installed separately in the conventional art, whereas they are integrally formed as a 7300 current connector in the present disclosure.
[00601] Preferably, the 7300 current connector is implemented as a 6-pin connector where a 3-pin connector for applying a current to the external winding portion is integrated with a 3-pin connector for applying a current to the inner winding portion. In the conventional technique, an external current connector and an internal current connector have the same structure, a 3-pin structure, respectively. However, in the present invention, an external power connector and an internal power connector are integrally formed as a 7300 power connector, a 6-pin connector.
[00602] As shown in FIG. 47, current connector 7300 supplies a current from a power unit 7100 to the outer winding portion and the inner winding portion in parallel. As a current is supplied to the outer winding portion and the inner winding portion through a current connector 7300, a simple structure can be implemented, an assembly process can be facilitated and the number of components can be reduced.
[00603] As shown in FIG. 47, current applied to the outer winding portions 2100 and the inner winding portions 2200 through the current connector 7300 which is integrally connected to the ground (GND). As a result, the outer winding portion 2100 and the inner winding portion 2200 have a parallel structure.
[00604] The 7500 hall sensor connector serves to integrate an external hall sensor connector and an internal hall sensor connector that perform hall sensing functions in relation to the external stator and the internal stator, respectively, as a connector. As shown in FIG. 46, the hall sensor connector 7500 is formed as an external hall sensor connector 7510 and an internal hall sensor connector 7520 of a hall sensor unit 7500 are integrated with each other.
[00605] As shown in FIG. 48, it is preferred to supply a current from the power unit 7100 to the external hall sensor 7510 and the internal hall sensor 7520 in parallel via the integrated hall sensor connector 7500, and connect sensed hall sensing signals from the external stator and the internal stator to the connector of integrated hall sensor 7500 in parallel.
[00606] As shown in FIG. 48, the current applied from the outdoor hall sensor 7510 and the indoor hall sensor 7520 is connected to ground (GND) through the integrated hall sensor connector 7500 in parallel.
[00607] Still according to another modality of the present disclosure, as shown in FIG. 46, the dual motor of the present disclosure may further include an external temperature sensor 7610 and an internal temperature sensor 7620 for sensing external stator and internal stator temperatures, respectively.
[00608] Referring to FIG. 46, the outdoor temperature sensor 7610 and the indoor temperature sensor 7620 are installed on a lower surface of the hall sensor unit 7500, respectively. The 7610 external temperature sensor is mounted to the external stator, and the 7620 internal temperature sensor is mounted to the internal stator.
[00609] The external temperature sensor 7610 is installed to contact the outer winding portion to measure heat temperature generated from the outer winding portion, and the inner temperature sensor 7620 is installed to contact the portion winding for measuring temperature of heat generated from the inner winding portion.
[00610] When superheat is generated from the respective stators, these 7610 and 7620 temperature sensors are configured to control the operation of the dual motor by detecting the generated superheat.
[00611] Referring to FIG. 48, a current from the power unit 7100 is supplied to the external temperature sensor 7610 and the internal temperature sensor 7620, in parallel, through the integrated hall sensor connector 7500. Preferably, the signals sensed from the external temperature sensor 7610 and the internal temperature sensor 7620 are connected to the integrated hall sensor connector 7500 in parallel.
[00612] As the 7500 hall sensor connector is implemented as an integrated connector it provides applied power from the 7100 power unit to the external and internal stator in parallel. This can implement a simple structure and enhance a set feature. As a result, under coupling or under operation due to complicated structure can be prevented.
[00613] Referring to FIG. 48, the hall sensor unit 7500, including the outdoor hall sensor 7510 and the indoor hall sensor 7520, and a temperature sensor unit including the outdoor temperature sensor 7610 and the indoor temperature sensor 7620 are connected to each other in parallel. . And, the hall sensor unit and the temperature sensor unit fully grounded (GND).
The hall 7500 sensor connector has a parallel structure for connecting the hall 7500 sensor unit and the temperature sensor unit (7610, 7620) to each other. A simple mounting structure through a 7100 power unit and the ground can be implemented, and a stable system can be implemented.
[00615] A method for putting together the drum according to an embodiment of the present disclosure is applied to a washing machine, comprising a main drum and a secondary drum driven independently in a tub fixed to the above-mentioned main body; and a drive motor having a stator, an outer rotor and an inner rotor to independently drive the main drum and the secondary drum.
[00616] FIG. 8 illustrates a method for putting the drum together in accordance with an embodiment of the present disclosure. Referring to FIG. 8, the method for putting the cylinder together includes manufacturing a spider-shaft assembly by coupling a shaft and a spider to each other, the shaft which transmits the driving force to the main drum and the secondary drum of the engine. of the drive (S100), coupling the spider-shaft assembly to a rear side of the secondary drum (S200), coupling the secondary drum to the main drum (S300), and coupling the spider-shaft assembly to a rear side of the main drum (S400).
[00617] The above steps are performed after the main drum, secondary drum, main drum spider, secondary drum spider, etc. were manufactured. For example, for the main drum and for the secondary drum, a plate is made in roll to have a cylindrical shape and a coupling part undergoes a splicing process. In addition, the end of the drum goes through a crimping process. FIG. 6 illustrates a splice coupling 66 and a waved end portion 67 of the secondary drum. Preferably, the secondary drum goes through a crimping process after a splicing process so that the crimped end can be continued. The main drum spider and the secondary drum spider can be manufactured in a casting manner.
[00618] FIG. 3 is an exploded perspective view illustrating the main drum, secondary drum, etc. Referring to FIGS. 3 and 7, at S100, an outer shaft 81 for transmitting a driving force to the main drum of the inner rotor is coupled to the main drum spider 91 (S110), an inner shaft 82 for transmitting a driving force to the secondary drum of the outer rotor is coupled to secondary drum spider 95 (S120). The step (S110) for coupling the outer shaft to the main drum spider is independent from the step (S120) for the inner shaft coupling to the secondary drum spider. Therefore, steps S110 and S120 can be performed in reverse order, or they can be performed simultaneously.
[00619] The inner shaft 82 coupled to the secondary drum spider is coupled on the inside of the outer shaft 81 coupled to the secondary drum spider (S130). At the same time, a bearing (S131) and a waterproof seal (S132) are inserted into the inner shaft 82. Referring to FIG. 7, the inner shaft is coupled to the inside of the outer shaft, a bearing is forcibly inserted into it, and then a waterproof seal is inserted into it.
[00620] On the S200, for coupling the spider-shaft assembly to the rear side of the secondary drum, the spider of the secondary engine is coupled to the rear surface of the secondary drum. In this case, since the secondary drum spider is included in the spider-shaft assembly, the spider-shaft assembly is coupled to the secondary drum. The secondary drum spider and the back of the secondary drum can be attached to each other by screws or welding.
[00621] On the S300, for coupling the shaft-spider assembly main drum, the secondary drum is inserted inside the main drum. In the case of a drum guide assembly, as shown in FIG. 2, the drum guide 55 for sealing is mounted inside the main drum before inserting the secondary drum into the main drum (S250). drum guide to a recess formed in an inner circumferential surface of the main drum.
[00622] On the S400, for coupling the spider-shaft assembly to the rear side of the main drum, the spider end of the main drum is coupled to the main drum. In this case, since the main drum spider is included in the spider-shaft assembly, the spider-shaft assembly is coupled to the secondary drum. The secondary drum spider and the back of the secondary drum can be attached to each other by screws or welding.
[00623] Hereinafter, a shaft structure for transmitting a rotational force by connecting a drive motor to a drum of a washing machine in accordance with the present disclosure will be explained.
[00624] FIG. 49 is a view illustrating a washing machine having an axle structure (A) in accordance with another embodiment of the present disclosure, FIGS. 50 and 51 are detailed sectional and perspective views illustrating the axle structure (A) and FIG. 52 is a view illustrating a spring washer 900 for attenuating vibrations in the shaft structure (A).
[00625] Yet another embodiment of the present disclosure will be explained in more detail with reference to FIGS. 50 to 52. The axle structure (A) of the dual motor according to the present disclosure includes an outer axle 81 of a hollow type; an inner shaft 82 inserted into the outer shaft 81; a drive motor 70 having an outer rotor 72 connected to a stator 71 and inner shaft 82 and rotating outwardly of the stator 71 and having an inner rotor 73 connected to the outer shaft 81 and rotating within the stator 71; and a spring washer 900 inserted into a connecting piece of the outer shaft 81 and the inner rotor 82. In this structure, the vibrations of the outer shaft are attenuated to prevent noise, and separation of the outer shaft 81 due to vibrations can be prevented.
[00626] Referring to FIG. 50, the inner shaft 82 rotates in a state inserted into the outer shaft 81 of a hollow type. The outer shaft 81 rotates in a state connected to the inner rotor 73, and the inner shaft 82 rotates in a state connected to the outer rotor 72.
[00627] The outer shaft 81 rotates rapidly receiving a rotational force from the inner rotor 73. In this case, vibrations and noise occur when the rotational force is transmitted. Therefore, spring washer 900 is installed between outer shaft 81 and inner rotor 73 to attenuate vibrations in the axial direction.
[00628] As shown in FIG. 50, an inner ball bearing 83 is installed between the outer shaft 81 and the inner shaft 82 so that the drive motor can drive the outer shaft and the inner shaft independently.
[00629] An outer ball bearing 84 is provided on an outer circumference of the outer shaft 82, thereby rotating the outer shaft 82 in the shaft frame.
[00630] As shown in FIGS. 50 and 51, the shaft frame may additionally include a stop ring 800 configured to secure the spring washer 900 to a connecting piece of the outer shaft 81 and the inner rotor 73. Here, the stop ring 800 is implemented as a ring of C.
[00631] As shown in FIG. 52, the spring washer 900 may be implemented as a concave-convex member of a ring shape having a protruding portion 910 and a concave portion 930. As shown in FIG. 50, since the spring washer 900 is snap-coupled to an outer circumference of the outer shaft 81 by the concave-convex parts and is secured by the stop ring 800, vibrations of the outer shaft 81 in the axial direction can be attenuated.
[00632] To compress the spring washer 900 in an axial direction and to implement a spring force by the concave-convex parts, the stop ring 800 has to constrain an upper surface of the spring washer 900 as shown in FIG. 50.
[00633] The outer shaft 81 is provided with a set-off ring recess 81a concave towards the center of an outer circumference thereof, thus preventing the separation of the spring washer 900 in the axial direction by inserting the stop ring 800 (ring C) in stop ring recess 81a.
[00634] As shown in FIG. 51, stop ring 800 is formed in a partially cut ring shape (ring C) to be fitted into stop ring recess 81a formed in an outer circumference of outer shaft 81. Ring C is fitted in stop ring recess 81a formed on an outer circumference of the outer shaft 81 as a cut portion thereof is enlarged.
[00635] Referring to FIGs. 50 and 51 in accordance with another embodiment of the present disclosure, an inner bush 73a is installed between the outer shaft and the inner rotor, thereby transmitting a rotational force from the inner rotor 73 to the outer shaft 81.
[00636] An outer bush 72a is also installed between the inner shaft 82 and the outer rotor 72, thus transmitting a rotational force from the inner rotor 72 to the inner shaft 82.
[00637] To prevent vibration and noise from the outer shaft 81 in an axial direction, the spring washer 900 additionally includes a stop ring 800 installed between the inner bush 73a and the outer shaft 81, and configured to secure the spring washer 900 to an outer shaft connecting piece 81 and the inner bush 73a.
[00638] As shown in FIGS. 50 and 51, the spring washer 900 may be formed in an annular member that encompasses an outer circumference of the outer shaft 81 on the upper surface of the inner bush 73a.
[00639] A stop ring recess 81a is concave from an outer circumference of the outer shaft 81 towards the center. The stop ring 900 is implemented as a C-ring inserted into the recess of the stop ring 81a and prevents the spring washer separating in an axial direction by contacting an upper surface of the spring washer 900.
[00640] According to yet another modality of the present disclosure, a structure to couple a serration of the internal shaft 82 to the external bush 72a has a conical shape. This can improve a user's convenience when carrying out the coupling process and can increase the coupling force.
[00641] Referring to FIGs. 50 and 51, one end of the inner shaft 82 on a drive motor side is provided with serrations to transmit a rotational force from the outer rotor to the inner shaft 82. The serrated inner shaft 82 and an inner circumferential surface of the inner bush 72a form it is in a saw-toothed shape so that a rotational force is transmitted to the inner shaft 82 of the inner bush 72a when they are engaged with each other.
[00642] The serrations of the inner shaft 82 are fitted into the toothed saw of an inner circumferential surface of the inner bush 72a. As shown in FIGS. 33 and 34, the inner shaft 82 and the inner bush 72a are formed into parallel cylindrical shapes. In this case, the serrations of the inner shaft 82 and the inner circumferential surface of the inner bush 72a may have a gap between them and may have a difficulty in being coupled together. As a result, it can be difficult to transmit a rotational force onto the rotor shaft.
[00643] Although not shown, the serrations of the inner shaft 82 can be formed into a conical shape, and the inner circumferential surface of the inner bush 72a can be implemented as a tapered through hole. This can allow the inner shaft 82 to be insert-coupled with the inner bush 72a with a large coupling force. And, a coupling strength can be enhanced and a mounting characteristic can be improved.
[00644] Yet another embodiment of the present invention will be explained in more detail with reference to Figs. 52 and 53. A shaft structure for a double drum washing machine comprises an outer shaft 81 formed in a hollow type; an inner shaft 82 inserted into the outer shaft 81; a drive motor having a stator 71, an outer rotor 72 connected to the inner shaft 82 and rotating outside the stator 71 and an inner rotor 73 connected to the outer shaft 81 and rotating within the stator 71, a spring washer 500 inserted. on the outer shaft in a connecting piece of outer shaft 81 and inner rotor 82; and an inner rotor nut 310 configured to forcibly secure the inner rotor after the spring washer 500 is insert-coupled to the outer shaft. By this configuration, external shaft vibrations in an axial direction can be attenuated to prevent noise, and entangled state release due to vibration can be avoided.
[00645] Referring to FIG. 53, inner shaft 82 is inserted into outer shaft 81 for rotation. Outer shaft 81 is connected to inner rotor 73, and inner shaft 82 is connected to outer rotor 72 for rotation.
[00646] The outer shaft 81 rotates at a high speed receiving a rotational force from the inner rotor 73. When the rotational force is transmitted, vibrations and noise occur. To prevent vibrations in the axial direction, the spring washer 500 is disposed between the outer shaft 81 and the inner rotor 73.
[00647] Referring to FIG. 53, an inner ball of the ball bearing 83 is installed between the outer shaft 72 and the inner shaft 73 so that the drive motor can drive independently of the outer shaft and the inner shaft.
[00648] An outer ball bearing 84 is provided in the outer circumference of the outer shaft 82, which allows the rotation of the outer shaft 82 in the shaft frame for the washing machine.
[00649] As shown in FIG. 53, the shaft structure of the present invention may additionally include an inner rotor nut 310 configured to secure the spring washer to a connecting piece of the outer shaft 81 and the inner rotor 73.
[00650] As shown in FIG. 52, the pressure washer 500 is implemented in the form of an annular concave-convex member having a protrusion portion 510 and a concave portion 530. Referring to FIG. 53, when the spring washer 500 is snap-fitted to the outer circumference of the outer shaft 81 by the concave-convex part, thus to be fixed by the inner rotor nut 310, vibrations of the outer shaft 81 in the axial direction can be attenuated.
[00651] In order to provide an elastic force due to the concave-convex portion, compressing the spring washer 500 in an axial direction as shown in FIG. 53, the inner rotor nut 310 must be screw-coupled to an outer circumferential surface of the outer shaft end 81 for restraining an upper surface of the spring washer 500.
[00652] The shaft structure of the present invention may further comprise a flat washer 501 inserted by inserting the part between the inner rotor 73 and the spring 500 at the outer circumference of the outer shaft 81. As shown in FIG. 53, the flat washer is forcibly inserted by insertion between the upper surface of the spring washer 500 and the upper surface of the inner rotor 73.
[00653] The inner rotor nut 310 serves to forcibly correct the spring washer 500 on the outer circumference of the outer shaft 81. As the inner rotor 73 and the spring washer 500 do not directly contact each other due to the flat washer 501, a coupling force between them can be reinforced and vibrations can be reduced. This can prevent entangled state release.
[00654] As shown in FIG. 53. a male thread portion 81a is formed on the outer circumference of the outer shaft 81, and a female thread portion 310a is formed on the inner circumference of the inner rotor nut 310. Whereas the male thread portion 81a and the female thread portion 310a are threaded together, spring washer 500 can prevent deflection in an axial direction.
[00655] According to another embodiment shown in FIGS. 51e 53, an inner bush 73a is installed between the outer shaft and the inner rotor so that a rotational force from the inner rotor 73 can be transferred to the outer shaft 81.
[00656] An inner bush 72a is installed between the outer shaft82 and the inner rotor 72, so that a rotational force from the inner rotor 72 can be transferred to the outer shaft 82.
[00657] In order to avoid vibrations and noise of the outer shaft 81 in an axial direction, the spring washer 500 is installed in a connecting part of the inner bush 73a and the outer shaft 81. Therefore, the present invention further comprises 310a inner rotor nut 310 configured to secure spring washer 500 to an outer shaft connecting portion 81 and inner bushing 73a.
[00658] As shown in FIGS. 52 and 53, the spring washer 500 is formed on an annular member covering an outer circumference of the outer shaft 81 on the upper surface of the inner bush 73a.
[00659] Flat washer 501 can be provided between inner bushing 73a and spring washer 500. This can enhance a coupling force of inner bush 73a and reduce vibrations, thus avoiding release of entangled state.
[00660] Hereinafter, with reference to FIGS. 54-56 will be explained a structure for improving a mounting characteristic between a bearing frame and a stator of a double motor applied in a washing machine, in accordance with the present disclosure.
[00661] First, a set structure of the present disclosure will be explained with reference to FIG. 54. The bearing housing 6100 is provided with a bearing shaft hole 6140 for penetration of a rotor shaft of a stator 2000 therethrough, and is concentrically coupled to the stator 2000 in a covering manner.
[00662] The disclosure of the present can be applied to a dual engine system as well as a single engine system. FIG. 54 illustrates that bearing housing 6100 and stator 2000 are joined together in a dual motor system in accordance with the present disclosure. Hereinafter, descriptions will be explained with reference to FIG. 54.
[00663] The present disclosure provides a structure to improve a mounting feature between the bearing housing and the stator of a double motor and a washing machine having the structure. In the present disclosure, the bearing housing 6100 having a housing body 6110, a bearing shaft hole 6140, and a stator coupling opening 6130 is placed together in the stator 2000 having outer teeth 2100, inner teeth 2200, a yoke. 2500 and a casing coupling opening 2300. The stator coupling opening 6130 includes a mating protrusion 6130a, and the casing mating opening 2300 includes a mating recess 2300a. For assembly, the socket protrusion 6130a is inserted into the socket recess 2300a.
[00664] The stator 2000 is provided with a 2700 water lock mounting edge, a ring shape protruding from a 2500 yoke in an axial direction.
[00665] Preferably, the water lock mounting edge 2700 has a diameter equal to or slightly larger than the diameter of the body 6110 of the bearing housing.
[00666] More specifically, the body 6100 of the bearing casing 6100 is fixed by insertion into an inner circumferential surface of the mounting edge of the casing 2510. Here, the coupling opening of the stator 6130 and the opening of a casing coupling 2300 are aligned with a with the other.
[00667] For alignment, the mating protrusion 6130a of the stator coupling opening 6130 is inserted into the mating recess 2300a of the housing coupling opening 2300.
[00668] The coupling opening of the stator 6130 of the bearing housing 6100 is provided with the snap-in protrusion 6130a instead of the snap-in recess. Since the engaging recess 6130a is integrally protruding from the bearing housing 2000, it must be implemented as a metallic member having a high intensity.
[00669] The 2000 stator is a stator applied to a twin motor including an inner rotor and an outer rotor.
[00670] The stator 2000 is provided with external teeth 2100 protruding from an outer circumference in a radial direction. Although not shown, an outer rotor is mounted on an outer circumference of the stator at a distance from outer teeth 2100, and rotates by magnetic force.
[00671] The stator 2000 is provided with internal teeth 2200 protruding from an inner circumference towards the center. Although not shown, an inner rotor is mounted on an inner circumference of the stator at a distance from inner teeth 2200, and rotates by magnetic force.
[00672] As shown in FIG. 54, the bearing housing 6100 is coupled to the stator of the 2000 by being fixed to the yoke 2500 of the stator 2000. In this sense, the inner rotor is in a completely covered state.
[00673] Heat from a high temperature generated from the internal rotor is not easily radiated to the outside. This could damage a spool wound on the 2200 internal teeth, or cause a malfunction.
[00674] Therefore, as shown in FIGS. 54 and 56, the stator 2000 is provided with a spacer 2510 protruding from the yoke 2500 so that the stator 2000 can be coupled to the bearing housing 6100 with a gap between them.
[00675] The heat generated from the inner rotor circulates in a space between the bearing housing 6100 and the fork 2500 of the stator 2000 and is radiated to the outside without being excessively heated.
[00676] The 2510 stator is formed in the fork 2510 in plurality with a gap between them, so that bearing housing 6100 can be spaced enough from an inner rotor formed on the inside of the stator 2000.
[00677] Hereinafter, shapes and structures of the stator coupling opening 6130 and the housing opening 2300, and coupling between them will be explained with reference to FIGS. 55 and 56.
[00678] Stator coupling opening 6130 and casing coupling opening 2300 are provided with coupling openings 6130b and 2300b communicated with each other when bearing casing 6100 and stator 2000 are together with each other.
[00679] In a state that the socket protrusion 6130a has been fixed by insertion into the socket recess 2300a, the bearing housing 6100 and the stator 2000 are placed together with each other by screws through mating openings.
[00680] As mentioned above, the body 6110 of the bearing housing 6100 is fixed by insertion into the water lock mounting edge 2700 of the stator 2000. In this case, it is difficult to align the coupling openings 6130b and 2300b with each other for communications.
In this regard, the socket protrusion 6130a and the socket recess 2300a can be coupled together for alignments.
[00682] In the conventional technique, the stator 2000 is provided with a mating protrusion, and the bearing housing 6100 is provided with a mating recess for alignments. However, in a case that the fitting protrusion of the stator 2000 is formed of a plastic material, the fitting protrusion may be damaged, for example, it may be broken, bent, etc. This can cause a difficulty in aligning coupling opening 6130b of bearing housing 6100 and coupling opening 2300b of stator 2000 to each other for communications.
[00683] in order to solve these problems, in the present disclosure, the bearing 6100 formed of a metallic material, having a high intensity provided with the protrusion fitting 6130b and stator 2000 formed of a plastic material is provided with the fitting recess 2300b. This can solve difficult assembly processes due to damage from the snap protrusion.
[00684] As shown in FIGS. 55 and 56 in accordance with yet another embodiment of the present disclosure, the coupling opening of the stator 6130 protrudes from the body 6110 of the bearing housing 6110 by a predetermined height (H) in the axial direction. Like said spacer 2510, the stator coupling opening 6130 serves to separate the inner rotor bearing housing from the stator, thus circulating heat generated from the inner rotor and radiating heat. This can increase a radiant effect.
[00685] In the present disclosure, the casing coupling opening 2300 may protrude from the yoke 2500 to 2000 by a predetermined height (H2) in an axial direction.
[00686] Preferably, the spacing distance between the bearing housing 6100 and the inner rotor is sufficiently obtained by making the stator coupling opening 6130 and the housing coupling opening 2300 protruding by predetermined heights (H1, H2).
[00687] The casing coupling opening 2300 is integrally formed with the water lock mounting rib 2700 to have a higher intensity. This can allow the 2300 case coupling opening to be easily aligned with the 6130 stator coupling opening.
[00688] The water lock mounting edge 2700 serves to prevent water from the washing machine having a double motor from being introduced into the inner rotor and serves to facilitate the coupling of the bearing housing 6100 to the stator 2000.
[00689] According to yet another embodiment of the present disclosure, the inner rotor 73 is separately mounted on the outer shaft 81, unlike the rewound embodiment where the inner rotor 73 and stator 71 are integrally manufactured using the bearing housing.
[00690] Referring to FIGS. 1, 4 and 5, the inner rotor 73 is the fit-mounted on the outer shaft 81 separately. In this case, the fitting process can be difficult because the inner rotor 73 has a magnetic component.
[00691] In the present disclosure, an auxiliary assembly jig is further extending from the end of the outer shaft 81, thus orienting an inner rotor assembly. The outer shaft 81 for the socket-coupled inner rotor 73 can be implemented as a magnetic substance formed of a metallic material, having a high intensity. Therefore, it is preferable for the auxiliary mounting template to form a non-magnetic substance not influenced by a magnetic component and to be sufficiently extended from the outer axis 81.
[00692] Next, a method to drive a washing machine in the form of 3D movement by a double drum and a method of controlling it will be explained.
[00693] The method for driving a washing machine, or a washing operation has been cited above in FIG. 58. Referring to FIG. 58, a method for driving a washing machine in accordance with an embodiment of the present disclosure comprises a washing step of carrying out a washing process by feeding wash water and a detergent (S100), a washing step of the carrying out a rinsing process through the feeding of rinsing water, a dehydration step of unloading rinse water and carrying out a dehydration process (S300), and a step of arranging the clothing of the main drum and the secondary drum and releasing a tangled state of the garment after the dehydration process (S400).
[00694] In a washing step (S100), a washing process is carried out by supplying water and a detergent. In S100, garments are washed by rotating the main drum and the secondary drum.
[00695] The washing step (S100) can include a 3D washing process and a general washing process. In the 3D washing process, the garment moves in a circumferential direction by the rotations of the main drum and the secondary drum. The garment then rotates at an interface between the main drum and the secondary drum by relative movements of the main drum and the secondary drum and moves in an axial direction.
[00696] As indicated by the arrow in FIG. 10, garment moves in tangled state belt shape. This is because the garment moves in a circumferential direction and descends by gravity as it rotates.
[00697] In the general washing process (S120) the garment moves in a circumferential direction by the rotations of the main drum and the secondary drum. Unlike the 3D washing process, the main drum and secondary drum rotate integrally without having relative movements performed in the general washing process.
[00698] In the washing step (S100), the washing process 3D and the general washing process can be carried out alternately. More concretely, the 3D washing process and process and the general washing process can be carried out sequentially, or in reverse order. Alternatively, the general wash process can be carried out while the 3D wash process is carried out a plurality of times, or vice versa.
[00699] In the rinse step (S200), wash water is provided to remove a detergent, etc., remaining on the garment. In the dewatering step (S300), the wash water is discharged by a centrifugal force due to the drum rotation, and the garment is dewatered.
[00700] In the garment arrangement step (S400), the garment is separated from the main drum and the secondary drum and is out of a tangled state. The garment arranging step (S400) includes a garment separation process (S410) for separating the garment from the inner surfaces of the main drum and the secondary drum in response to relative movements between the main drum and the secondary drum, and a tangled state release process, of releasing a tangled state of the garment while the garment rotates by relative motions of the main drum and the secondary drum moving in a circumferential direction and an axial direction.
[00701] In clothing the separation process (S410), the garment is separated from an inner circumferential surface of the drum by 3D movements of the same after the dehydration process.
[00702] In the entangled state release process (S420), the garment separated from the inner circumferential surface of the drum is subjected to 3D movements for a predetermined time in order to be taken out of a tangled state. The main drum and the secondary drum have to rotate integrally in order to remove water by centrifugal force during a dewatering process. In this case, the garment may be in a tangled state. In this sense, the process of releasing the entangled state is necessary. The separation process and the entangled state release process can be carried out consecutively. Alternatively, the garment separation process can be carried out first, and then the tangled state release process can be carried out after a predetermined time has elapsed.
[00703] The garment separation process and the tangled state deliberation process can be carried out for a long period. It is enough for the garment separation process and the tangled state release process to be carried out for a period of time so that the garment is separated from the inner circumferential surface of the drum and the garment is not in a tangled state. The reason is because dehydrated garments can be damaged when the two drums perform relative movements for a long time.
[00704] If the washing machine is implemented as a washing machine for dual washing and drying purposes, the method may include a further garment drying step (S500) after the garment arrangement step (S400).
[00705] Under this configuration, the garment is separated from the cylinder through 3D movements after a dewatering process and then is out of a tangled state to avoid creasing. In a washing machine for dual purpose washing and drying purposes, garments can be arranged before a drying step in order to avoid creases, etc. occurring during the drying step.
[00706] The method for driving a washing machine may further comprise a step of automatic extraction of clothing to the outside by the relative movements of the main drum and the secondary drum (S600) after the drying step (S500).
[00707] The automatic extraction step (S600) is performed only after a door 21 of the washing machine has been opened. FIG. 57 illustrates garment movements through the automatic garment extraction step. Referring to FIG. 57, once the door 21 disposed on a front surface of a body of 10 has been opened, the garment is discharged to the outside (indicated by the arrow of G) by the relative movements of the main drum and the secondary drum. The reason is because the garment can be unloaded outside the drum when the secondary drum rotates rapidly, since the garment moves in an axial direction by the relative movements of the main drum and the secondary drum as indicated in FIG. 10.
[00708] Under this configuration, the garment is automatically extracted in a simple way, by relative movements of the main drum and the secondary drum after the end of the washing machine operation. This can improve a usage convenience.
[00709] The method for driving a washing machine comprises a garment separation step (S410) of separating the garment from the inner surfaces of the main drum and the secondary drum by the relative movements of the main drum and the secondary drum through the motor. actuation after this dehydration, and a tangled state release step (S420) of releasing a tangled state of garment that is rotating in a circumferential direction and an axial direction by relative movements of the main drum and the secondary drum. And, the method can further comprise a step of automatic extraction of the garment (S600), to carry out relative movements of the main drum and the secondary drum by the drive motor so that the garment can be unloaded outside the door after the door has been opened.
[00710] The garment separation step, the tangled state release step and the garment automatic extraction step have been explained based on the aforementioned drive motor, and thus detailed explanations thereof will be omitted. FIG. 59 illustrates a method for controlling the washing machine. Referring to FIG. 59, the drive motor 70 controls the main drum 50 and the secondary drum 60 to perform relative movements by independently rotating the outer rotor 72 and the inner rotor 73. This control by the drive motor can be performed by a controller 110 of the driving machine. to wash. Controller 110 controls the operation of the drive motor by transmitting a preset signal to the drive motor at each step.
[00711] Various relative movements of the main drum and the secondary drum by the drive saucer are illustrated in FIG. 60. The drive motor controls the secondary drum and main drum to rotate in opposite directions. Preferably, the secondary drum is controlled to rotate faster than the main drum. This relative motion is illustrated in FIG. 60th. Referring to FIG. 60a, the main drum 50 rotates in a clockwise direction (indicated by the arrow of E), and the secondary drum 60 rotates in a counterclockwise direction. Main drum 50 and secondary drum 60 rotate in opposite directions in a state that a secondary drum rotation speed (the arrow size of F) is faster than a main drum rotation speed (the arrow size of E ).
[00712] The drive motor can allow the secondary drum and main drum to rotate in the same direction at different speeds of rotation. Preferably, the secondary drum is controlled to rotate faster than the main drum. This relative motion is illustrated in FIG. 60b. Referring to FIG. 60b, the main drum 50 rotates in a counterclockwise direction (indicated by the arrow of E), and the secondary drum 60 rotates in a clockwise direction (indicated by the arrow F). The main drum 50 and the secondary drum 60 rotate in the same directions in a state that a secondary drum rotation speed (the arrow size of F) is faster than a main drum rotation speed (the arrow size of E ).
[00713] The drive motor can only allow the slave drum to rotate. This relative motion is illustrated in FIG. 60c. Referring to FIG. 60c, the main drum 50 is attached, and the secondary drum 60 rotates in a counterclockwise direction (indicated by arrow F).
[00714] Under these settings, the main drum and secondary drum can perform various relative movements under control of the drive motor. This can allow the garment inside the drum to perform 3D movements.
[00715] Under these settings, the laundry performs 3D movements by relative movements of the drums controlled by the drive motor. This can prevent creases in the garment and allow the garment to be automatically removed.
[00716] According to yet another embodiment of the present disclosure, a washing step in a method for driving a washing machine is performed in a more divided manner.
[00717] The method for driving a washing machine was previously mentioned in FIG. 8. Referring to FIG. 61, a method for operating a washing machine in accordance with an embodiment of the present disclosure comprises a step of washing of carrying out a washing process by feeding wash water and a detergent (S100), a step of rinsing the carrying out a rinsing process through the feeding of rinsing water (S200), and a dehydration step by discharging rinsing water and carrying out a dehydration process (S300). The washing step (S100) includes a 3D washing process (S110) of rotating clothing and moving the clothing in a circumferential direction and an axial direction by relative movements of the main drum and the secondary drum.
[00718] As previously mentioned, the washing step (S100), includes a 3D washing process (S110) and a general washing process (S120).
[00719] In the washing step, to carry out a washing process by supplying washing water and a detergent, the drive motor controls the main drum and the secondary drum to perform relative movements, so that the garment can rotate and move up in a circumferential direction and an axial direction.
[00720] FIG. 62 illustrates a method for controlling a washing machine, in accordance with another embodiment of the present disclosure. In this embodiment of FIG. 62, a washing process is performed differently according to a quantity of clothing.
[00721] More specifically, the drive motor controls the main drum and the secondary drum according to an amount of garment measured in the step to carry out a washing process by supplying wash water and a detergent. For example, the drive motor controls the main drum and secondary drum to perform relative rotations so that garments can move in an axial direction and a circumferential direction with rotations, or controls the main drum and secondary drum to rotate fully to that garments can only move in a circumferential direction.
[00722] In this embodiment of FIG. 62 is applied to the washing machine for 3D movements. In this mode, an amount of garment (M) has to be measured in advance (S150). The measurement can be performed based on a drum load by rotating the drum at an early stage. Alternatively, the measurement can be carried out by an additional load sensor.
[00723] Washing processes are carried out differently according to a measured garment quantity (S160) based on a maximum load (Mmax) of the drive motor 70.
[00724] More specifically, when a desctuary quantity is less than 1/3 of the maximum load of the drive motor, the drive motor rotates the main drum and the secondary drum in opposite directions (S171).
[00725] When an amount of garment is greater than 1/3 and less than 2/3 of the maximum load of the drive motor, the drive motor rotates the main drum and secondary drum in the same direction at different speeds (S172) .
[00726] When a garment quantity is more than 2/3 of the maximum load of the drive motor, the drive motor integrally rotates the main drum and the secondary drum in the same direction (S173).
[00727] Under these settings, the garment performs general planar movements or 3D movements according to quantity. This can implement better washing performance without causing an overload on the drive motor.
[00728] Hereinafter, the method for driving a washing machine by varying RPMs of the main drum and the secondary drum will be explained in more detail.
[00729] Referring to FIG. 63, a control unit 100 can control currents to be applied to the inner and outer winding portions of the drive motor 70. This can allow the inner and outer rotors to rotate independently. As a result, as shown in FIG. 5, the main drum 50 and the secondary drum 60 can be rotated independently by a drive motor 70.
[00730] Referring to FIGS. 1 and 63, the unit control 100 can be installed in a control panel 30, or in a container additionally provided on one side in the washing machine. Control unit 100 is usually implemented as one or more PCBs.
[00731] The washing machine further comprises a storage unit 400 configured to store in it a triggering program, information about the washing process, drying, dehydration, etc., and so on. The washing machine further comprises an input unit 500, each type of manipulation buttons arranged on the control panel, 30. And, the washing machine may further comprise an output unit 600 configured to emit a time, a temperature, a status, an error, etc.
[00732] The control unit 100 initially operates the outer rotor 72 and the inner rotor 73 with the same starting RPM lower than the target RPMs of the outer rotor 72 and the inner rotor 73. The target RPM can be variable according to an amount of garment and a drive type and each of the outer rotor and inner rotor can have a defined target RPM. The start RPM can be a target RPM of the inner rotor.
[00733] Referring to FIG. 64, the washer drive motor starts operating at an internal rotor target RPM. After a predetermined time has been prescribed, the outer rotor 72 rotates with increasing speed at a predefined target RPM. Inner rotor 73, on the other hand, runs with the initial RPM maintenance. Here the start RPM can be set as a value instead of the target inner rotor RPM. If the inner rotor and outer rotor start to operate and at the same time run at different target RPMs, excess current can be applied to the drive motor.
[00734] As shown in FIG. 64, an excess current is applied to the outer rotor to have a high RPM, and a large amount of heat is generated from the motor. On the other hand, if the drive motor starts operating in a state that the inner rotor and outer rotor have the same RPM, a motor load is reduced and the amount of heat is reduced. This can prevent the initial operation of the drive motor from failing due to excess current.
[00735] Referring to FIG. 63 turn, the washing machine, according to another embodiment, includes the control unit 100 configured to operate the outer rotor 72 and the inner rotor 73 of the drive motor 70, respectively. The control unit 100 is connected to the input unit 500, the output unit 600, a garment quantity detection unit 200 and a temperature detection unit 300.
[00736] The control unit 100 controls an outer rotor 72 and inner rotor 73 having a higher torque to start operating first. The same configuration of the washing machine as the one mentioned above in one modality will not be explained.
[00737] FIG. 65 is a graph showing inner rotor and outer rotor temperature changes after an initial operation (including reset). Referring to FIG. 65, inner rotor 73 has a higher temperature than outer rotor 72 according to time lapses. The reason is because a large amount of current is applied to the inner rotor 73 as the inner rotor 73 starts to operate faster than the outer rotor 72.
[00738] If the outer rotor and inner rotor start to operate and at the same time rotate with differently set target RPMs for various movements, an excess current is applied to the drive motor. Especially, an excess current is applied to a rotor having a relatively small torque, and the amount of heat generated from the motor is increased. Control unit 100 compares torques of outer rotor 72 and inner rotor 73 to each other, and controls a rotor having a relatively large torque to start operating first. For example, when the inner rotor 73 has a higher torque, the control unit 100 controls the inner rotor to start operating first. This can reduce the external rotor load by having a lower torque and can prevent an excessive amount of heat. The outer rotor and inner rotor have different torques for 3D drives.
[00739] Referring to FIG. 63, the washing machine further comprises a garment quantity sensing unit 200 configured to detect a garment quantity. If a predetermined time fails after the drive motor 70 has started to operate, the control unit 100 controls a direction of rotation or an RPM of each outer rotor and inner rotor in accordance with a garment quantity.
[00740] For example, when a quantity of garment is less than a quantity of reference garment, the control unit 100 rotates the main drum and secondary drum by driving the outer rotor and inner rotor in opposite directions, since the drive motor has sufficient torque. This can allow garments to perform 3D moves, and can shorten a wash time. Here, the reference garment quantity can be set as 4kg, 6kg, etc.
[00741] On the other hand, when a garment quantity is greater than a reference garment quantity, the control unit 100 rotates the outer rotor and inner rotor in the same direction with different RPMs. That is, the control unit 100 controls the main drum and the secondary drum to perform relative movements with different RPMs. This can allow the garment to perform enhanced movement. Additionally, when a garment quantity is greater than a reference quantity, the control unit 100 can reduce the amount of heat generated from the drive motor by further reducing the outer rotor and inner rotor RPM as the garment quantity increases .
[00742] As another example, when a desctuary quantity is less than a first quantity of reference garment, the control unit 100 rotates the outer rotor and the inner rotor in opposite directions. When a garment quantity is greater than a second reference garment quantity more than the first reference quantity, the control unit 100 rotates the outer rotor and inner rotor in the same direction. The first quantity of reference garment and the second quantity of reference garment can be preset based on experiments, etc. and can be set as 4kg, 6kg, 8kg, etc.
[00743] The control unit 100 allows the garment to perform 3D motions by differently setting rotation directions and RPMs according to an amount of garment. And, the control unit 100 improves washing machine stability by operating the drive motor with consideration of an amount of heat generation or torque from the drive motor. For example, when a garment quantity is greater than the first reference garment quantity and less than the second reference garment quantity, the control unit 100 controls the rotation directions or RPMs of the outer rotor and inner rotor of according to the amount of heat generation or torque of the drive motor.
[00744] When a garment quantity is more than the first reference garment quantity and less than the second reference garment quantity, the control unit 100 controls the outer rotor and inner rotor to continuously rotate in opposite directions and reduce The relative speeds of the outer rotor and inner rotor as the amount of garment increases. This can reduce the amount of heat generated from the drive motor. When a garment quantity is greater than a second reference garment quantity, the control unit 100 reduces the relative speeds of the outer rotor and inner rotor as the garment quantity increases.
[00745] The washing machine may further comprise a temperature detection unit 300 provided on the outer rotor or on the inner rotor and configured to detect a temperature. The washing machine is provided with a temperature sensing unit such as a thermistor, and the control unit 100 compares a detected drive motor temperature with a predefined reference temperature. When a detected temperature is greater than a reference temperature, the control unit 100 changes a rotation direction or an RPM of the outer rotor or inner rotor. For example, the control unit 100 can lower the drive motor temperature by reducing or compensating for vibrations by making outer rotor and inner rotor RPM the same.
[00746] Referring to FIG. 66, a method for controlling the washing machine in accordance with an embodiment of the present disclosure comprises initially operating the drive motor with the same starting RPM lower than the inner rotor and outer rotor (S130) target RPMs, and operating the outer rotor and inner rotor relative to target RPMs when a predetermined time fails after initially operating the drive motor (S150).
[00747] The washing machine initially operates the outer rotor and inner rotor with the same starting RPM lower than the outer rotor and inner rotor (S130) target RPMs. The target RPM can be variable according to an amount of clothing, a type of movement, etc., and each of the outer rotor and inner rotor can have a defined target RPM (S120). For example, if a user puts garments in the washing machine and then inputs an run command (S10) and the washing machine detects a garment quantity (S110) and calculates a target RPM according to the detected garment quantity (S120). Here, the start RPM can be an inner rotor target RPM.
[00748] Referring to FIG. 64, the washer drive motor starts operating at an internal rotor target RPM (S130). After a predetermined time has failed (S140), the outer rotor 72 rotates with increasing speed to a preset target RPM (S150). On the other hand, the inner rotor rotates with the initial RPM maintenance. Here the Start RPM can be set as a value instead of the inner rotor target RPM. If the inner rotor and outer rotor start to run and at the same time run at different target RPM, excess current can be applied to the drive motor. As shown in FIG. 64, a current is applied to the external rotor set to have a high RPM, and a large amount of heat is generated from the motor. On the other hand, if the drive motor starts operating in a state that the inner rotor and outer rotor have the same RPM, a motor load is reduced and the amount of heat is reduced. This can prevent the initial operation of the drive motor from failing due to excess current.
[00749] Referring to FIG. 67, a method for controlling a washing machine in accordance with another embodiment of the present disclosure comprises comparing torques of the outer rotor and the inner rotor (S220), firstly operating one rotor having a higher torque and then initially operating another rotor having a lower torque, based on a comparison result (S230), and operation of the outer rotor and inner rotor with respective target RPMs, if a predetermined time fails after the drive motor 70 has started to operate (S240) .
[00750] FIG. 65 is a graph showing inner rotor and outer rotor temperature changes after an initial operation (including reset). Referring to FIG. 65, the inner rotor has a higher temperature and a higher rate of change than the outer rotor according to time lapses. The reason is because a large amount of current is applied to the inner rotor as the inner rotor starts to operate faster than the outer rotor.
[00751] If the outer rotor and inner rotor start to operate and at the same time rotate with differently set target RPMs for various movements, an excess current is applied to the drive motor. Especially, an excess current is applied to a rotor having a relatively small torque, and the amount of heat generated from the motor is increased. The washing machine compares outer rotor and inner rotor torques with each other (S220), and controls a rotor having a relatively large torque to start operating first (S230). For example, when the inner rotor has a higher torque, the washing machine first initially operates the inner rotor and then initially operates the outer rotor (S233, S234). This can reduce the external rotor load by having a lower torque and can prevent an excessive amount of heat. On the other hand, when the outer rotor has a higher torque, the washing machine first initially operates the outer rotor and then initially operates the inner rotor (S231, S232). The outer rotor and inner rotor have different torques for 3D drives. Then, the washing machine operates the drive motor by differently setting target RPMs and rotation directions according to a detected garment amount (S240).
[00752] The washing machine controls the directions of rotation or RPMs of the outer rotor and inner rotor according to a garment quantity if a predetermined time fails after the drive motor 70 has started to operate.
[00753] For example, when an amount of clothing is less than a quantity of reference clothing, the washing machine rotates the main drum and secondary drum by driving the outer rotor and inner rotor in opposite directions, since the motor drive has sufficient torque. This can allow garments to perform 3D moves, and can shorten a wash time. Here, the reference garment quantity can be set as 4kg, 6kg, etc. On the other hand, when a garment quantity is greater than a reference garment quantity, the washing machine rotates the outer rotor and inner rotor in the same direction with different RPM. In other words, the washing machine controls the main drum and the secondary drum to carry out relative movements with different RPMs. This can allow the garment to perform enhanced movement. Additionally, when a garment quantity is greater than a reference quantity, the washing machine can reduce the amount of heat generated from the drive motor by further reducing outer rotor and inner rotor RPM as the garment quantity increases.
[00754] Referring to FIG. 68, as another example, when a garment quantity is less than a first reference garment quantity (S310), the washing machine rotates the outer rotor and inner rotor in opposite directions (S320). When a garment quantity is greater than a second reference garment quantity more than the first reference quantity (S330), the washing machine rotates the outer rotor and the inner rotor in the same direction (S340). The first quantity of reference garment and the second quantity of reference garment can be preset based on experiments, etc., and can be set as 4kg, 6kg, 8kg, etc.a. The washing machine allows garments to perform 3D movements by differently defining rotation directions and RPMs according to a quantity of garments. And, the washer has improved stability by operating the drive motor with consideration of an amount of heat generation or torque from the drive motor. For example, when a garment quantity is greater than the first reference garment quantity and less than the second reference garment quantity, the washing machine controls the rotation directions or RPMs of the outer rotor and inner rotor accordingly with a drive motor torque or heat generation amount (S350). When a garment quantity is greater than the first reference garment quantity and less than the second reference garment quantity, the washing machine controls the outer rotor and inner rotor to rotate continuously in opposite directions (S372) and reduce Relative speeds of outer rotor and inner rotor as the amount of garment increases (S373). This can reduce the amount of heat generated from the drive motor. When a garment quantity is greater than a second reference garment quantity (S361), the washing machine reduces the relative speeds of the outer rotor and inner rotor as the garment quantity increases (S362).
[00755] The washing machine can be further configured to detect an internal rotor temperature. Referring to FIG. 69, the washing machine is provided with a temperature sensing unit as a thermistor in the drive motor to detect a drive motor temperature (S410), and compare the detected temperature with a preset reference temperature (S421. S431) When the detected temperature is greater than a reference temperature, the washing machine changes a rotation direction or an RPM of the outer rotor or inner rotor (S422, S432). For example, the washing machine can lower the drive motor temperature by reducing or compensating for vibrations by making outer rotor and inner rotor RPM the same. On the other hand, if the detected reference temperature is lower than the reference temperature, the washing machine maintains the current state (S420).
[00756] According to yet another embodiment of the present disclosure, as shown in FIG. 63, control unit 100 drives inner rotor 73 and outer rotor 72 at particular RPMs, respectively, and applies a brake command to inner rotor 73 and outer rotor 72. Then, control unit 100 detects a first quantity of garments inside the main drum 50 and a second quantity of garments inside the secondary drum 60 based on the braking times of the inner and outer rotors. The particular RPMs of the inner rotor and outer rotor can be set to different values, or they can be set to the same value (eg RPM of 150, RPM of 160, etc.). In the above-mentioned description, the first garment quantity and the second garment quantity are detected based on the braking times. However, the first garment quantity and the second garment quantity can be detected based on the number of pulses per revolution.
[00757] The control unit 100 can brake the outer rotor and inner rotor in different ways or the same way. That is, the control unit 100 can brake both the internal and external rotors, using the generated energy, or it can brake both the internal and external rotors, using redundant power supplies. Alternatively, the control unit 100 can brake one of the internal and external rotors using generated energy, and brake both using redundant energy. Explanations of generated energy braking and redundant energy braking settings, eg resistor, circuit connection, etc. will be omitted.
[00758] The washing machine further comprises a current detector 200 configured to detect a first current and a second current applied to the inner rotor and the outer rotor, respectively. The washing machine further comprises an output unit 300 configured to display one of the first garment quantity, the second garment quantity, and a final garment quantity determined based on the first and the second garment quantity.
[00759] The washing machine further comprises a storage unit 400 configured to store therein a drive program for the washing machine, information about washing, drying, dehydration, etc. The washing machine further comprises an input unit 500, including all kinds of manipulation buttons arranged on a control panel, 30. The output unit 300 can display time, temperature, status, error, etc.
[00760] FIG. 70 is a graph showing change in RPM of each rotor when both outer rotor 72 and inner rotor 73 are under power-generated braking.
[00761] FIG. 71 is a graph showing currents applied to the outer rotor and inner rotor of FIG. 70.
[00762] Referring to FIG. 70, control unit 100 initially drives the inner and outer rotor, thereby increasing the RPM of the inner and outer rotor to a particular value, RPM of 160. Then, the control unit 100 generates a braking command for the inner and outer rotor, and produces the braking command generated to the internal and external rotor. Preferably, the brake command is simultaneously produced to the inner rotor 73 and the outer rotor 72 for a minimized change in the amount of clothing. In the case of both inner and outer rotor braking using generated power, the outer rotor (RPM2) is braked first than the inner rotor (RPM1) as indicated in FIG. 70; Referring to FIG. 71, current (I1) applied to the inner rotor 73 is greater than the current (I2) applied to the outer rotor 72, and braking time (T1) of the inner rotor 73 is greater than the braking time (T2) of the outer rotor 72.
[00763] FIG. 72 is a graph showing change in RPM of each rotor when both outer rotor 72 undergo redundant power and inner rotor 73 undergo generated power braking. FIG. 73 is a graph showing currents applied to the outer rotor and inner rotor of FIG. 72.
[00764] Referring to FIG. 72, the control unit 100 initially drives the inner and outer rotor, thus increasing the inner and outer rotor RPMs to a particular value, RPM of 160. Then, the control unit 100 generates a braking command for the inner and outer rotor, and produces the braking command generated to the internal and external rotor. Preferably, the brake command is simultaneously produced to the inner rotor 73 and the outer rotor 72 for a minimized change in the amount of clothing. In the case of braking the inner rotor 73 using generated power and braking the outer rotor 72 using redundant energy, the inner rotor (RM1) is braked first than the outer rotor (RPM2) as indicated in FIG. 72; Unlike FIG. 70, the outer rotor undergoing redundant power braking has a higher RPM than the outer rotor undergoing generated power braking (RPM2 > RPM2). Referring to FIG. 73, the current (l1) applied to the inner rotor undergoing power-generated braking is greater than the current (l2) applied to the outer rotor 72 undergoing redundant power braking. That is, the inner rotor undergoing energy braking is instantly applied with a large current, and has a shorter braking time (T1) than the inner rotor undergoing redundant energy braking. On the other hand, the external rotor undergoing redundant power braking has an immediate current change of 0 upon receipt of a braking command, and has a longer braking time (T2) than the external rotor undergoing power braking generated as shown in FIGS. 72 and 73.
[00765] Referring to FIGS. 1 and 74, a washing machine in accordance with yet another embodiment of the present invention comprises a main body 10 which forms an outward appearance; a bowl 40 disposed within the main body 10; a main drum 50 rotatably mounted on the tub 40, and accommodating the garment therein; a secondary drum 60 mounted on the main drum 50 to be relatively rotatable relative to the main drum 50; a drive motor 70 including a stator 71, an outer rotor 72 connected to the secondary drum 60 and which rotates outside the stator 71, and an inner rotor 73 connected to the main drum 50 and which rotates inside the stator 71 ; and a control unit 100 configured to drive outer rotor 72 and inner rotor 73.
[00766] The control unit 100 includes a master controller110 configured to drive the inner rotor 73 and to detect the first amount of garment based on the braking time of the inner rotor; and a slave controller 120 connected to the master controller 110, configured to drive the outer rotor 72 and to detect the second amount of garment based on the braking time of the outer rotor.
[00767] The master controller 110 generates a braking command to the external rotor 72 and transmits the braking command to the slave controller 120. Then, the master controller 110 generates a braking command to the internal rotor 73 after a particular time has failed . Here, the particular time is determined based on a communication speed between the master controller and the slave controller, ie communication delay. For example, the particular time can be set to 50ms, etc. The master controller and slave controller are configured as different microcomputers. The master controller and the slave controller produce the braking commands for the inner rotor and the outer rotor simultaneously.
[00768] After producing braking commands, the master controller 110 detects a first quantity of garment inside the main drum 50 driven by the inner rotor 73. And, the slave controller 120 detects a second quantity of garment inside of secondary drum 60 driven by outer rotor 72. Here, the master controller and slave controller detect the first and second quantity of garments based on the braking time of the outer rotor and based on the number of pulses until the outer rotor stops de rotate. The particular RPMs of the inner rotor and outer rotor can be set to different values, or they can be set to the same value (eg RPM of 150, RPM of 160, etc.). In the above-mentioned description, the first garment quantity and the second garment quantity are detected based on the braking times. However, the first garment quantity and the second garment quantity can be detected based on the number of pulses per revolution.
[00769] The control unit 100 can brake the outer rotor and inner rotor in different ways or the same way. That is, the control unit 100 can brake both the internal and external rotors, using the generated energy, or it can brake both the internal and external rotors, using redundant power supplies. Alternatively, the control unit 100 can brake one of the internal and external rotors using generated energy, and brake one and the other using redundant energy.
[00770] Referring to FIGS. 70 to 73, the master controller and slave controller initially drive the inner rotor and outer rotor, thus increasing inner and outer rotor RPMs to a particular value, RPM of 160. Then, the master controller generates a braking command for the outer rotor and transmits the generated braking command to the slave controller. Then the master controller generates a brake command for the inner rotor. The master controller and the slave controller produce the braking commands for the inner rotor and the outer rotor simultaneously, taking into account a communication delay between them. The master controller detects a first garment quantity based on a rotor brake time (ie the time required for the inner rotor to stop after receiving the brake command). And, the slave controller detects a second quantity of garments based on a braking time of the outer rotor (ie the time taken for the external rotor to stop after receiving the brake command) and transmits information about the second quantity of garments in the master controller. Consequently, the master controller determines the final garment quantity based on the first and second garment quantity in the following ways. For example, the first and second quantity of garments can be added to each other at a predefined rate. Alternatively, the garment quantity or the second quantity can be defined as the final garment quantity. More simply, the first garment quantity can be defined as the final garment quantity. FIGS. 70 and 71 show a case where an amount of garment is detected after braking the inner and outer rotor using generated energy. FIGS. 72 and 73 show a case where an amount of garment is detected after braking the inner rotor using generated energy and braking the outer rotor using redundant energy.
[00771] Referring to FIG. 75, there is provided a method for detecting a quantity of garments for a washing machine, in accordance with an embodiment of the invention, the washing machine comprising a main body which forms an outward appearance; a tub disposed inside the main body; a main drum rotatably mounted in the tub, and accommodation of garments therein; a secondary drum mounted on the main drum to be relatively rotatable with respect to the main drum; and a drive motor, including a stator, an external rotor connected to the secondary drum and which rotates outside the stator, and an internal rotor connected to the main drum that rotates inside the stator, the method comprising: o initially driving the inner rotor and the outer rotor (S110); braking the inner rotor and outer rotor (S130) when the RPMs of the inner rotor and outer rotor reach a particular value (S120); and detecting a first quantity of garment inside the main drum and a second quantity of garment inside the secondary drum based on the braking times of the inner rotor and outer rotor (S140, S150). The method further comprises displaying a first garment quantity, the second garment quantity, and a final garment quantity determined based on the first and second garment quantity (S160).2. Referring to FIG. 70, the washing machine initially drives the inner and outer rotor, and increases RPM of the inner and outer rotor to a particular value, RPM of 160 (S110, S120). The washing machine then generates brake commands for the inner and outer rotor, and produces the brake commands for the inner and outer rotor (S130). Here, the washing machine simultaneously produces the brake command for the inner and outer rotor to minimize the change in garment quantity due to braking.
[00772] In the case of braking both the inner and outer rotor using generated energy, the outer rotor (RPM2) is first braked than the inner rotor (RPM1) as indicated in FIG. 70; Referring to FIG. 71, current (I1) applied to the inner rotor 73 is greater than the current (I2) applied to the outer rotor 72, and braking time (T1) of the inner rotor 73 is greater than the braking time (T2) of the outer rotor 72.
[00773] In the case of braking the inner rotor 73 using generated power and braking the outer rotor 72 using redundant power, the inner rotor (RM1) is braked first than the outer rotor (RPM2) as indicated in FIG. 72; Unlike in FIG. 70, the outer rotor undergoing redundant power braking has a higher RPM than the outer rotor undergoing generated power braking (RPM2 > RPM2). Referring to FIG. 73, the current (l1) applied to the inner rotor undergoing power-generated braking is greater than the current (l2) applied to the outer rotor 72 undergoing redundant power braking. That is, the inner rotor undergoing energy braking is instantly applied with a large current, and has a shorter braking time (T1) than the inner rotor undergoing redundant energy braking. On the other hand, the external rotor undergoing redundant power braking has an immediate current change of 0 upon receipt of a braking command, and has a longer braking time (T2) than the external rotor undergoing power braking generated as shown in FIGS. 72 and 73.
[00774] The washing machine detects a first garment quantity and a second garment quantity based on the braking times (T1, T2) (S150). The washing machine can display on a screen one of the first garment quantity, the second garment quantity, and a final garment quantity determined based on the first and second garment quantity, through an output unit. The washing machine determines the final garment quantity based on the first and second garment quantity in the following ways. For example, the first and second quantity of garments can be added to each other at a predefined rate. Alternatively, the garment quantity or the second quantity can be defined as the final garment quantity. More simply, the first garment quantity can be defined as the final garment quantity.
[00775] Referring to FIG. 76, there is provided a method for detecting garment quantity for a washing machine, in accordance with another embodiment of the present invention, the washing machine comprising a main body forming an outward appearance; a tub disposed inside the main body; a main drum rotatably mounted in the tub, and accommodation of garments therein; a secondary drum mounted on the main drum to be relatively rotatable with respect to the main drum; and a drive motor, including a stator, an external rotor connected to the secondary drum and running outside the stator, and an internal rotor connected to the main drum running inside the stator, a master controller for driving the rotor. internal; a slave controller to drive the outer rotor, the method comprising driving the inner rotor and outer rotor drive through the master controller and slave controller, respectively; braking of inner rotor and outer rotor by the master controller, when RPMs of inner rotor and outer rotor reach a particular value; and detecting a first quantity of garments inside the main drum and a second quantity of garments inside the secondary drum through the master controller and slave controller, based on the braking times of the inner rotor and the rotor external.
[00776] Referring to FIGS. 70 to 73, the master controller and slave controller initially drive the inner rotor and outer rotor, thereby increasing inner and outer rotor RPM at a particular RPM, 160 RPM (S210, S220). Then, the master controller generates a brake command to the external rotor and transmits the generated brake command to the slave controller (S231, S232). Then the master controller generates a brake command for the inner rotor (S233)... The master controller and the slave controller produce the brake commands for the inner rotor and outer rotor simultaneously, taking into account a delay of communication between them. The master controller detects a first garment quantity based on an inner rotor brake time (ie the time taken for the inner rotor to stop after receiving the brake command) (S250). And, the slave controller detects a second quantity of garments based on a braking time of the outer rotor (ie the time taken for the external rotor to stop after receiving the brake command) and transmits information about the second quantity of garments to the master controller (S250). Consequently, the master controller determines the final garment quantity based on the first and second garment quantity in the following ways. For example, the first and second quantity of garments can be added to each other at a predefined rate. Alternatively, the garment quantity or the second quantity can be defined as the final garment quantity. More simply, the first garment quantity can be defined as the final garment quantity. The washing machine can display, on the screen, one of the first garment quantity, the second garment quantity, and the final garment quantity determined based on the first and second garment quantity (S260). As mentioned above, in the washing machine and the method for detecting the quantity of garments thereof according to the present invention, the drums are driven independently to enable the garment to perform 3D movements in various ways. Due to the 3D movements of the garment, washing performance of the washing machine can be improved, and washing time can be reduced. In the present invention, the washing machine has improved the washing performance, through 3D movements of the garment, taking into account the torque distribution due to the drive of two drums, a mechanical force applied to the garment, and the movements of the garment. The washing machine is provided with two drums, and a single drive motor to independently drive the two drums. Once an amount of clothing is detected in relation to each drum, the amount of clothing can be accurately detected. In the present invention, the amounts of garments within the two drums are detected in different ways. This can allow the amount of garments to be more accurately detected and can reduce the amount of wash water and electricity required to carry out washing, rinsing and dewatering processes.

权利要求:
Claims (27)
[0001]
1. Washing machine, comprising: a rotating main drum (50) mountable in a tub (40); a secondary drum (60) mounted within the main drum (50) to be relatively rotatable with respect to the main drum (50 ); an outer shaft (81) for rotating the main drum (50); an inner shaft (82) for rotating the secondary drum (60) being disposed within the outer shaft (81); drive means configured to rotate the drum main (50) and secondary drum (60) in different directions and/or with different rotational speeds; a main drum spider (91) for connecting the main drum (50) to the outer shaft (81) to transfer a driving force of the drive means to the main drum (50), and a secondary drum spider (95) for connecting the secondary drum (60) to the inner shaft (82) to transfer a drive force from the drive means to the secondary drum (60), in which the two spiders (91, 95) are arranged to be independent rotatable, characterized by the fact that the secondary drum (60) has an open front side and a rear side closed by a rear part of the secondary drum (62) forming a rear surface, in which the secondary drum spider (95) is disposed between the rear of the secondary drum (62) and the main drum spider (91), and is provided with a receiving portion (63a) for receiving the secondary drum spider (95), wherein the main drum spider. (91) comprises a shaft coupling portion (92) coupled to the outer shaft (81), a spider support portion (93) extending radially from the shaft coupling portion (92), and a fastening portion of drum (94) arranged at one end of the spider support portion (93) to be attached to the main drum (50), and wherein the drum attachment portion (94) is formed in a ring shape to be coupled to an outer circumferential surface of the main drum (50).
[0002]
2. Washing machine according to claim 1, characterized in that the secondary drum spider (95) comprises a shaft coupling portion (92) coupled to the inner shaft (82), and a plurality of shaft coupling portions (82). drum attachment (97) extending radially from the shaft coupling portion (92), radial ends of the drum attachment portions (97) being attached to the secondary drum (60).
[0003]
3. Washing machine according to claim 1 or 2, characterized in that the main drum (50) has openings on the front and rear sides.
[0004]
4. Washing machine according to claim 1 or 2, characterized in that the main drum (50) has an open front side and the back closed respectively by a rear part of the main drum.
[0005]
5. Washing machine according to any one of claims 1 to 4, characterized in that only a part of the inner circumferential surface (50b) of the main drum (50) is facing the outer circumferential surface of the secondary drum (60) .
[0006]
6. Washing machine according to claim 5, characterized in that the secondary drum (60) is shorter than the main drum (50) in length in an axial direction such that garments can contact both the drums at the same time.
[0007]
7. Washing machine according to claim 6, characterized in that a proportion (d2/d1) of a length d2 of the inner circumferential surface (60b) of the secondary drum (60) in an axial direction with respect to a length d1 of the inner circumferential surface (50b) of the main drum (50) in an axial direction is equal to or less than 0.5, preferably being 1/3.
[0008]
8. Washing machine according to any one of claims 1 to 7, characterized in that the main drum (50) comprises a drum guide (55) provided along the inner circumferential surface (50b) thereof to protect a gap between the main drum (50) and the secondary drum (60).
[0009]
9. Washing machine according to claim 8, characterized in that the drum guide (55) comprises a body portion (56) protruding inwardly from the inner circumferential surface (50b) of the drum main (50), and a guide portion extending from the body portion (56) towards an inner circumferential surface (60b) of the secondary drum (60).
[0010]
10. Washing machine according to claim 9, characterized in that the secondary drum (60) comprises a reinforcing bead (65) to prevent twisting of the secondary drum (60).
[0011]
11. Washing machine according to claim 10, characterized in that the reinforcing bead (65) protrudes either into or out of a circumferential surface of the secondary drum (60).
[0012]
12. Washing machine according to claim 10, characterized in that the reinforcing bead (65) protrudes inwardly along the circumferential surface being spaced apart from an end portion of the secondary drum (60) by a predetermined interval, and wherein the guide portion of the drum guide (55) is provided at the same height with the bead of the secondary drum (60) to avoid a step.
[0013]
13. Washing machine according to claim 12, characterized in that the end portion of the secondary drum (60) is rolled out along the circumferential surface.
[0014]
14. Washing machine according to any one of claims 5 to 13, characterized in that the part of the inner circumferential surface (50b) of the main drum (50) facing the outer circumferential surface of the secondary drum (60) has an inner diameter larger than the secondary drum (60), and the other part of the inner circumferential surface (50b) of the main drum (50) has the same inner diameter as the secondary drum (60), thus protecting a gap between the main drum (50) and the secondary drum (60).
[0015]
15. Washing machine according to any one of claims 1 to 14, characterized in that the axes for rotating the drums are inclined in relation to a horizontal direction by a predetermined angle.
[0016]
16. Washing machine according to any one of claims 1 to 15, characterized in that a plurality of elevators (101, 102) is provided on at least one inner circumferential surface (50b) of the main drum (50) and the secondary drum (60), configured to guide garment movements.
[0017]
17. A washing machine according to claim 16, characterized in that the plurality of elevators (101, 102) includes a plurality of main drum elevators (101) protruding inwardly from an inner circumferential surface (50b ) of the main drum (50) in a radial direction and a plurality of secondary drum elevators (102) protruding inwardly from an inner circumferential surface (60b) of the secondary drum (60) in a radial direction.
[0018]
18. Washing machine according to claim 17, characterized in that the inner circumferential surface (50b) of the main drum (50) includes a first surface not facing the outer circumferential surface of the secondary drum (60), and a second surface facing the outer circumferential surface of the secondary drum (60), and wherein main drum elevators (101) are provided on the first surface.
[0019]
19. Washing machine according to claim 18, characterized in that a proportion of the length of the main drum elevator (101) and the secondary drum elevator (102) in an axial direction of the drums is proportional to a length of the first surface of the inner circumferential surface (50b) of the main drum (50) and a length of the inner circumferential surface (60b) of the secondary drum (60).
[0020]
20. Washing machine according to claim 19, characterized in that the main drum elevators (101) and the secondary drum elevators (102) have a predetermined angle from the axial direction of the drums.
[0021]
21. Washing machine according to claim 18 or 19, characterized in that the main drum elevators (101) or secondary drum elevators (102) have variable heights along a direction of length thereof, the variable heights forming a straight line slope or a curved slope along the axial direction.
[0022]
22. Washing machine according to claim 3, characterized in that the secondary drum (60) has a cylindrical portion and the rear side of the secondary drum drum (60) is integrally formed with the cylindrical portion as one piece .
[0023]
23. Washing machine according to claim 22, characterized in that the receiving portion (63a) has coupling openings for coupling the secondary drum spider (95), and the secondary drum spider (95) has openings of coupling corresponding to the coupling openings of the receiving portion (63a).
[0024]
24. Washing machine according to claim 3, characterized in that the secondary drum (60) has a cylindrical portion as an independent member from the rear side of the drum, the rear side of the drum being coupled to a circumference outside the rear of the cylindrical portion to close the rear side.
[0025]
25. Washing machine according to claim 24, characterized in that the receiving portion (63a) extends to the outer circumference of the rear side of the drum, wherein an outer circumference of the rear side of the drum is folded into a direction along the length of the drum, and in which coupling openings are formed in a rear end portion of the cylindrical portion and in the bent portion of the rear side of the drum correspondingly.
[0026]
26. Method for assembling the drum for a washing machine, according to claim 1, characterized in that the method comprises: coupling an external shaft (81) to transfer driving force from the drive motor to the main drum (50) with a main drum spider (91), thereby fabricating a first spider-shaft assembly; coupling an inner shaft (82) to transfer driving force from the drive motor to the secondary drum (60) with a secondary drum spider (95) thereby manufacturing a second spider-shaft assembly; coupling the second spider-shaft assembly to the rear of the secondary drum (60); coupling the secondary drum (60) to the main drum (50); and coupling the first spider-shaft assembly to the rear of the main drum (50), wherein the secondary drum (60) has an open front side and a rear side closed by a rear of the secondary drum (62) forming a rear surface, wherein the secondary drum spider is disposed between the rear of the secondary drum (62) and the main drum spider (91), and is provided with a receiving portion (63a) for receiving the secondary drum spider (95), wherein the main drum spider (91) comprises a shaft coupling portion (92) coupled to the outer shaft (81), a spider support portion (93) extending radially from the shaft coupling portion (92 ), and a drum fastening portion (94) disposed at one end of the spider support portion (93) to be attached to the main drum (50), and wherein the drum fastening portion (94) is formed in a ring shape to be coupled to an outer circumferential surface of the primary drum. main (50).
[0027]
27. Method for assembling the drum according to claim 26, characterized in that the step of coupling the first spider-shaft assembly to the rear of the main drum (50) includes: coupling the inner shaft (82) to the outer shaft (81); press-fit a bearing onto the inner shaft (82); and after the bearing is press-fitted, mount a waterproof seal over the inner shaft (82).

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法律状态:
2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

---

2019-08-13| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-03-02| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-06-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-08-24| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/10/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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