KR20110023877A - Direct drive apparatus for drum-washing machine including an integrated cover-structured stator - Google Patents

Abstract

PURPOSE: A direct-coupled type operating unit of a drum washing machine including a stator of a cover unitary structure is provided to steadily operate a motor by minimizing the height in a shaft direction of the motor. CONSTITUTION: A stator support member(52) includes an internal extension part(58) and an external extension part(55). The internal extension part support one end of a rotary shaft(70) to be rotatable. The external extension part is expanded to an external direction in the internal extension part. The internal extension part and the external extension part surrounds a rotor(60) between a tub(40) of a drum washing machine and a stator(50). The stator support member constitutes a cover of the rotor.

Description

Direct Drive Apparatus for Drum-Washing Machine including an Integrated Cover-Structured Stator}

The present invention relates to a motor used in a drum washing machine, and more particularly, a direct connection of a drum washing machine including a stator having a split core structure and a stator having a cover integral structure for manufacturing a BLDC motor having a double rotor for a drum washing machine. It relates to a type drive device.

In general, the drum washing method is a method of washing the laundry using the friction force of the rotating drum and the laundry by receiving the driving force of the motor in a state in which detergent, washing water and laundry are put in the drum, there is little damage to the laundry, laundry These don't get tangled with each other and can have a pounding and scrubbing wash effect.

Existing drum washing machine has an indirect connection method in which the driving force of the motor is indirectly transmitted to the drum through a belt wound between the motor pulley and the drum pulley, and the shaft connected to the rotor of the BLDC motor is directly connected to the drum depending on the driving method. It is divided into a direct drive (DD) through which the driving force of the motor is transmitted.

Here, the belt-pulley driving method in which the driving force of the motor is not directly transmitted to the drum but is transmitted through a belt wound between the motor pulley and the drum pulley causes energy loss during the driving force transmission process, and generates a lot of noise in the power transmission process. Done.

Therefore, in order to solve the problems of the conventional drum washing machine, the use of a direct drum washing machine using a BLDC motor is increasing.

Meanwhile, in Japan and Europe, medium and small drum washing machines with a washing capacity of 5-8 kg are installed in a built-in manner for efficient use of indoor living spaces.

The size of a given installation space in which the washing machine can be installed in this built-in method is generally set to 600 × 600 × 600 mm, and the drum washing machine is installed from the tub of the drum washing machine in consideration of the washing capacity of the medium / small drum washing machine. The space (length) for installing the drive up to the rear housing of is set to approximately 45mm.

In this case, the tub is elastically supported by a spring and a damper inside the housing of the drum washing machine so as to absorb shock during forward / reverse rotation driving of the basket that is rotatably supported therein.

Therefore, in order to prevent the tub from being damaged when the flow occurs in the front and rear direction, it is necessary to secure a clearance (length) of approximately 15-20 mm, so that the space (length) for installing the driving device is subtracted from 45 mm to 20 mm. A space of 25 mm is given.

In the built-in drum washing machine, the driving device, that is, the driving motor, which can satisfy the 25 mm thickness condition cannot be presented due to the narrow space (length) in which the driving device can be installed.

That is, the drive motors developed to date have been developed for large drum washing machines having a thickness of 63 mm or more. Therefore, in a built-in drum washing machine, it is inevitable to reduce the washing capacity in order to implement them directly using such large drive motors. There was a problem to take to reduce the length of the tub.

Due to this situation, in order to reduce the size of the tub conventionally, the belt-pulley indirect driving method is adopted to place the motor in the lower part of the drum washing machine, and the basket must be indirectly driven through the belt wound on the pulley. The problem remains. Therefore, the need to reduce the size of the motor has been increased to apply to the drum washing machine.

Therefore, there is a demand for the development of a slim driving motor capable of satisfying the condition of 25 mm thick, which can be directly applied to a medium / small built-in drum washing machine having a washing capacity of 5-8 kg.

Hereinafter, referring to the attached FIG. 1, the structure of a direct drum washing machine using a BLDC motor according to the related art disclosed in Korean Laid-Open Patent Publication No. 2005-12399 is as follows.

1 is a schematic view showing a conventional direct drum washing machine.

Referring to FIG. 1, a tub 200 is installed inside a cabinet 100, and a drum (or basket) 300 is rotatably installed at an inner center of the tub 200. The motor 500 for rotating the drum 300 is installed in the support bracket 250 coupled to the tub 200.

The motor 500 is rotatably coupled by two upper / lower bearings 610 and 620 provided in the bearing housing 600 installed on the support bracket 250 facing the rear center portion of the tub 200. ) And a core type stator 520 which forms a rotating magnetic field by winding a coil and flowing current through the coil after laminating a plurality of iron cores, and is rotated by a rotating magnetic field formed by the stator 520 to drive a shaft ( The outer rotor 510 includes a magnet disposed at an outer circumference of the stator to rotate 700.

Here, the rotor 510 constituting the motor 500 is fastened to the center of the rear end of the driving shaft 700, and the tub 200, that is, the rear wall portion of the support bracket 250 is inside the rotor 510. The stator 520 which is fastened and fixed and constitutes the motor 500 together with the rotor 510 is positioned.

In the washing machine of FIG. 1, when an operation button is pressed to drive, a rotating magnetic field is generated in the stator 520 while power is applied to the stator 520 of the motor 500. This rotor magnetic field is generated at the tip of the winding part by a coil wound around the winding part (not shown) of the stator 520, so that the rotor 510 close to the tip of the winding part rotates according to Fleming's left hand law. Done.

Therefore, as the drive shaft 700 coupled to the upper and lower bearing housings 600 and the tub 200 is rotated by the rotation of the rotor 510, the drum 300 may be reversed to wash the laundry.

As described above, in the conventional direct type drum washing machine, when the motor 500 adopts the outer rotor structure and is installed in the space between the tub 200 and the back of the washing machine, the rear space from the tub 200 to the back of the drum washing machine ( A) is divided into the motor installation space B occupied by the motor 500 and the shaking space C of the tub 200 of approximately 20 mm.

However, the conventional motor 500 shown in FIG. 1 has a plurality of cooling fins and cooling holes around the tub of the rotor 510 to cool the heat generated by the stator 520. In the conventional motor 500, the cooling fin structure extending into the motor and the support bracket 250 coupled to the rear of the tub 200 serve as obstacles in designing a slim motor, and have a large capacity (washing capacity). 10Kg) It is mainly used for washing machines.

In general, a motor used as a drum driving device of a washing machine includes a stator wound around an integrated stator core or a split stator core in a single outer rotor to obtain large rotational inertia.

Therefore, designing such a conventional outer rotor type drive motor as a slim motor (thickness of 25 mm) that can be directly applied to a built-in drum washing machine is required for medium and small drum washing machines having a washing capacity of 5-8 kg. There is a problem of failing to match the drive torque.

On the other hand, since the core type BLDC motor has a structure in which the magnetic circuit is symmetrical in the radial direction about the axis, there is little vibrational noise in the axial direction, suitable for low speed rotation, and extremely small portion of the void in the direction of the magnetic path. High magnetic flux density can be obtained even by using this low magnet or reducing the amount of magnet, which has the advantage of high torque and high efficiency.

However, these cores, that is, yoke structures, have a large loss of material in yokes when producing stators, and due to the complicated structure of yokes, special expensive winding machines must be used for winding coils on yokes. In addition, there is a drawback that the investment in equipment is high due to the high investment in mold when manufacturing the stator.

In core-type AC or BLDC motors, especially radial type core motors, the configuration of the stator core in the fully split type determines the competitiveness of the motor because the coil can be wound around the split core with high efficiency using a low cost universal winding machine. This is a very important factor. On the contrary, in the case of the integrated stator core structure, an expensive dedicated winding machine is used and a low efficiency winding is made, thus increasing the manufacturing cost of the motor.

In the radial type core motor, the configuration of the stator core in the fully split type in order to improve the efficiency of the coil winding has a problem of not forming a complete magnetic circuit when combined with a single rotor.

In view of this point, the present applicant has proposed a BLDC motor capable of constituting the stator core in a fully split type by having a double rotor / single stator structure as a radial core type in Korean Laid-Open Patent Publication No. 2004-0002349. have.

In Korean Patent Laid-Open Publication No. 2004-0002349, the permanent magnet rotor is disposed on the inside and the outside of the stator core at the same time to form the flow of the jar by the inside and outside of the permanent magnet and the rotor yoke to completely divide the stator core. It is possible to propose a structure that can greatly increase the productivity of the stator core and the output of the motor by means of individual coil windings.

In addition, in Korean Patent Laid-Open Publication No. 2004-0002349, after preparing a plurality of split core assemblies having coils wound in accordance with splitting of cores, the integrated stator is formed by molding into a reduced shape by insert molding using a thermosetting resin. A schematic method of preparation was proposed.

However, Korean Patent Laid-Open Publication No. 2004-0002349 does not provide a stator assembly structure / method which can be effectively assembled when interconnecting coils by assembling a plurality of individual cores integrally before insert molding.

In consideration of this point, Korean Laid-Open Patent Publication No. 2005-0000245 discloses a reduced core support plate for accommodating and supporting a plurality of stator core assemblies wound at bobbins at regular intervals and simultaneously connecting a plurality of coils to phases. And, there is proposed a structure that can increase the assembly productivity of the stator by having an automatic positioning / support means for automatically positioning and supporting a plurality of stator core assemblies at regular intervals on the core support plate.

* The above-described BLDC motor will be described in more detail with reference to FIG. 2.

Referring to FIG. 2, the BLDC motor is supported by various fastening means such as bolts / nuts on the inner circumference of the core support plate 14 on the housing 20, and a plurality of fully split stator cores have a coil on the outer circumference of the bobbin. The stator 13 is wound and assembled in a reduction type, and a plurality of magnets 16a and 16b are disposed in a reducing type with a predetermined magnetic gap in the inner and outer circumferences of the stator 13, and the inner rotor 15a is disposed. ) And the outer rotor 15b are rotatably supported by the rotor 15 having a double rotor structure supported by the yoke frame 18 and the housing 20 through a bearing 11 and the yoke frame 18. It includes a rotary shaft 19 connected through the bushing 17 in the center of the.

The stator 13 is reduced by insert molding using a thermosetting resin in a state where a plurality of split stator cores are preassembled to a reduced core support plate 14 with a plurality of stator core assemblies wound around coils on a periphery of the bobbin. It is formed integrally with the mold.

In FIG. 2, reference numeral 12 denotes, for example, a power supply terminal block for a three-phase driving stator coil, and 10 denotes a cooling hole.

In the above-described motor, a core support plate 14 is disposed below the stator 13 to provide a connection space for connecting coils wound on a plurality of split stator cores, and to supply power to the motor coil. Since the terminal block 12 protrudes from the stator support, the overall thickness of the motor is made thick, such as about h = 63 mm, as shown in FIG. In addition, when the above-described motor is applied to the drum washing machine, since the drum diameter of the drum washing machine is large diameter of 220 to 260 mm, the diameter of the annular core support plate should also be large diameter in proportion thereto, which is very disadvantageous in terms of manufacturing cost and assembly of the annular core support plate. .

Since the overall thickness of the motor is so thick, it is desirable to integrate a plurality of stator cores wound with coils by insert molding using a thermosetting resin, without using the annular core support plate as described above.

On the other hand, in the case of a large motor, in general, a plurality of stator poles and a plurality of rotor poles form a combined structure, and in the case of a split core method, a continuous winding is made on a plurality of cores consisting of a plurality of split cores. It is preferable in terms of assembly productivity rather than winding the split cores individually.

The technique of fabricating a motor by assembling a plurality of split cores without an annular core support plate by such a continuous winding is disclosed in Patent No. 663641 registered by the present applicant.

In addition, the motor proposed in the patent performs the wiring of coils wound on a plurality of split cores in the lower space of the stator, the terminal block for supplying power to the motor coil protrudes in the thickness direction from the stator support, washing machine Since the inner extension of the stator support for coupling with the housing (for example, the tub) does not have a slim structure, it could not be applied as a slim motor that can be directly applied to the built-in drum washing machine.

Moreover, the conventional drum washing machine motor is exposed to the outside of the tub, so the driving noise of the motor is high, which is not preferable when installed indoors in a built-in manner.

On the other hand, tubs having a stator seating surface on which the stator is generally installed are large products made of injection molds, and thus, a large tolerance is generated due to difficulty in concentricity.

By the way, in the conventional drum washing machine, a pair of support bearings are provided on the tub at intervals to support the rotating shaft. As a result, the rotor is assembled on the basis of the rotation axis, and the stator is assembled on the basis of the tub having the stator seating surface with a large tolerance as described above, so that the air between the rotor and the stator is equal to the concentricity tolerance between the rotation axis and the tub. The gap will cause an error.

For example, if the air gap is set to 1mm, if an error of 0.5mm occurs, the air gap on one side is reduced to 0.5mm, the air gap at the opposite point is increased to 1.5mm.

As such, when an air gap error between the rotor and the stator occurs, non-uniform electromagnetic force is generated at opposite sides of the rotor when the rotor rotates, and vibration occurs, and the vibration noise is particularly disturbed by a low noise washing machine of a built-in type. To be an element.

Accordingly, an object of the present invention is to install the installed tubing in a 25-mm allowable space without reducing the size of the tub associated with the laundry capacity in the built-in medium / small drum washing machine can directly drive the basket inside the tub and low noise structure To provide a direct drive for a built-in drum washing machine having a cover-integrated stator of the.

Another object of the present invention is to provide a cover-integrated stator and a drum washing machine using the same, which can achieve a low noise and at the same time by arranging the rotating rotor to the inside of the motor and the opposite stator to the outside of the motor in an integrated cover structure To provide a direct drive for the drive.

Still another object of the present invention is to place a rotating rotor inside the motor and the opposite stator to the outside of the motor in a cover-integrated structure, and at the same time the rotating shaft support bearing is built in the stator and the rotating shaft support bearing is installed on the tub The present invention provides a cover-integrated stator capable of reducing the thickness of the tub by reducing the size of the tub to one, and a direct drive device for a built-in drum washing machine using the same.

Another object of the present invention is to support the one end of the rotary shaft to the rotating shaft support bearings built in the stator both the rotor and the stator can be assembled based on the rotation axis for a washing machine that can uniformly set the air gap between the rotor and the stator It is to provide a direct drive.

Another object of the present invention is to cover the stator of the rotor is coupled to the rotating shaft in the center of the motor and the outer surface of the stator is designed so that there is no protrusion to reduce the axial length (ie, thickness) of the motor to a minimum It is to provide a direct drive for the drum washing machine having a.

Another object of the present invention is to omit the wiring work between the divided core assembly in which coils are wound for each phase by continuously winding coil windings for a plurality of split stator cores for each of U, V, and W phases, and a thermosetting resin. It is to provide a slim stator that can be manufactured in a slim type by removing the PCB for split core assembly by using a coupling between bobbins for pre-assembly between adjacent split core assemblies for furnace molding, and a direct drive device for a drum washing machine using the same. .

Another object of the present invention is to increase the diameter of the motor and reduce the spot rate of the coils between adjacent split cores by increasing the number of slots and poles of the stator and rotor, thus ensuring a three-phase coil terminal in the space between the cores secured. By providing a terminal assembly holder and a terminal housing for connecting the power supply terminal block to minimize the height of the terminal block to provide a direct type drive device for a drum washing machine having a cover-integrated stator that can be made slim.

Another object of the present invention is a direct type drive (DD) of a drum washing machine which operates in a quick reversal method due to the high efficiency of the motor and the high driving torque of the motor by adopting a double rotor structure which does not reduce the size of the magnet, even though it is slim. To provide a slim motor suitable for).

Still another object of the present invention is to provide a slim motor that can be applied even if the inclination angle of the inclined drum washing machine is increased by shortening the axial length of the motor to the minimum and lowering the overall height and increasing the outer diameter.

Another object of the present invention is to insert a Hall sensor to the inside of the stator to fit the top loading structure, the outer sensor that can be mounted on the outer side of the rotating rotor to control the stop position of the motor to control the motor to the top loading drive outer It is to provide a direct drive for a drum washing machine having a stator structure.

A slim stator having a cover-integrated structure applied to a direct type driving device for a drum washing machine according to the present invention for achieving the above object comprises a plurality of split cores; Between the split stator core bobbins formed on the outer circumference of each of the plurality of split cores, surrounding the middle part, and having coupling flanges and coupling grooves at both side ends of the first flanges having flanges and disposed inside during assembly, respectively. A plurality of bobbins arranged in an annular shape by coupling the coupling grooves and the coupling protrusions to each other; A U, V, W three-phase coil continuously wound on bobbins of each phase alternately arranged for each of the U, V, and W phases; A stator support molded into an annular shape by insert molding using a thermosetting resin except for the inner and outer surfaces of each split core of the split stator core assembly having coils wound around the plurality of bobbins; It is characterized by consisting of an outer extension portion extending forward from the outer peripheral portion of the stator support coupled to the tub of the drum washing machine.

According to another feature of the invention, the slim stator having a cover-integrated structure applied to the direct drive device for a drum washing machine of the present invention is formed on the outer periphery of each of the plurality of split cores surrounding the middle portion and the first on one side and the other side. And U, V, and W three-phase coils are continuously wound on a plurality of bobbins each having a second flange and a coupling protrusion and a coupling groove at both end portions of the first flange disposed inwardly, and adjacent split core bobbins. A split stator core assembly assembled in an annular manner by coupling the coupling groove and the coupling protrusion to each other; A stator support molded into an annular shape by insert molding using a thermosetting resin except for the inner and outer surfaces of each split core of the split stator core assembly; It is characterized by consisting of an outer extension portion extending forward from the outer peripheral portion of the stator support coupled to the tub of the drum washing machine.

The stator support and the outer extension form a cover surrounding the rotor disposed between the stator and the tub.

In this case, the stator support further includes a support bearing for rotatably supporting one end of the rotating shaft coupled to the rotor at a central portion extending in the axial direction from the outside of the stator.

In addition, U, V, W three-phase coils are disposed between a plurality of divided cores wound around the first to the first to be used to connect the coil terminal on one side of the U, V, W three-phase coil and the three-phase lead wire for external drawing The terminal assembly holder may further include a terminal housing having a common terminal housing used to connect the other terminal of the three-terminal housing and the U, V, and W three-phase coils to form a neutral point.

In this case, the bobbin further includes first and second coupling protrusions respectively formed at centers of lower ends of the first and second flanges, and the terminal assembly holder is coupled to and fixed to the first and second coupling protrusions. It is preferable to further include.

The coil wound around the split stator core is preferably made of Al.

According to another feature of the present invention, the drum type washing machine direct drive device includes a rotating shaft having one end rotatably mounted to the tub of the drum washing machine and having a basket coupled to the front end thereof; Internal and external rotors each of which a plurality of N-pole and S-pole magnets are alternately arranged in a reducing phase on different concentric circles, and opposite magnets are arranged to have opposite polarities at a predetermined distance between the inside and the outside; And a double rotor having a rotor support connected to one end of the outer rotor and extending in a bushing in which the inner circumferential portion is positioned at the center of gravity of the rotor and engaged with the rotating shaft; A split stator core assembly, which is assembled in an annular shape by winding U, V, and W three-phase coils continuously and alternately around a plurality of split cores each having an integral bobbin integrally formed on the outer circumference thereof, is integrated by a stator support, and the tip portion is integrated inside the stator support. Disposed between the rotor and the outer rotor, wherein the stator support extends forwardly from the outer circumference to form an inner extension portion extending in the axial direction so as to rotatably support the other end of the rotating shaft at a center thereof, and a cover surrounding the rotor; And characterized in that it comprises a stator having an outer extension that is fixedly coupled to the tub.

According to another feature of the present invention, a direct type driving device for a drum washing machine of the present invention includes: a rotating shaft having one end rotatably mounted on a tub of the drum washing machine and having a basket coupled to a front end thereof; Internal and external rotors each of which a plurality of N-pole and S-pole magnets are alternately arranged in a reducing phase on different concentric circles, and opposite magnets are arranged to have opposite polarities at a predetermined distance between the inside and the outside; And a double rotor having a rotor support connected to one end of the outer rotor and extending in a bushing in which an inner circumference thereof is coupled to the rotating shaft. A split stator core assembly, which is assembled in an annular shape by winding U, V, and W three-phase coils continuously and alternately around a plurality of split cores each having an integral bobbin integrally formed on the outer circumference thereof, is integrated by a stator support, and the tip portion is integrated inside the stator support. A stator disposed between the rotor and the outer rotor and rotatably supporting the other end of the rotating shaft at the center of the inner extension extending axially from the stator support, the stator support forming a cover surrounding the rotor; It extends forward from the outer peripheral portion is characterized in that it further comprises an outer extension fixedly coupled to the tub.

In this case, the bobbin is formed on the outer periphery of each of the plurality of split cores and surrounds the middle part, and has first and second flanges on one side and the other side, respectively, and is coupled to both side ends of the first flanges disposed inside during assembly. The protrusion and the coupling groove may be arranged in an annular shape by coupling the coupling groove and the coupling protrusion between adjacent split stator core bobbins.

In addition, the U, V, W three-phase coil is disposed between a plurality of divided core windings, the first to third terminals connecting one coil terminal of the U, V, W three-phase coil and the three-phase lead wire for the external extraction It is preferable to further include a terminal assembly holder having a common terminal housing for connecting the housing and the other coil terminals of the U, V, W three-phase coil to form a neutral point.

The bobbin is formed on the outer circumference of each of the plurality of split cores and surrounds the intermediate portion, and includes first and second flanges on one side and the other side, and adjacent bobbins respectively adjacent to both side ends of the first flange disposed inside during assembly. It is preferable to have a coupling protrusion and a coupling groove coupled to each other.

In addition, the driving device includes a first support bearing installed on the tub to support one end of the rotating shaft, and a second support bearing installed on the inner center of the stator support to rotatably support the other end of the rotating shaft. It is preferable to further include.

Furthermore, the apparatus may further include a magnetic member installed on an outer circumferential surface of the rotor and a Hall sensor installed inside the outer extension of the stator to generate a signal for detecting a position of the magnetic member. have.

According to another feature of the invention, the slim motor having a cover-integrated stator of the present invention includes a rotating shaft rotatably mounted to the housing of the device and the driven body coupled to the front end; Internal and external rotors each of which a plurality of N-pole and S-pole magnets are alternately arranged in a reducing phase on different concentric circles, and opposite magnets are arranged to have opposite polarities at a predetermined distance between the inside and the outside; And a double rotor having a rotor support connected to one end of the outer rotor and extending in a bushing in which the inner circumferential portion is positioned at the center of gravity of the rotor and engaged with the rotating shaft; A split stator core assembly, which is assembled in an annular shape by winding U, V, and W three-phase coils continuously and alternately around a plurality of split cores each having an integral bobbin integrally formed on the outer circumference thereof, is integrated by a stator support, and the tip portion is integrated inside the stator support. Disposed between the rotor and the outer rotor, wherein the stator support extends forwardly from the outer circumference to form an inner extension portion extending in the axial direction so as to rotatably support the other end of the rotating shaft at a center thereof, and a cover surrounding the rotor; And a stator having an outer extension portion fixedly coupled to the housing.

In addition, the slim motor according to the present invention includes a rotating shaft rotatably mounted in the housing of the device; Internal and external rotors each of which a plurality of N-pole and S-pole magnets are alternately arranged in a reducing phase on different concentric circles, and opposite magnets are arranged to have opposite polarities at a predetermined distance between the inside and the outside; And an end portion extending from the inner rotor to the center portion while forming a trench-type space between the inner and outer rotors while simultaneously integrating into a reduction type except for the opposite magnet surface of the outer rotor, and connecting with the outer peripheral surface of the bushing coupled to the rotating shaft. An integrated double rotor comprising a rotor support molded to be thermosetting resin; And a plurality of independent split stator cores each having a bobbin wound around U, V, and W phase coils, and the input terminals of each of the U, V, and W phases are drawn out in a space between the split stator cores, and a neutral point It is arranged in a reducing type so as to be connected to a common terminal, and is integrally formed in a reducing type by a stator support except for the inner and outer surfaces of the split type stator core by insert molding using a thermosetting resin. One end is disposed in the trench space between the rotors, and an outer circumference and a central axis are fixed to the housing of the device and include an integrated stator covering the double rotor.

As described above, in the present invention, the built-in medium / small drum washing machine may be installed in an allowable 25 mm space without reducing the size of the tub related to the washing capacity, thereby directly rotating the basket inside the tub.

In addition, in the present invention, a plurality of split core assemblies may be assembled by injection molding using a thermosetting resin without using a separate core support plate by using a coupling structure of a bobbin and a continuous coil winding to implement a slim stator. Can be.

Furthermore, in the present invention, it is possible to minimize the axial height of the motor suitable for installation in a built-in drum washing machine with a narrow motor employing space, thereby achieving stable motor driving, and suitable for a drum washing machine operating in a quick reverse type with high torque. To provide the effect of driving the motor.

In addition, the present invention provides an effect that can be applied even if the inclination angle of the inclined drum washing machine is minimized because the axial height of the motor is minimized.

Furthermore, in the present invention, the stator is an outer-stator structure in which the stator is disposed on the outside of the motor to form a cover-integrated structure, thereby preventing the noise generated from the rotor rotating therein from leaking to the outside, thereby reducing the noise level. . In addition, in the present invention, since the stator forms the cover structure of the motor, a separate cover is not required, which may contribute to slimming of the motor.

In addition, in the present invention, the stator covered on the outside of the tub of the drum washing machine does not rotate in an exposed state, thereby providing an excellent effect in terms of stability.

In addition, in the present invention, the rotating rotor is placed inside the motor, and the opposite stator is disposed outside the motor in a cover-integrated structure, and the rotating shaft supporting bearing is installed in the tub by embedding the rotating shaft supporting bearing in the stator. By reducing the size from two to one, the back thickness of the tub can be slimmed down.

1 is a schematic view showing a conventional direct drum washing machine,
2 is a cross-sectional view of a motor incorporating a plurality of split core assemblies into a core support plate;
Figure 3a is a cross-sectional view cut along the axial direction of the drum washing machine coupled to a slim motor according to an embodiment of the present invention,
3B is an exploded perspective view of FIG. 3A;
4 is a perspective view of a split stator core used in a slim motor according to the present invention;
5A and 5B are side views of the split stator core of Fig. 4 and cross-sectional view taken along line BB of Fig. 5A, respectively;
6 is a perspective view for explaining a fastening state of adjacent divided stator cores;
7 is a perspective view of a split stator core assembly completed by assembling a plurality of split stator cores in an annular shape;
8 is a perspective view for explaining a terminal assembly holder disposed on the completed split stator core assembly;
FIG. 9 is a conceptual view illustrating a coil winding, a layout, and a connection state of a three-phase driving method for the split stator core assembly of FIG. 8; FIG.
10A is a reference diagram for explaining a U-phase terminal assembled to the terminal assembly holder of FIG. 8;
10B is a reference diagram for explaining a common terminal assembled to the terminal assembly holder of FIG. 8;
11A and 11B are a perspective view and a plan view of a stator in a slim motor according to the present invention;
12A and 12B are a perspective view and a bottom view of a rotor in a slim motor according to the present invention.

The present invention provides a slim-type motor having a thickness (or height) of about 25 mm or less so as to be suitable for use in a narrow motor installation space in a built-in type direct drive device for a medium / small drum washing machine or another device requiring a motor. In particular, the present invention relates to a motor having an outer-stator structure in which a stator is disposed externally and at the same time having an integrated cover structure.

In the slim motor of the present invention, first, the slim structure and the high driving torque suitable for the quick reverse type driving of the drum washing machine are shown, and considering the coil winding workability by the complete division of the stator core, The double rotor structure was not employed in size, and as a result, the magnetic circuit of the motor was defined as a double rotor / single stator structure circulating "inner rotor-division core-external rotor-adjacent split core".

In addition, the stator performs a winding operation between the split core assembly in which coils are wound for each phase by continuously winding coil windings for a plurality of split cores for each phase (U, V, and W) in order to slim the thickness direction. Omitted, pre-assembly between adjacent split core assemblies for molding with a thermosetting resin was used to avoid the use of any assembly PCB or support required for assembly of split cores by the use of coupling between bobbins.

In general, as the number of poles of the motor increases as in the present invention, the rotation speed (rpm) is lowered (a drum washing machine does not require a high rpm), but a coil can be wound around each stator core.

In view of this, the present invention contemplates that the coil between adjacent split cores may be increased by increasing the diameter of the motor and increasing the number of slots and poles of the stator and rotor to minimize the height of the terminal block for powering the stator. Slimming was achieved by disposing a terminal assembly holder and a terminal housing for connecting the three-phase coil terminal with the power supply terminal block in the space between the cores secured by lowering the spot ratio.

Furthermore, in the present invention, the bushing of the rotor coupled to the rotating shaft and the inner extension of the stator coupled to the tub are disposed on the center of gravity of the motor and its circumference to prevent the thickness from increasing in the axial direction of the motor.

In addition, it is possible to use the stator as a cover of the motor to achieve a low noise structure desirable for the built-in type, and to contribute to the slimming of the motor because a separate cover is not needed. It is also possible to install a magnet on the outside of the hall sensor and the corresponding rotor.

Hereinafter, exemplary embodiments will be described in detail with reference to the accompanying drawings.

A. Motor overall structure

Figure 3a is a cross-sectional view taken along the axial direction of the drum washing machine coupled to a slim motor according to an embodiment of the present invention, Figure 3b is an exploded perspective view thereof.

Referring to FIG. 3A, the slim motor 1 is installed on the rear surface of the tub 40 of the built-in medium / small drum washing machine to directly rotate the basket 30 located inside the tub 40 in the forward / reverse direction. It can be used to drive and can also be applied to devices other than washing machines.

The slim type motor 1 according to the present invention is a reduced stator manufactured by insert molding using a thermosetting resin after the coil 59 is wound around the bobbin, in which a plurality of split type stator cores 51 are not shown. A stator 50 integrally formed by the support body 52; An inner rotor 60a having a predetermined magnetic gap in the inner and outer peripheral portions of the stator 50 and a plurality of magnets 63 and a ring-shaped inner yoke 64 are disposed in a reducing manner. The outer rotor 60b, in which the magnet 62 and the ring-shaped outer yoke 61 are disposed, and one end of the inner rotor 60a and the outer rotor 60b are interconnected and extended to the center of the bushing ( A rotor (60) made of a rotor support frame (65) coupled to the back; Involute Serration bushing 67 in the center of the rotor 60 is engaged with the rotor 60 and one end is rotatably supported through the bearing 71 is integrally installed on the stator 50 and the other end The rotary shaft 70 is rotatably supported by at least one bearing 73 or 75 provided in the tub 40.

The stator 50 has a plurality of split stator cores 51, which are completely divided, are integrally formed in a reduced type by the reduced stator support 52, and the stator support 52 has an inner extension 58 inwardly. ) Is extended to be coupled to the bearing 71 and the rotating shaft 70 is rotatably supported by the bearing (71).

The motor 1 of the present invention has an outer-stator structure in which the stator 50 is disposed outside and the rotor 60 is disposed inside, as shown in FIG. 3, and the stator 50 has an outer stator structure. The outer extension part 55 which forms the annular cover for fastening with the tub 40 of the washing machine is formed along the annular outer peripheral part.

Therefore, the motor 1 of the present invention can be slimmed down because the stator 50 performs the role of a cover at the same time without having to provide a separate motor cover, and can achieve a low noise structure suitable for the built-in type.

The stator 50 has a plurality of fully divided split stator cores 51 are integrally formed by a reduced stator support 52 into a reduced type, and the stator support 52 has an outer circumferential portion extending forward. The extension part 55 is fixed to the tub 40 of the washing machine.

In this case, the rotor 60 is connected to the bushing 67 disposed about the center of gravity of the rotor by a bushing support 68 extending from the rotor support frame 65 so that the rotational force is transmitted to the rotation shaft 70, The rotation shaft 70 is rotatably supported by the bearings 71, 73, 75 disposed at the center of the stator support 52 and the center of the tub 40, respectively. In addition, the front end of the rotating shaft 70 is rotatably supported in the tub 40 of the washing machine and the basket 30 for receiving the laundry is coupled, and drives the basket 30 in accordance with the operation of the motor (1). .

Here, when used as a drive for a large-capacity washing machine, for example, it is designed in a 27-24 pole or 36 pole structure, the slim type motor 1 according to the present invention has a diameter of the motor in order to lower the spot ratio of the coil to the stator Is relatively large, and thus, for example, a 36 slot-48 pole structure is designed to increase the number of magnets in the stator core and the rotor.

Accordingly, the inner rotor 60a and the outer rotor 60b of the double rotor 60 may be formed on the outer and inner surfaces of the inner and outer yokes 64 and 61 having 48 magnets 63 and 62 annular, respectively. In the annular space between the double rotors 60, an integrated stator 50 including a split stator core 51 wound with 36 coils is inserted.

The slim motor 1 according to the present invention increases the diameter of the motor relatively large in order to lower the droplet rate of the coil relative to the stator, and thus, for example, is designed in a 36 slot-48 pole structure. In addition, it has a structure that increases the number of magnets of the stator core and the rotor.

Accordingly, the motor 1 of the present invention basically comprises a double stator 50 and a single stator 50 in which the inner rotor 60a and the outer rotor 60b are supported by the rotor support frame 65. Core type BLDC motor is formed.

On the other hand, when the above-described motor (1) is applied to a drum washing machine driven in the top loading (top loading) form, as shown in Fig. 3a, the hall sensor 91 is inserted into one side of the stator 50, and corresponding thereto The magnet 92 can be provided on the outside of the rotor 60. Therefore, the hall sensor 91 senses the position of the magnet 92 for the top loading driving to determine the stop position of the laundry inlet of the basket 30 to enable the top loading driving. Here, the detection signal of the hall sensor 91 may detect a signal from the hall sensor 91 and control the driving of the motor 1 in the motor driving controller without using a separate signal sensing controller.

3B is an exploded perspective view of the drum washing machine and the slim motor, in which the basket 30 is disposed inside the tub 40, and the rear side of the tub 40 is coupled to the motor 1, which is a basket driving device. The disk-shaped support bracket 45 is coupled by using a plurality of fixing screws or bolts / nuts for ease.

In addition, a plurality of, for example, eight coupling fixing protrusions 45a protrude from the outer surface of the support bracket 45, and the coupling fixing protrusions are formed in the outer extension part 55 of the stator 50 corresponding thereto. The same large number as 45a), for example, eight coupling fixing parts 55a are integrally formed. Therefore, the stator 50 is fixed to the rear surface of the tub 40 by fastening the fixing bolt to the coupling fixing portion 55a.

Therefore, in the present invention, when assembling and fixing the support bracket 45 to the rear surface of the tub 40 when assembling the motor 1 to the tub 40, one end is connected to the basket 30, the middle portion of the tub The other end of the rotation shaft 70 rotatably supported by the bearings 73 and 75 provided in the 40 protrudes outward.

Thereafter, the bushing 67 of the rotor 60 is fastened to the serration portion 70a of the protruding rotation shaft 70, and then a fixing bolt is attached to the coupling fixing portion 55a of the outer extension portion 55. When fastened and fixed to the coupling fixing protrusion 45a of the support bracket 45, the stator 50 is fixed to the rear surface of the tub 40, and the other end of the rotation shaft 70 is rotated on the bearing 71 installed on the stator 50. Possibly supported.

Therefore, in the present invention, the stator 50 is disposed in the cover-integrated structure outside the rotor 60 and the rotary shaft support bearing 71 is installed in the tub 40 by embedding the rotary shaft support bearing 71 in the stator 50 ( It is possible to reduce the number 73,75 from two to one, and as a result, at least one bearing can be slimmed down the back thickness of the tub 40 by a corresponding thickness.

In addition, in the present invention, as described above, by supporting one end of the rotary shaft 70 to the rotary shaft support bearing 71 built in the stator 50, the rotor 60 and the stator 50 are all one rotary shaft 70. Assembly is made on the basis of. As a result, in the present invention, the air gap between the inner rotor 60a and the outer rotor 60b and the stator 50 can be set uniformly, and vibration noise due to air gap nonuniformity can be solved.

Moreover, when the stator is bolted to the tub and fixed in the outer rotor type motor as in the prior art, deformation or damage caused by stress while the tub or the support bracket are applied by the electromagnetic force generated when power is applied to the coil of the stator This can happen.

However, when the rotary shaft 70 is supported by the rotary shaft support bearing 71 built in the stator 50 as described above, the damage can be reduced, the warpage is prevented, and the load generated during the rotation of the rotor is distributed and supported. It has an advantageous structure.

B. Stator Structure and Manufacturing Process

4 is a perspective view of a split stator core used in a slim motor according to the present invention, and FIGS. 5A and 5B are front and cross-sectional views of the split stator core of FIG. 4.

4 to 5B, the split stator core 51 may be formed, for example, in an “I” shape, and may have an “I” shape in the insulating bobbin 54 surrounding the split core 53 therein. The coil (not shown) is wound around the outer periphery of the bobbin 54 in an integrally formed state, and then the outer surface is molded with a thermosetting resin by an insert molding method to obtain an annular integrated stator 50. . Cu is generally used as a material of the coil, but in order to reduce the weight of the motor, specific gravity is 1/3, and it is also possible to use Al, which is relatively inexpensive. Generally, Al is difficult to apply as a motor coil due to an oxidation problem, but in the present invention, the coil is wound around the stator core assembly using a thermosetting resin, so that the oxidation problem does not occur.

In addition, the split core 53 is formed by stacking a plurality of silicon steel sheets in order to prevent loss of magnetic flux due to eddy current that may occur when the motor rotates, or soft magnetic material having high permeability and high permeability. Soft magnetic compounds can be sintered and used.

The bobbin 54 of the I-shape is composed of a square barrel portion in the middle portion of which the coil is wound, and inner and outer flanges 54a and 54b which are bent and extended respectively inside and outside the square barrel portion, and these flanges ( The square cylinder portion between 54a and 54b is a space in which the coil can be wound. Here, the inner and outer flanges 54a and 54b of the bobbin 54 should preferably be made relatively larger than the inner flange 54a because the outer flange 54b is disposed outside the stator. .

Split stator core 51 has a coupling groove (A) and the engaging projection (B) formed in the vertical direction on both sides for the coupling between the inner circumferential surface of the inner flange (54a) to be assembled later annular, the outer flange ( 54b) The outer circumferential surface is formed by contacting the circumferential forming surfaces C with each other. And the lower part of the inner and outer flanges 54a and 54b of the bobbin 54 is provided with a pair of engaging protrusion D for assembling the terminal assembly holder 80 (refer FIG. 7), respectively.

FIG. 5A shows the front of the split stator core 51, and a cross-sectional view taken along the line B-B in FIG. 5A is shown in FIG. 5B.

Referring to FIG. 5B, it can be seen that an I-shaped split core 53 inserted into the split stator core 51 is formed, and a bobbin 54 wrapped along the outer periphery of the core is formed. The bobbin 54 has a coupling groove A and a coupling protrusion B formed in the inner flange 54a, and a circumferential forming surface C is formed in the outer flange 54b.

The assembly between the split core 53 and the bobbin 54 is preferably integrally molded by an insert molding method using a thermosetting resin, but is not limited thereto, and may be assembled by other well-known methods.

A method of manufacturing the annular unitary stator 50 by assembling each of the divided stator cores 51 will be described below.

FIG. 6 is a perspective view illustrating a fastening state of the split stator core of FIG. 4, and FIG. 7 is a perspective view of a completed split stator core assembly in which the split stator core of FIG. 4 is annularly assembled.

Hereinafter, for convenience of description, a coil is not wound around each of the split stator cores. However, when the stator 50 is manufactured by insert molding, a three-phase (U-phase, V-phase, W-phase) coil is used. It is obvious that this must be wound. A three-phase coil and its connection will be described below with reference to FIG. 9.

6 and 7, the bobbin 54 of each split stator core 51 has a coupling groove A formed at one side of the inner flange 54a, and a coupling protrusion B formed at the other side. The outer flange 54b has a circumferential forming surface C formed thereon. Each split stator core 51 has an inner circumferential surface as the engaging groove A of the split stator core 51 'adjacent to its engaging protrusion B is coupled, and when the inner circumferential surfaces are coupled, two splits are provided. The circumferential forming surfaces C of the mold stator cores 51 and 51 'abut each other to form an outer circumferential surface.

When the coupling grooves A and the coupling protrusions B of the respective divided stator cores 51 bobbin 54 are continuously interconnected, the divided stator core assembly 2 is completed as shown in FIG. 7.

Referring to FIG. 7, the inner circumferential surface is coupled to each split type stator core 51 by the coupling groove A on one side and the coupling protrusion B on the other side, and the outer circumferential surface is formed by contacting the circumference forming surface C. The bottom view of the state in which the annular split stator core assembly 2 is formed is shown in perspective view.

A terminal assembly holder 80 for connecting the coil is coupled to a portion of the bottom surface of the split stator core assembly 2. A pair of engaging projections D provided at both ends of the inner circumferential surface and the outer circumferential surface of the split stator core 51 are coupled to the engaging holes 85 of the terminal assembly holder 80.

FIG. 8 is a perspective view illustrating a terminal assembly holder disposed on the completed split stator core assembly, and FIG. 9 is a view illustrating a state in which a coil is wound around the split stator core assembly of FIG. 8 and drawn out to the terminal assembly holder. This is a conceptual diagram.

Referring first to FIG. 8, the terminal assembly holder 80 has a plurality of engaging holes 85 for engaging with the split stator core assembly 2. In addition, the terminal assembly holder 80 and the U-phase terminal housing 81 for connecting with the U-phase lead wire 81c (see Fig. 10A) of the U-phase coil 59a wound on the split stator core assembly 2, V-phase terminal housing 82 for connecting the V-phase terminal of the V-phase coil 59b wound on the split-type stator core assembly 2 with the V-phase lead wire (not shown), and the split-type stator core assembly 2 W-phase terminal housing 83 for connecting the W-phase terminal of the W-phase coil 59c wound around the W-phase lead wire (not shown), and the coil 59a of three-phase (U-phase, V-phase, W-phase). -59c) a common terminal housing 84 for interconnecting each other. Each housing 81, 82, 83, 84 of the terminal assembly holder 80 configured as described above is disposed between each of the split stator cores 51 when connected to the split stator core assembly 2, and thus, a slim motor. (1) can be manufactured to minimize the height of the motor (1).

Hereinafter, a method of manufacturing the stator 50 will be described with reference to FIGS. 7 to 10.

In the present invention, when the stator 50 is a three-phase driving method, the coil windings for the plurality of split stator cores 51 ', 51 ", and 51"' are continuously wound for each phase (U, V, W). do. When the magnetic circuit of the motor consists of, for example, 36 slots-48 poles, each of the U, V, and W phases is provided with coils 59a-59c in each of the 12 divided stator cores 51 ', 51 ", 51"'. By winding continuously, the wiring work between the divided stator cores in which coils are wound for each phase can be omitted.

Subsequently, 36 divided stator cores 51 ', 51 ", 51"' wound with coils are alternately arranged for each of U, V, and W phases as shown in FIG. 9, and adjacent divided stator cores 51 'are disposed. , 51 ", 51 " 'are continuously connected to the coupling groove A and the coupling protrusion B of the bobbin 54 as shown in FIG.

Thereafter, the engaging stator D provided at both ends of the inner circumferential surface and the outer circumferential surface of the split stator core 51 is engaged with the engaging hole 85 of the terminal assembly holder 80 to thereby form the split stator core assembly 2. The terminal assembly holder 80 for connecting the coils (59a-59c) to a portion of the bottom surface is coupled as shown in FIGS.

Subsequently, one terminal of the three coils 59a-59c, which are sequentially wound on 12 divided stator cores 51 ', 51 ", 51"' for each phase, is connected to the wire holder using the terminal housing 81-83. Connect the U, V, and W phase lead wires to the 57, and the other terminals of the three coils 59a to 59c connect the U, V, and W phases to each other to form a neutral point (COMMON). Is connected to the inserted common terminal housing (84).

Hereinafter, a method of assembling one terminal and the other terminal of the three-phase (U, V, W) coil with each housing will be described in more detail with reference to FIG. 10.

10A is a reference diagram for explaining a U-phase terminal assembled to a U-phase terminal housing in a terminal assembly holder.

Referring to FIG. 10A, the U-phase coil 59a drawn out in FIG. 9 is inserted before the U-phase terminal housing 81. Then, the mat mate terminal 81a is inserted into the groove provided in the upper portion of the U-phase terminal housing 81, and the unnecessary U-phase coil is cut. The poke-in terminal 81b to which the U-phase lead wire 81c is connected is inserted into and connected to the mate terminal 81a. The V-phase coil 59b and the W-phase coil by inserting and processing the V-phase coil 59b and the W-phase coil 59c into the terminal housings 82 and 83 in the same manner for the V-phase terminal and the W-phase terminal, respectively. The V-phase and W-phase lead wires are respectively connected to 59c.

FIG. 10B is a reference diagram for explaining a method of forming the neutral point NP using the common terminal housing installed in the terminal assembly holder.

Referring to FIG. 10B, the other terminals of the three-phase coils 59a to 59c drawn in FIG. 9 are inserted before the three insertion grooves formed in the common terminal housing 84. Then, when the common mat for mat mate 84a is inserted into the common terminal housing 84, the other terminals of the three-phase coils 59a to 59c are interconnected by the conductors for the mat mate 84a so that the neutral point NP is formed. Is formed.

When the terminal processing of the three-phase coil (59a-59c) using the terminal assembly holder 80 and the housing (81-84) is made, as shown in FIG. 8, the connection of the divided stator core assembly (2) is divided. Since the stator is formed on the terminal assembly holder 80 inserted between the stator cores 51, the stator can achieve a slim structure.

As described above, the divided stator core assembly 2 having completed the connection is completed molding the stator support 52 by insert molding. This will be described below with reference to FIG. 11.

11A and 11B are a perspective view and a plan view of a stator applied to a slim motor according to the present invention.

Referring to FIGS. 11A and 11B, the stator 50 uses a thermosetting resin for the split stator core assembly 2 obtained by assembling a plurality of split stator cores 51 along an annular outer circumference as shown in FIG. 7. The stator support 52 formed by insert molding is integrally molded in a reduction type, and an outer extension 55 extends forward in the outer peripheral portion of the stator support 52. A plurality of coupling fixing parts 55a are formed at the front end of the annular outer extension part 55 and are coupled to the tub 40 through the coupling part 55a.

In addition, the stator 50 has a rotation shaft support bearing 71 disposed at the center thereof, and the stator support 52 has an inner extension 58 extending in the axial direction. The inner extension portion 58 is formed in a plate shape from the bearing support surrounding the rotating shaft support bearing 71 to the stator support 52 surrounding the split stator core assembly 2, and the outer surface is a radial majority. Ribs 56a are arranged, and a weight loss groove 56 is formed in the space between the ribs 56a.

In this case, the stator support 52 and the inner extension portion 58 of the stator 50, as shown in Figure 3a, because the outer surface is implemented in a slim shape that does not protrude any portion from the vertical line slim rotor 60 ) And organically assembled, the overall motor has a slim structure.

In addition, a wire holder or a terminal block 57 is provided on the outer circumferential surface of the outer extension part 55 so as to draw the three-phase lead wire drawn out from the inner terminal assembly holder 80 to the outside. A Hall IC assembly 76 is formed which generates a position signal for detecting the position of the rotor 60 which is being rotated to control the supply of current to the stator 50 coil of the phase drive method.

The stator 50 may be directly coupled to the tub 40 or the support bracket 45 to serve as a cover surrounding the outside of the motor 1, and the rotating rotor 60 may be formed of the stator 50. Since it is inserted inside and there is no rotating body on the outside, safety is improved. In addition, the stator 50 also serves to reduce the level of noise generated when the rotor 60 rotates by covering the rotating rotor 60.

The insert molding described above may include, for example, a space between each split stator core assembly 2 except for the split core 53 exposed to the outside of each split stator core 51 with a bulk molding compound (BMC). When molded so as to cover the upper and lower winding coil portions and the bobbin 54, a reduced type integrated stator 50 is obtained.

In addition to the insert molding BMC, other thermosetting resins may be used.

C. Rotor Structure and Manufacturing Process

12A and 12B are a perspective view and a bottom view of a rotor that can be employed in a slim motor according to the present invention.

12A and 12B, the rotor 60 is disposed on an injection molding mold such that an involute serration bushing 67 is positioned at the center of the inner rotor 60a and the outer rotor 60b. It is prepared by insert molding with a thermosetting resin, for example, BMC (Bulk Molding Compound) in one state.

The inner rotor 60a and the outer rotor 60b are thermosetting so as to maintain a plurality of magnets 63 and 62 disposed on the ring-shaped yokes 61 and 64, respectively, as described in the cross-sectional view of FIG. 3A. It is connected by a rotor support frame 65 made of resin, and as a result, a trench type groove 65a is formed between the inner rotor 60a and the outer rotor 60b into which the front end portion of the stator 50 is inserted.

In addition, the rotor support frame 65 is integrally connected to the bushing support 68, the front end of which supports the bushing 67 through an inclined connection 69 extending toward the center of gravity of the rotor 60. The outer surface of the inclined inclined connecting portion 69 is made of a flat surface, a plurality of ribs with a thickness gradually decreasing from the outer side to the center direction may be disposed radially.

As a result, the rotor 60 has a slim structure that prevents the thickness from increasing in the axial direction while minimizing vibration generated when the rotor 60 rotates.

Therefore, the rotor support frame 65 is formed of the upper and lower surfaces and the ring-shaped yokes 61 and 64 except for the opposing surfaces of the plurality of magnets 63 and 62 in the inner rotor 60a and the outer rotor 60b. Trench forming portion 65b and a trench forming portion 65b which form a trench-shaped groove 65a in which the tip of the stator 50 is inserted between the inner rotor 60a and the outer rotor 60b. From the inclined connector 69 inclined toward the center of gravity of the rotor 60 and a bushing support 68 supporting the bushing 67 therein and having a tip portion of the inclined connector 69 connected to the outer periphery thereof. It is integrally formed with a thermosetting resin.

Referring to FIG. 3A, the double rotor 60 has a plurality of magnets 63 divided and magnetized into an N pole and an S pole, respectively, on the outside of the reducing inner yoke 64 by alternatingly using an adhesive. A rotor 60a is formed, and a plurality of magnets 62 divided and magnetized into N and S poles are alternately arranged using an adhesive, respectively, inside the reduced outer yoke 61 to form the outer rotor 60b. Form. In this case, the opposing magnets of the inner rotor 60a and the outer rotor 60b are disposed to have opposite polarities.

In addition, the magnets of the inner rotor (60a) and the outer rotor (60b) may be integrated into an internal shape that can be fixed to the magnet position on the mold without a separate bonding process.

When the insert molding, the inner rotor (60a) and the outer rotor (60b) is molded in an annular shape of the outer surface except for the opposite surface of the magnet facing each other.

In addition, since the rotor 60 of the present invention has a plurality of magnets 63 and 62 of the inner rotor 60a and the outer rotor 60b arranged concentrically by insert molding, the roundness is high and assembled with the stator 50. It is possible to maintain a uniform magnetic gap.

Therefore, as described above, in the present invention, the rotor 60 and the stator 50 are each designed to be slim, and by combining them, the overall thickness (that is, the height) of the motor 1 can be reduced. The motor thickness of the embodiment can be manufactured to 25mm or less.

In addition, in the present invention, in order to improve the coil winding workability, while the core of the stator 50 is made of a fully divided core, the double rotor 60 is employed to improve the efficiency of the magnetic circuit.

Furthermore, in the present invention, the core is designed by designing the magnetic circuit in such a way that the number of slots (i.e. split cores) and poles (i.e. magnets) is increased in such a way as to increase the diameter of the rotor and stator without reducing the size of the magnet. Lowers the spot ratio of the coil between the core and the core, and consequently the terminal assembly holder 80 and the housing 81 which are required to draw out from the three-phase coil terminal to the outside through the wire holder 57 in the space between the split core and the split core. -84) is arranged to perform the terminal processing of the coils 59a-59c, and the continuous winding method is applied to the divided cores of each phase to remove the wiring of the coils between the divided cores, thereby implementing a stator with a slim structure.

In addition, in the present invention, despite the slim structure, the number of slots (ie, split cores) and poles (ie, magnets) is increased by increasing the diameter of the rotor and stator without reducing the size of the magnet and the split core. By implementing a rotor / single stator structure, the motor efficiency and torque can be further increased compared to a motor of a general large capacity single rotor / single stator.

As a result, in the case of a typical single rotor / single stator structure, the maximum torque is 32 Nm and the motor efficiency is about 27.6%. However, in the present invention, a slim structure and high driving torque (maximum torque: 42 Nm) and high efficiency are provided. (44%), and therefore, the slim motor of the present invention has a torque sufficient for driving a quick reverse type of a drum washing machine.

In addition, in the present invention, it is possible to provide a slim motor having a thickness (or height) of about 25 mm or less, and is adopted in a given motor installation space inside a built-in medium / small drum washing machine and directly connected to a tub. A direct drive (DD) for rotating the basket can be implemented.

In addition, since the split stator core 51 has a small size, the waste ratio of the silicon steel sheet is smaller than that of the integrated stator core structure, so that there is almost no material loss, the shape is simplified, and the manufacturing is easy, and the split stator core 51 It is possible to wind the windings using a general-purpose winding machine, thereby reducing the coil winding cost and the investment in the winding equipment.

In addition, the embodiment of the rotor and the stator are all integrally formed using a resin, so it is excellent in durability, moisture resistance, etc., but is suitable as a drum driving source for a washing machine used in a high humidity environment, but is not limited thereto. Deformation is possible depending on the device to which it is applied.

In addition, since the stator 60 performs a role of a cover to the outside of the motor 1, a separate cover is not required, and thus, the motor can be slimmed, and the hall sensor 91 is inserted into the stator 50 and rotated. By placing the magnet 92 on the rotor 60, the top loading driving can be easily implemented.

The present invention can provide a slim motor having a thickness (or height) of about 25 mm or less, and can be applied to a built-in direct drive (DD) for a medium / small drum washing machine.

In addition, the present invention can be applied to a built-in medium / small drum washing machine as well as a large capacity washing machine for a direct drive (DD) for a drum washing machine.

1: slim motor 30: basket
40: Tub 50: Stator
60: rotor 70: rotation axis
80: terminal assembly holder

Claims (10)

A stator 50 comprising a stator core 51, a coil wound around the stator core, and a stator support 52 supporting the stator core, and a rotating shaft rotatably mounted to one end of the tub 40 of the drum washing machine. 70), A direct type drive device for a drum washing machine comprising a rotor (60) coupled to a central portion of the rotating shaft,
The stator support 52 includes an inner extension portion 58 extending in the axial direction so as to rotatably support one end of the rotation shaft 70 in the center and an outer extension portion extending in the circumferential direction from the inner extension portion 58. Includes 55,
The stator support 52 is formed by surrounding the rotor 60 disposed between the stator 50 and the tub 40 of the drum washing machine. Direct drive device for a drum washing machine comprising a cover-integrated stator, characterized in that the cover of the rotor (60). The stator core 51 is a three-phase coil is continuously wound around a plurality of split cores 53 having bobbins 54 formed at respective outer peripheries, and the bobbins of adjacent split cores are mutually connected. Direct type drive device for a drum washing machine, characterized in that the combined stator core assembly (2) to be assembled in an annular shape. 3. The bobbin according to claim 2, wherein the bobbin has inner and outer flanges 54a and 54b extending inwardly and outwardly, respectively, and at each end of each side of the inner flange 54a, the stator core assembly 2 is disposed. Direct type driving device for a drum washing machine comprising a coupling protrusion (B) and a coupling groove (A) coupled to an adjacent bobbin at the time of assembly. 3. The first to third terminal housings 81 and 82 of claim 2, wherein the first to third terminal housings 81 and 82 are disposed between the plurality of split cores 53 and are used to connect one coil terminal of the three-phase coil and the three-phase lead wire for external drawing. And a terminal assembly holder (80) having a common terminal housing (84) used to interconnect the other coil terminals of the three-phase coil to form a neutral point (NP). Direct drive for drum washing machine. The direct type washing machine of claim 1 or 2, further comprising at least one bearing (73, 75) installed on the tub (40) for supporting the other end of the rotating shaft (70). Drive system. The magnet 92 is installed on the outer circumferential surface of the rotor 60, and the inside of the outer extension part 55 of the stator 50, the position of the magnet 92 according to claim 1 or 2 Direct drive device for a drum washing machine, characterized in that it further comprises a top (Hall) sensor (91) for generating a sensing signal. According to claim 1 or 2, further comprising a bearing (71) installed in the center of the inner extension portion 58 of the stator support (52) for rotatably supporting one end of the rotating shaft (70) Direct drive device for a drum washing machine, characterized in that. According to claim 1 or 2, characterized in that it further comprises a disk-shaped support bracket 45 is fixed to the back of the tub 40 and a plurality of engaging fixing projections (45a) protruding on the outer surface. Direct drive device for drum washing machine. According to claim 8, A plurality of coupling fixing portion (55a) coupled to the coupling fixing projection (45a) is directly connected to the drum washing machine, characterized in that formed integrally with the outer extension portion 55 of the stator (50) Type drive. The direct drive device for a drum washing machine according to claim 1, wherein the rotor is any one selected from a double rotor, an outer rotor, and an inner rotor.

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