KR102595183B1 - Motor for washing machine and Washing machine having the same - Google Patents

Abstract

It relates to a motor for a washing machine that can efficiently generate torque by improving the winding coefficient of the coil with a relatively simple configuration. The motor for a washing machine (12) includes an outer rotor (20), an inner rotor (30), and a stator ( 60). The outer rotor 20 and the inner rotor 30 share the coil 63 of the stator 60, and by supplying a composite current to the coil 63, the outer rotor 20 and the inner rotor 30 Runs independently. The outer rotor 20 has 48 outer magnets 24 arranged continuously in the circumferential direction so that the N poles and S poles are alternately arranged. The inner rotor 30 has 42 inner magnets 34 arranged continuously in the circumferential direction so that the N poles and S poles are alternately arranged. The stator 60 has 36 I-shaped cores 61 and coils 63.

Description

Motor for washing machine, and washing machine equipped with same {Motor for washing machine and Washing machine having the same}

The present invention relates to a motor for a washing machine, and a washing machine equipped with the same.

Technologies related to the first to tenth embodiments disclosed are disclosed in the following patent documents 1 to 4.

〈Patent Document 1〉

Patent Document 1 discloses a dual rotor type motor. Patent Document 1 discloses a technology for independently driving the inner rotor and the outer rotor using a composite current that additionally adds the current corresponding to each rotor. However, the motor in Patent Document 1 is for automobiles, and the stator of the motor is composed of independent cores that are larger than the number of poles of the inner rotor and the outer rotor.

〈Patent Document 2〉

Patent Document 2 discloses a motor that rotates the drum and pulsator of a washing machine in a direct drive type (a type in which the drum and pulsator are directly driven by a motor without going through a complex transmission mechanism).

The motor of this washing machine has an outer rotor-shaped washing motor (driving the pulsator) and an inner rotor-shaped dewatering motor (driving the drum) arranged inside and outside, and a stator placed between the rotors of the two motors. The unit is equipped with two stators, one for the washing motor and the other for the spin-drying motor.

When washing or rinsing is performed, the drum is filled with a large amount of water, so the motor is required to output high torque at low speed. Meanwhile, during dehydration, the water in the drum is removed, so it can be driven at low torque, but the motor requires high-speed rotational output. For this reason, motors for washing machines are required to have specific output performance corresponding to low-speed high torque and high-speed low torque.

Therefore, in this washing machine, the dewatering motor that does not require high torque is arranged in the inner motor shape, and the washing motor is arranged in the outer rotor shape that has a large outer diameter of the rotor and high torque is obtained, thereby realizing appropriate output performance.

In addition, in this washing machine, in the washing or rinsing process that requires high torque, the drum is kept from rotating, just like in the conventional control, and only the pulsator rotates while reversing forward and reverse. It is controlled to do so.

In the dehydration process, the rotation of the washing motor and the dehydration motor are configured to be offset, and when the rotation speeds of the two motors differ by more than a predetermined speed, the motor with the smaller rotation speed is similar to the rotation speed of the other motor. It is controlled as much as possible.

In addition, in the dehydration process, the washing motor and the dehydration motor are operated synchronously, and at the timing when the washing motor reaches a predetermined rotation speed, only the dewatering motor is driven, and the electricity supply to the washing motor is stopped, so that the washing motor rotates. Make sure it is in a free state.

〈Patent Document 3〉

Patent Document 3 discloses a method for manufacturing a stator of a dual rotor type motor.

Specifically, by winding a coil around a prismatic stator core equipped with an insulator member (insulating material) at both ends, 18 coil-wound stator cores are formed. With such a stator core wound with 18 coils arranged in the circumferential direction, both ends of these are sandwiched between a pair of ring-shaped gallery plates, and these gallery plates are secured with bolts or nuts while taking insulation measures. By doing so, a stator skeleton structure is formed.

In order to fix the stator core in an appropriate position, convex portions extending in the axial direction are formed on the inner and outer surfaces of the stator core. When these convex portions are inserted into the concave portions provided in the stator forming container, the stator skeleton structure is formed in the stator forming container. is inserted. Afterwards, a resin molded product is formed by filling the space between the stator molding vessel and the stator skeleton structure with resin.

Since a convex portion remains in the resin molded product, the stator is completed by removing this convex portion through machining.

〈Patent Document 4〉

Patent Document 4 discloses a vertical washing machine that rotates a drum during washing or rinsing. In this washing machine, both the drum and the pulsator are driven by one motor, so when washing or rinsing, contrary to conventional control, the pulsator is fixed so that it does not rotate, and only the drum is rotated while reversed. I am ordering it. Additionally, during dehydration treatment, the pulsator is unfastened and the drum is rotated at high speed while the pulsator is allowed to rotate.

Patent Document 1: Japanese Patent Laid-Open No. 11-275826 (Patent No. 3480300) Patent Document 2: Japanese Patent Laid-Open No. 11-276777 (Patent No. 3524376) Patent Document 3: Japanese Patent Application Publication No. 2006-174637 Patent Document 4: Japanese Patent Application Publication No. 2004-321636

(First Example)

The motor of Patent Document 1 is set so that the number of rotating magnetic fields generated by the stator and the number of magnetic fields of the rotor are equal. However, for example, when the outer rotor side is driven in three phases and the inner rotor side is driven in six phases, the winding coefficient of the outer rotor side is 0.87, but the winding coefficient of the inner rotor side becomes as small as 0.5, especially , it is difficult to generate a certain amount of torque during low-speed rotation.

Here, in order to obtain high torque during low-speed rotation, it may be considered to use a 3-phase drive for the outer rotor side and a 9-phase or 12-phase drive for the inner rotor side. However, in this case, there is a problem that manufacturing costs increase because the number of driving elements such as IGBTs or MOSFETs increases to 18 or 24.

So, the first embodiment relates to a motor that can efficiently generate torque by improving the winding coefficient of the coil with a relatively simple configuration.

(Second Embodiment)

In many vertical washing machines, a drum (dewatering tank) having a large number of water passage holes is accommodated inside a water tub (tub), and a pulsator (stirring blade) is disposed at the bottom of the drum. A motor is installed at the bottom of the water tank, and the drum and pulsator are driven to rotate by this motor. Recently, a format in which the drum and pulsator are directly driven by a motor without going through a complicated transmission mechanism has become common (direct drive format).

During washing or rinsing when the pulsator is rotated, a large amount of water is filled in the drum, so the motor is required to have low speed but high torque output. Meanwhile, during dehydration, the water in the drum is removed, so it can be driven at low torque, but the motor requires high-speed rotational output. For this reason, motors for washing machines are required to have specific output performance corresponding to high torque at low speed and low torque at high speed.

Therefore, in the washing machine of Patent Document 2, appropriate output performance is realized by arranging the dewatering motor, which does not require high torque, in the inner rotor shape, and arranging the washing motor in the outer rotor shape, where the outer diameter of the rotor is large and high torque is obtained. there is.

However, in recent years, operation control has become more complex, and rotation of not only the pulsator but also the drum is sometimes required during washing or rinsing. In this case, high torque is required to rotate the drum, but it is difficult to obtain high torque due to the structure of the motor of the washing machine in Patent Document 2. High torque can be obtained by increasing the outer diameter of the rotor of the dehydration motor, but in this case, the overall size of the motor becomes larger.

If it is a dual-rotor type motor such as Patent Document 1, since there is only one stator, the outer diameter of the inner rotor can be increased correspondingly, so it is possible to increase the torque of the dehydration motor while avoiding the overall size of the motor.

However, in the case of such a dual-rotor type motor, as in the motor of Patent Document 1, if the number of independent cores of the stator is greater than the number of poles of the inner rotor and the outer rotor, a large cogging torque or a large mutual ripple occurs. . As a result, there is a problem that unpleasant noise or vibration is generated and the commercial value of the washing machine is reduced.

Therefore, the second embodiment relates to a dual-rotor type motor that can reduce cogging torque and mutual ripple, and suppress noise, etc., to a level comparable to that of a conventional washing machine.

(Third Embodiment)

As described above, with a dual rotor type motor such as Patent Document 1, it is possible to increase the torque of the dehydration motor while avoiding increasing the overall size of the motor.

However, in the case of a motor for a washing machine, the number of stator poles is large (usually 20 or more), so a manufacturing method of individually forming and assembling stator cores with coils, as in Patent Document 3, increases the number of workers and reduces productivity. There is a problem with this lack.

In addition, the manufacturing method of Patent Document 3 involves properly arranging the stator core around which each coil is wound and then sandwiching it between a pair of gallery plates, fastening a number of bolts and nuts that require attention to insulation and tightness, and tightening the stator core. There are many tasks in which the amount of work or work difficulty increases due to an increase in the number of stator poles, such as removal of convex portions that require precision, so not only is productivity lacking, but quality assurance is also hindered.

Therefore, the third embodiment is related to the practical use of a motor for a washing machine that can respond to various operation controls by making it possible to efficiently manufacture the stator of a dual-rotor type motor with a large number of poles.

(Example 4)

In a washing machine such as Patent Document 2, in the deceleration process of slowing down the drum and pulsator after dehydration, if there is a difference in rotation speed between the drum and pulsator, laundry may be pulled between the drum and pulsator, causing damage to the fabric. . To prevent this, it is necessary to perform synchronous control so that the rotation speeds of the drum (dewatering motor) and the pulsator (washing motor) are the same or similar in the above-mentioned deceleration process.

Also, when the drum and pulsator are independently rotated using two motors, as in the washing machine of Patent Document 2, the regenerative power based on the torque of the motor becomes larger compared to the case where there is only one motor. For this reason, if the rotation speed of the drum and pulsator is suddenly reduced, the regenerative power from the motor may not be fully consumed, and there is a risk that the regenerative current will flow back to the power source and damage the power source. So, to prevent this, it is necessary to gently slow down the drum and pulsator so that the regenerative power is consumed appropriately.

As described above, in order to appropriately consume regenerative power while executing synchronous control, it is desirable to adjust the rotation speed to the lower deceleration rate, that is, the higher rotation speed. However, if the rotation speed is set to the higher rotation speed, it takes a long time to stop the drum and pulsator.

So, the fourth embodiment relates to shortening the deceleration time when decelerating while performing synchronous control of the drum and pulsator while appropriately consuming the regenerative power of the motor.

(Example 5)

Since fabrics such as sweaters are easily damaged, in order to properly wash such delicate laundry, it is necessary to wash or rinse with a gentle touch while properly dispersing the laundry in water. On the other hand, there are also laundry items that are difficult to wash properly with a weak water flow, such as laundry with stains that are not easily removed or large laundry.

For this reason, it is necessary to generate water flows with various directions and flow speeds within the drum, but a washing machine that rotates only one of the pulsator and the drum, such as the washing machine in Patent Document 2 or Patent Document 4, cannot properly wash various laundry. It is insufficient to do this.

So, the fifth embodiment relates to a washing machine that can respond to a wide variety of different types of laundry.

(Example 6)

In the washing machine of Patent Document 2, the pulsator is alternately rotated in different directions (hereinafter referred to as reverse rotation) to generate twisting force on the water in the drum to prevent laundry from being washed evenly.

In contrast, if the drum is also rotated simultaneously with the pulsator, further improvement in washing effect can be expected. For example, a mode in which the drum is rotated clockwise and the pulsator is rotated counterclockwise at the same time, and a mode in which the drum is rotated counterclockwise and the pulsator is rotated clockwise at the same time, can be considered. If you run them alternately, the direction of the water flow changes, allowing you to unpack the laundry.

However, when changing the direction of reverse rotation, a relatively large starting load is applied to the motors (dehydration motor and washing motor) to reverse the rotation direction of the drum and pulsator. In particular, the drum is a large part even in a washing machine, and when the drum is rotated, a relatively large inertial force is applied to the drum with respect to the direction of rotation. For this reason, when the rotation direction of the drum is reversed, an excessive starting load is applied to the motor (particularly the dewatering motor) compared to the case of a configuration in which the drum is fixed or a configuration in which the drum is allowed to rotate freely. This excessive starting load may cause the motor to malfunction.

Therefore, the sixth embodiment is related to reducing the load applied to the motor when reversing the rotation direction of the drum and the pulsator, thereby preventing malstarting of the motor.

(Embodiment 7)

In the washing machine of Patent Document 2, during dehydration processing, the rotation of the washing motor and the rotation of the dewatering motor are configured to be offset, so it can be expected that the position of the laundry will change. However, simply changing the position of the laundry cannot necessarily reliably prevent the occurrence of unbalance because the position may be changed to increase the amount of unbalance.

Therefore, the seventh embodiment is related to providing a washing machine that more stably prevents unbalance, has low vibration, and can shorten spin-drying time.

(Eighth Example)

As with the washing machine in Patent Document 2, in the dewatering process, if the motor with a smaller rotation speed is controlled so that it approaches the rotation speed of the other motor, positional misalignment between the drum and the pulsator occurs due to the accumulation of this speed difference. Because it becomes relatively large, there is a problem that it cannot sufficiently prevent damage to the fabric.

Specifically, when the rotation speed of the washing motor is larger, the rotation speed of the dehydration motor is accelerated and controlled to approach the rotation speed of the washing motor. However, at this time, the rotation speed of the dehydration motor is overshooted to reduce the rotation speed of the washing motor. There are cases where it is exceeded. In this case, it is necessary to accelerate the rotation speed of the washing motor and control it so that it approaches the rotation speed of the dehydration motor. In this way, there is a problem that control becomes unstable due to the random cycle of a motor with a high rotation speed, and the positional discrepancy between the drum and the pulsator becomes relatively large.

So, the eighth embodiment relates to a washing machine capable of spin-drying operation that can reduce damage to laundry fabric.

(Example 9)

The appropriate timing for turning the laundry motor into a rotation-free state may vary depending on the weight, condition, type, etc. of the laundry. For this reason, if the rotational speed of the washing motor is fixed when the washing motor is set to the free rotation state during dehydration processing, as in the invention in Patent Document 2, there may be cases where the washing motor cannot be brought to the free rotating state at the appropriate timing. You can.

For example, if the washing motor is turned to a free state sooner than the appropriate timing, the laundry rotating along the drum may rub against the freed pulsator and cause the pulsator to rotate together, which may damage the laundry. On the other hand, if the washing motor is put into the rotation-free state later than the appropriate timing, the time for supplying power to the washing motor becomes longer, thereby increasing power consumption.

Therefore, the ninth embodiment relates to a washing machine that can perform spin-drying operation while reducing damage to laundry fabric and saving electricity.

(Example 10)

In the washing machine of Patent Document 2, even if the washing motor is set to a rotation-free state during the spin-drying operation, for example, because the clothes press the rotating tub and the agitating body due to gravity, the agitating body may rotate along with the rotation of the dehydrating motor. there is

That is, there are cases where the washing motor also rotates while following the dewatering motor. Then, a resistance force (a force in the direction that prevents rotation of the dehydration motor) due to the counter electromotive force is generated, which may cause problems such as making high-speed rotation impossible, or cause step-out or loss of control. To avoid this phenomenon, it is conceivable to drive both the washing motor and the dewatering motor simultaneously in the same direction. However, this method has the problem of low efficiency because it requires energy to rotate two motors.

So, the tenth embodiment relates to a washing machine that can increase energy efficiency during spin-drying operation.

(First Example)

In the first embodiment, a motor is provided that has a ring-shaped stator and first and second rotors with different driving method constants, and the driving constant of the first rotor is greater than the driving constant of the second rotor. , the following solutions were sought.

That is, the stator has a coil that generates respective rotating magnetic fields for independently driving the first and second rotors by supplying a composite current in which currents corresponding to the first and second rotors overlap each other, The number of rotating magnetic fields generated by the stator is different from the number of magnetic poles of the first and second rotors. Additionally, the winding coefficient of the coil with respect to the fundamental wave of the magnetic flux distribution of the rotor is greater than 0.5 on both the first rotor side and the second rotor side.

In the first embodiment, the number of rotating magnetic fields generated by the stator and the number of magnetic poles of the first rotor and the second rotor are different, and the winding coefficient of the coil with respect to the fundamental wave of the magnetic flux distribution of the rotor is greater than 0.5.

Because of this, torque can be efficiently generated by improving the winding coefficient of the coil. In particular, it is possible to obtain high torque even during low-speed rotation.

When the number of slots (S) of the stator, the number of poles (P1) of one of the first rotor or the second rotor, and the number of poles (P2) of the other are set to n as an integer of 1 or more,

S=12n

P1=(6±1)·2n

P2=(6±2)·2n

You may set it to satisfy the condition.

In this case, the number of stator slots, the number of poles of the first rotor, and the number of poles of the second rotor are set to satisfy the above-mentioned conditions. As a result, it is possible to obtain a motor in which the winding coefficient of the coil with respect to the fundamental wave of the magnetic flux distribution of the rotor is greater than 0.5.

The winding coefficient of the coil with respect to the fundamental wave of the magnetic flux distribution of the rotor can be 0.7 or more on both the first rotor side and the second rotor side.

In this case, high torque can be generated by setting the winding coefficient of the coil with respect to the fundamental wave of the rotor's magnetic flux distribution to 0.7 or more.

The disconnection coefficient of the coil with respect to the harmonics of the magnetic flux distribution of the rotor, either on the first rotor side or the second rotor side, can be set to be less than 1.

In this case, by setting the coil disconnection coefficient with respect to the harmonics of the magnetic flux distribution of the rotor to less than 1, torque ripple can be reduced and vibration and noise can be suppressed.

A motor having at least one of the above-described characteristics, a drum connected to an inner rotor consisting of one of the first rotor or the second rotor to receive laundry, and another of the first rotor or the second rotor. It can be configured as a washing machine with a pulsator that is connected to a single outer rotor and agitates the laundry in the drum.

Then, the washing machine motor of the first embodiment can be applied as a motor for independently driving the drum and pulsator.

(Second Embodiment)

The second embodiment relates to a dual-rotor type motor having an inner rotor and an outer rotor inside and outside one stator, and the stator is jointly used by the inner rotor and the outer rotor.

The stator includes a plurality of core elements independently arranged at regular intervals in the circumferential direction and a plurality of coils formed by winding a wire around each of the core elements. The core element has inner teeth facing the inner rotor and outer teeth facing the outer rotor. The inner rotor and the outer rotor have different numbers of poles, and the core element is composed of a smaller number of poles than either the inner rotor or the outer rotor.

And, of the inner rotor and the outer rotor, in any one of the inner teeth and the outer teeth that opposes the rotor with a large number of poles, the tooth opening angle of the corresponding tooth is ∼180°/Nc. It can be set within the range of 257°/Nc (Nc is the number of core elements).

In other words, this motor is a dual-rotor type motor in which one stator is shared by an inner rotor and an outer rotor with different numbers of poles, and this stator has a plurality of core elements that are independent in the circumferential direction and are smaller than the number of poles of these rotors. It is provided. And, the tooth opening angle of the teeth of the core element facing the rotor with a large number of poles is set within the range of 180°/Nc to 257°/Nc (Nc is the number of core elements).

In this way, by setting the tooth opening angle of the teeth of the core element facing the rotor with a large number of poles to a predetermined range, in a dual-rotor type motor, as will be described later, the cogging torque is comparable to that of a conventional washing machine. can be reduced and noise can be suppressed.

In addition, in the other one of the inner and outer teeth, which faces the rotor with fewer poles among the inner rotor and the outer rotor, the tooth opening angle of the corresponding tooth is 96°/Nc to 342°/Nc ( Nc can be set within the range of the number of core elements.

In this way, as will be described later, in the dual rotor type motor, mutual ripple can be reduced to a level comparable to that of a conventional washing machine, and noise, etc. can be further suppressed.

Specifically, when the number of poles of the inner rotor and the outer rotor with a small number of poles is set to P1, and the number of poles of the rotor with a large number of poles is set to P2, it can be applied to a motor that satisfies the following conditions.

Nc＝12n

P1=(6±1)·2n

P2=(6±2)·2n

(n is an integer greater than or equal to 1)

Nc＝6n

P1=6n±2

P2=6n±4

(n is an integer greater than or equal to 2)

Nc＝6n

P1=6n±4

P2=6n±8

(n is an integer greater than or equal to 2)

A motor that satisfies these conditions can effectively reduce cogging torque and mutual ripple.

Additionally, such a dual rotor type motor is suitable for a washing machine. That is, it is a washing machine equipped with such a motor, a drum rotatably provided inside a water tank, and a pulsator rotatably provided inside the drum, and the drum is equipped with one of the inner rotor and the outer rotor. It is sufficient that the other one of the inner rotor and the outer rotor is connected to the pulsator.

In this way, it is possible to realize a washing machine that can exert high torque from both the drum and the pulsator while suppressing noise and vibration.

In particular, in this case, the inner rotor is connected to the drum, and the outer rotor is connected to the pulsator.

Doing so is more efficient because structurally, a relatively high torque can be exerted in a pulsator that requires relatively high torque.

(Third Embodiment)

One of the third embodiments relates to a motor for a washing machine that individually rotates two shafts around a rotating shaft.

The motor includes an inner rotor that is rotatable and connected to one of the shafts, an outer rotor that is disposed on the outer circumference of the inner rotor and is rotatable and connected to the other one of the shafts, and the inner rotor and the outer rotor. It is disposed between them and has a stator that is common to these inner rotors and outer rotors. The stator includes a plurality of core elements each independently disposed, a plurality of coils formed by winding a wire around each of the core elements through an insulator, and is molded from a thermosetting resin, the core element, the It has a coil and a resin molded body in which the insulator is embedded. The insulator is composed of a pair of ring-shaped connectors connected to each other in the axial direction, with the plurality of core elements sandwiched between them. At least one of the ring-shaped connecting bodies becomes a main connecting body formed integrally, and a plurality of core insertion portions into which each of the core elements is inserted into the main connecting body are provided at approximately equal intervals in the circumferential direction.

That is, according to this motor, the insulator interposed between the plurality of core elements and the plurality of coils is composed of a pair of annular connectors connected to each other in the axial direction, at least one of which is integrated. It is formed as a main connector. In addition, since a plurality of core insertion portions into which each of the core elements is inserted into the main connection body are provided at equal intervals in the circumferential direction, the simple operation of inserting each core element one by one into these core insertion portions is sufficient. , multiple core elements can be placed in appropriate positions. Therefore, even the stator of a dual rotor type motor with a large number of poles can be manufactured efficiently.

The other of the ring-shaped connecting members may be configured as a sub-connecting body formed by connecting a plurality of arc-shaped connecting elements.

If the ring-shaped connecting body connected to the main connecting body is formed integrally, connection is difficult because the core insertion portion of the ring-shaped connecting body cannot be inserted unless it matches the positions of all core elements. However, if a sub-connection body is divided into a plurality of connection elements, connection becomes easier and work can be done efficiently.

In this case, a terminal portion to which the end of the wire leading from the coil is connected may be disposed on the subconnector.

In this way, the connection process can be easily performed because the stable main connector is located at the bottom and the terminal portion disposed on the sub-connector is located at the top.

The main connector may be composed of insulating resin and CFRP (carbon fiber reinforced plastic).

Then, since the rigidity of the main connector can be further strengthened, deformation or damage of the main connector can be suppressed, and handling becomes easier.

In this case, the resin constituting the CFRP can be the same type of resin as the insulating resin.

In this way, the integrity of the CFRP and the insulating resin is improved, so the rigidity of the main connector can be further improved.

The plurality of coils are, for example, formed by winding each of six wires around each of the plurality of core elements in a certain order, and are formed on both edges of the outer periphery of the core holding structure, which is formed by connecting a pair of ring-shaped connectors. A flange portion protruding in the axial direction may be provided, and three jumper wires of the wire may be assigned along each of the flange portions.

By assigning three jumper wires to each flange section on both sides to prevent the winding of the wire from collapsing, the axial height of the insulator and, by extension, the stator can be suppressed, making it possible to miniaturize the motor.

The core elements are exposed to form an inner core surface portion and an outer core surface portion on the inner and outer peripheral surfaces of the core holding structure, which is formed by connecting a pair of the ring-shaped connectors. The inner core surface portion may be positioned inside the inner peripheral surface of the insulator, and the outer core surface portion may be positioned outside the outer peripheral surface of the insulator.

In this way, since the inner core surface portion and the outer core surface portion come into contact with the mold during molding, the core element can be precisely positioned in the radial direction and the roundness of the stator can be increased. As a result, the gap between the inner rotor and the outer rotor can be reduced, improving motor performance.

Additionally, both edges of the inner and outer periphery of the adjacent core insertion portion may be connected by a connecting wall, and the central portion of the connecting wall may be thicker than both ends when viewed in the axial direction.

In this way, the rigidity of the main connector can be improved.

Additionally, instead of using an integrated main connecting body, both sides of the ring-shaped connecting body can be formed with a plurality of divided connecting bodies. Specifically, both sides of the ring-shaped connecting body are formed by connecting a plurality of arc-shaped connecting elements in which a plurality of core insertions into which each of the plurality of core elements is inserted are provided at approximately equal intervals in the circumferential direction; , the connecting portion between each of the connecting elements in one of the ring-shaped connecting bodies and the connecting portion between each of the connecting elements in the other ring-shaped connecting body are shifted in the circumferential direction. All you have to do is keep it positioned.

In this case, since the connecting portions of the upper and lower ring-shaped connecting bodies are different from each other, even if both ring-shaped connecting bodies are composed of a plurality of connecting elements, they can be integrated and stably supported. Since the mold can be made smaller than the mold for forming the integrated main connector, the mold cost can be significantly reduced.

In addition, the number of connecting elements of one ring-shaped connecting body is configured to be less than the number of connecting elements of another ring-shaped connecting body, and the wire derived from the coil is connected to the ring-shaped connecting body having a large number of connecting elements. The terminal portion to which the end is connected can be arranged.

In this way, by handling the terminal part from the upper side, a ring-shaped connector with fewer divisions and higher strength becomes the lower side, so that it can be stably supported and connection processing can also be easily performed.

Another third embodiment relates to a washing machine.

The washing machine includes a pulsator that is rotationally driven during washing, a drum that is rotationally driven during washing and spin-drying, and the above-described motor, one of the shafts is connected to the drum, and the other one of the shafts is It is connected to the pulsator.

With the above-described motor, not only can the stator of a dual-rotor type motor with a large number of poles be manufactured efficiently, but also a relatively high torque can be obtained on the inner rotor side to which the drum is connected while avoiding an increase in the size of the motor, so that various stators can be used. Washing machines capable of operating control can be provided at low cost.

Another third embodiment relates to a method of manufacturing the above-described motor for a washing machine.

The manufacturing method includes forming a core holding structure by inserting each of the plurality of core elements into each of the core insertion parts and then connecting the other one of the ring-shaped connectors to the main connector against each other. A first step, setting the core holding structure in a winding machine, and forming a winding body by winding a wire around each of the core elements covered with the insulator to form a plurality of coils, and forming the winding body into a mold. It may include a third step of setting and molding using a thermosetting resin.

That is, according to this manufacturing method, a core holding structure formed by a simple operation can be mechanically wound with a winding machine to form a winding body, and this winding body can be set in a mold and molded, so it is relatively easy. It can be manufactured and has excellent productivity.

In the second step, for example, the process of winding three wires simultaneously with the same operation is performed twice, and the jumper wires of the three wires processed the first time are pulled from both edges of the outer periphery of the core holding structure. The wiring can be done along one of the pair of flange parts protruding in one direction, and the jumper wire of the three wires processed second can be wired along the other one of the flange parts.

In this way, the jumper wires generated for each winding process can be wired efficiently, and the wiring structure of the wire is simplified, so the processing efficiency of the winding machine can be improved.

The main connection body may further include, for example, a removable ring-shaped support portion connecting each of the plurality of core insertions, and a fourth step of removing the ring-shaped support portion after the third step. there is.

In this way, the rigidity of the main connecting body can be strengthened in the annular support portion, so handling of the core holding structure and winding body becomes easier during winding processing or forming processing. Additionally, since mold forming can be performed while suppressing deformation of the core holding structure, etc., the quality of the motor can be improved.

A positioning structure is provided between at least one main surface inside and outside the winding body and an opposing surface of the mold that faces the main surface, and the positioning structure allows the winding body to be positioned in a circumferential direction with respect to the mold. The mold can be formed with the position determined.

The positioning structure may be composed of a concave portion formed in the core element exposed to the main surface and a convex portion formed in the mold to couple to the concave portion. Alternatively, it may be composed of a plurality of slot openings facing the main surface and a coupling protrusion formed on the mold to engage the slot openings. In particular, the positioning structure may be provided between the inner peripheral surface of the winding body and the opposing surface of the mold that faces the inner peripheral surface.

In this way, the winding body can be positioned precisely in the circumferential direction with respect to the mold.

A clamping structure is provided on either the inner or outer main surface of the core holding structure, and the winding machine performs a winding process (or winding process) on the wire with the clamping structure inserted. It can be done.

The clamping structure may be composed of a groove formed in the core element exposed to the main surface, or may be composed of edge parts on both sides of the core element protruding from the main surface.

In this way, the core holding structure can be strongly supported and winding processing can be performed stably.

Additionally, in the third step, the winding body may be set in the mold so that the insulator facing the outer circumference of the winding body is in contact with the mold.

In this way, the adhesion between the inner peripheral surface of the winding body and the mold increases, and the roundness of the inner peripheral side of the winding body can be improved.

(Example 4)

The fourth embodiment includes a rotatable drum that accommodates laundry, a pulsator that is provided concentrically with the rotation axis of the drum and agitates the laundry in the drum, and a pulsator that rotates the drum and the pulsator independently. The target is a motor control device for a washing machine equipped with a motor.

A drum-side inverter circuit connected to the motor and for rotating the drum, a pulsator-side inverter circuit connected to the motor and rotating the pulsator, and detecting rotational speeds of the drum and the pulsator, respectively. A control device for controlling the operation of the motor through the drum-side inverter circuit and the pulsator-side inverter circuit using a PWM-controlled electrical signal using a command signal and a carrier wave for detecting rotation speed for Equipped with

The drum-side inverter circuit and the pulsator-side inverter circuit are composed of a plurality of inverters consisting of an upper arm switching element and a lower arm switching element connected in series to each other in parallel.

The control device determines the detected rotational speeds of the drum and the pulsator, respectively detected by the rotational speed detection means, to be the same in a deceleration process after the end of the dehydration process of rotating the drum and the pulsator in the same direction. Synchronization control for adjusting the speed, upper arm short-circuit brake control for turning on all of the upper arm switching elements and turning off all of the lower arm switching elements, and applying a short-circuit brake to the motor, and all of the upper arm switching elements turns off and turns on all of the lower arm switching elements, executes lower arm short circuit brake control to apply a short circuit brake to the motor, and performs the PWM control based on the detected rotation speed per cycle of the carrier wave. Without changing the length of the synchronous control period, which is the period for executing the synchronous control, the upper arm short circuit brake period, which is the period for executing the upper arm short circuit brake control, is shortened, and at the same time, the lower arm short circuit brake control is executed. It is configured to execute lower arm side short circuit break period expansion control, which expands the lower arm side short circuit break period.

According to this configuration, the deceleration time when decelerating while synchronously controlling the drum and the pulsator can be shortened.

That is, for each cycle of the carrier wave used for PWM control, synchronous control is performed based on the detected rotation speed of the drum and pulsator according to the electrical signal set by the PWM control, and the drum and pulsator (specifically, , motor), a synchronous control period that adjusts the rotation speed of the inverter circuit, an upper arm side short-circuit brake period that shortens the upper arm side of the inverter circuit and applies a short-circuit brake to the motor, and a lower arm side short-circuit brake period that applies a short-circuit brake to the motor by short-circuiting the lower arm side of the inverter circuit. There is a short circuit break period on the dark side.

The control device performs lower arm short circuit break period expansion control to shorten the upper arm short circuit break period and expand the lower arm short circuit break period without changing the length of the synchronous control period for these three periods. Run.

In general, since the upper arm short-circuit brake is influenced by the power supply voltage, the braking effect is lower compared to the lower arm short-circuit brake. Therefore, by executing the lower arm side short-circuit brake period expansion control, it is possible to lengthen the period for applying the lower arm side short-circuit brake, which has a large braking effect on the motor, and at the same time appropriately execute synchronous control.

As a result, the deceleration time when decelerating by synchronously controlling the drum and pulsator can be shortened.

Additionally, by shortening the upper arm side short-circuit brake period, the risk of regenerative current from the motor flowing into the power supply side and damaging the power supply can be reduced.

In one embodiment of the motor control device of the washing machine, the carrier wave consists of a triangle wave, and the control device turns on the upper arm switching element, which is set by the command signal and the carrier wave in the PWM control. It is preferable that the threshold is moved to the peak side of the triangle wave by the same amount, thereby expanding the lower dark side short-circuit break period.

That is, by moving the threshold for turning on the upper arm switching element by the same amount to the peak side of the carrier wave, part of the upper arm switching element and part of the lower arm switching element are turned on, and the rotation of the drum and pulsator The length of the synchronous control period that keeps the speed at the same level can be left unchanged, and at the same time, the period of the lower arm short-circuit brake that turns off all of the upper arm switching elements and turns on all of the lower arm switching elements can be expanded. You can.

As a result, the length of the synchronization control period can not be changed and at the same time, the lower arm side short-circuit break period can be expanded.

In the motor control device of the washing machine, the control device short-circuits the lower arm side based on the duty ratio of the upper arm switching element with the smallest duty ratio in the PWM control among the upper arm switching elements. It is preferably configured to determine the length of the break period.

That is, in the lower arm side short-circuit brake control, the on period of the upper arm switching element is shortened, so the duty ratio of the upper arm switching element in the PWM control becomes smaller.

Therefore, the maximum length of the lower arm short circuit break period that can be extended until the duty ratio of the upper arm switching element, which has the smallest duty ratio in PWM control among the upper arm switching elements, is set to 0%. It becomes. Therefore, by controlling as described above, the lower arm side short circuit break period can be appropriately expanded.

In the motor control device of the washing machine, the control device is configured to determine the length of the lower arm side short-circuit brake period based on the difference between the detected rotation speed of the drum and the pulsator and a preset target rotation speed. It is desirable to have

According to this configuration, the drum and pulsator can be decelerated while comparing the detected rotation speed of the drum and pulsator with the preset target rotation speed, so the drum and pulsator can be quickly and accurately decelerated and stopped.

In addition, when the detected rotation speed is greater than the target rotation speed and there is a possibility that all of the regenerative power from the motor cannot be consumed, the short-circuit brake period on the lower arm side can be lengthened to appropriately consume the regenerative power from the motor. there is.

In the motor control device of the washing machine, the drum-side inverter circuit and the pulsator-side inverter circuit are connected in parallel with each other, and a voltage for detecting a direct current voltage applied to the drum-side inverter circuit and the pulsator-side inverter circuit It is preferable that the control device further includes a detection means, and is configured to lengthen the lower arm side short-circuit break period as the detection voltage detected by the voltage detection means becomes higher than a preset target voltage.

That is, when all of the regenerative power from the motor cannot be consumed, the potential on the motor side becomes higher than the potential of the DC power supply, and the detection voltage detected by the voltage detection means becomes high. Therefore, as the detected voltage becomes higher than the target voltage, the lower arm side short-circuit break period is lengthened, so that the regenerative power can be consumed. As a result, the drum and pulsator can be slowed down while appropriately consuming the regenerative power.

(Example 5)

The fifth embodiment is a vertical washing machine, and includes a drum rotatably provided inside a water tank, a pulsator rotatably provided at the bottom of the drum, and a motor that individually drives each of the drum and the pulsator. and a control device that controls the motor. In addition, the control device includes a dual rotation control unit that simultaneously and independently rotates both the drum and the pulsator in any one of the washing and rinsing processes.

In other words, according to this washing machine, during washing or rinsing, both the drum and the pulsator rotate independently at the same time, so water currents with various directions and flow speeds can be generated within the drum, and the laundry can be properly washed in the water. By dispersing, it is possible to effectively wash and rinse a wide variety of laundry.

Specifically, the dual rotation control unit may rotate the drum and the pulsator in the same direction at different rotation speeds.

In this way, while rotating the washing machine, it can be gently moved to the outside or inside of the drum, and the laundry can be properly distributed in the water and washed or rinsed with a soft touch.

In this case, among the drum and the pulsator, only the drum may be driven to rotate by the motor, and the pulsator may rotate in conjunction with the rotation of the drum.

By doing so, the pulsator can be rotated at a low rotation speed in the same direction as the drum in accordance with the rotation of the drum while suppressing power consumption.

Additionally, the dual rotation control unit may rotate each of the drum and the pulsator while reversing them at different cycles.

Even in this case, it is possible to effectively wash or rinse a wide variety of laundry while properly dispersing the laundry in water.

Additionally, the dual rotation control unit may rotate the pulsator while rotating the drum in the same direction.

By doing so, it is possible to effectively wash or rinse a wide variety of laundry while dispersing the laundry appropriately in water, and to efficiently wash or rinse with a small amount of laundry.

In addition, at least one of the startup time until the dual rotation control unit reaches the target rotation speed and the end time until it stops at the target rotation speed may be different for the drum and the pulsator.

By doing so, efficient maneuvering according to the inertial force of the drum or pulsator can be performed, and thus power consumption can be reduced.

In this case, the dual rotation control unit may vary the start timing of driving according to the motor for the drum and the pulsator.

In this way, the driving time according to the motor in the drum and pulsator is made the same, and even if there is a difference in the period when the drum and pulsator rotate at the target rotation speed at the same time, the timing of reaching the target rotation speed of the drum and pulsator is matched. The period can be optimized.

Also, in this case, the dual rotation control unit may vary at least one of the driving period and the driving stop period according to the motor for the drum and the pulsator.

By doing so, the length and timing of the rotation period and the stop period can be matched in the drum and the pulsator, and washing or rinsing processing can be performed efficiently.

In addition, the dual rotation control unit intermittently rotates the drum and the pulsator in opposite directions, and at the same time, in at least one of the drum and the pulsator, the rotation period of each rotation performed intermittently and these The length of at least one of each stop period between rotation periods may be different.

When the drum and pulsator are intermittently rotated in opposite directions, the water flow stagnates inside the drum, which tends to cause stagnant laundry. However, in this way, the length of each rotation period or each stop period can be varied. By doing so, it is possible to prevent the water flow from stagnating inside the drum, and the laundry can be moved as a whole.

In addition, the dual rotation control unit intermittently rotates the drum and the pulsator in opposite directions, and at the same time, varies the number of rotations of each rotation performed intermittently in at least one of the drum and the pulsator. You can do it.

Even in this case, the same effect can be obtained as varying the length of each rotation period or each stop period.

(Example 6)

The sixth embodiment includes a rotatable drum that accommodates laundry, a pulsator that is provided concentrically with the rotation axis of the drum and agitates the laundry in the drum, and a pulsator that rotates the drum and the pulsator independently. The target is a washing machine equipped with a motor and an inverter for driving the motor.

When the motor operates, load detection means for detecting a load applied to the motor, and based on the detection load detected by the load detection means, provide an electric signal to the motor through the inverter, It is further provided with a control device that controls the operation of the drum and the pulsator.

The control device includes a first half-phase drive mode that rotates the drum forward and the pulsator in reverse, and a second half-phase drive mode that rotates the drum in the reverse direction and the pulsator in the forward direction, and a stop period. A load reduction correction control that is alternately executed while being inserted in the middle and controls the timing of at least one on and off of at least one of the drum and the pulsator so that the detected load is below a preset target load. It is configured to run.

According to this configuration, the load applied to the motor can be reduced by utilizing the inertial force of the laundry in the drum.

Specifically, when the first or second reverse drive mode is turned on to rotate the drum and the pulsator in opposite directions, the laundry in the drum rotates according to either the drum or the pulsator. Because of this, an inertial force is generated in the laundry in the drum. And, when switching to the first or second reverse drive mode, the rotation direction of the drum or pulsator is reversed using the inertial force of the laundry by controlling the timing of turning on or off the drum or pulsator.

For example, when the laundry is rotating in the rotation direction of the pulsator, the drum can be turned on faster than the pulsator and the rotation direction is reversed, thereby utilizing the inertia of the laundry to reverse the rotation direction of the drum. For this reason, when the rotation direction of the drum or pulsator is reversed, the load applied to the motor is reduced.

In the washing machine, the load reduction correction control is performed after turning on either the drum or the pulsator when the first upper half drive mode or the second upper half drive mode is turned on after the stop period has elapsed, After the first predetermined time has elapsed, it is preferable that the control turns on the drum or the other one of the pulsator.

According to this configuration, when the first or second half drive mode is turned on, either the drum or the pulsator can be turned on faster than the other. Because of this, either the drum or the pulsator can be inverted using the inertial force of the laundry. For example, when the laundry is rotating in the rotation direction of the pulsator, the drum is turned on faster than the pulsator and the rotation direction is reversed, so that the rotation direction of the drum is changed before the rotation direction of the laundry is reversed by the pulsator. It can be reversed.

For this reason, when reversing the rotation direction of the drum, the inertial force of the laundry that is directed in the same direction as the rotation direction of the drum after reversal can be used. For this reason, when the rotation direction of the drum or pulsator is reversed, the load applied to the motor is reduced more efficiently.

Additionally, in the washing machine, the load reduction correction control is performed after turning off either the drum or the pulsator when the first upper half drive mode or the second upper half drive mode is turned off before entering the stop period. , control may be used to turn off the drum or the other of the pulsator after a second predetermined time period has elapsed.

According to this configuration, when the first or second half drive mode is turned off, either the drum or the pulsator is turned off later than the other, in other words, either the drum or the pulsator is turned off longer than the other. By rotating it, the laundry can be given a stronger inertial force.

For example, when laundry is rotating along the pulsator, if the pulsator is turned off later than the drum, a larger inertial force in the same direction as the rotation direction of the pulsator remains in the laundry. For this reason, when the rotation direction of the drum is reversed, the inertial force of the laundry remains larger in the same direction as the rotation direction of the drum after the rotation. Because of this, the rotation direction of the drum can be reversed using the inertial force of the laundry. In this way, when the rotation direction of the drum or pulsator is reversed, the load applied to the motor is reduced more efficiently.

In the washing machine, it is preferable that the control device is configured to execute the load reduction correction control when the stop period is shorter than a preset reference time.

In other words, if the stop period is set to be long enough to sufficiently reduce the inertial force of the drum and pulsator (hereinafter referred to as the standard time), the load applied to the motor when reversing the rotation direction of the drum and pulsator does not become large enough to cause motor starting failure. Therefore, load reduction correction control can be appropriately executed by executing load reduction correction control only when the stop time is shorter than the reference time.

In the washing machine, when the laundry stored in the drum is rotating in the same direction as the rotation direction of the drum, the rotation of the drum is slowed down and stopped during the stop period, and after the stop, the next first half cycle is performed. It is preferable that the drive mode or the second half drive mode is configured to turn on.

In other words, if laundry sticks to the drum, the laundry may rotate in the direction of rotation of the drum. However, in this case, the inertial force of the laundry acts on the drum in addition to the inertial force of the drum itself, so when the direction of rotation of the drum is reversed, the inertial force of the laundry acts on the drum. , excessive load is applied to the motor.

Therefore, when the laundry is rotating in the same direction as the drum rotation direction, the rotation of the drum is slowed down and stopped during the stop period between the first half drive mode and the second half drive mode, and after the stop, the next Turn on the first half-phase drive mode or the second half-phase drive mode. Because of this, the rotation direction of the drum is reversed while no inertial force remains in the drum, thereby preventing excessive load from being applied to the motor.

A washing machine configured to turn on either the drum or the pulsator when the first half drive mode or the second half drive mode is turned on, and then turn on the other drum or the pulsator after a first predetermined time has elapsed. further comprising vibration detection means for detecting vibration applied to the washing machine, wherein the control device detects the first vibration when the detected vibration detected by the vibration detection means is greater than a predetermined vibration. It is desirable to configure the predetermined time to be short.

That is, during the first predetermined time, when either the drum or the pulsator rotates in the same direction as the rotation direction of the laundry, if the laundry is tilted, strong vibration occurs in the washing machine due to the centrifugal force of the laundry during the first predetermined time. There is a risk of being harmed.

Therefore, when a vibration greater than the predetermined vibration is detected by the vibration detection means, the first predetermined time is shortened, and a water flow in a direction opposite to the rotation direction of the laundry is generated at an early stage, so that the rotation of the laundry is caused by the water flow. Slows down the speed and reduces the centrifugal force acting on the washing machine from the laundry. Because of this, it is possible to prevent vibration from acting on the washing machine.

In addition, when the first half drive mode or the second half drive mode is turned off, either the drum or the pulsator is turned off, and then after a second predetermined time has elapsed, the other one of the drum or the pulsator is turned off. A washing machine configured to turn off, further comprising vibration detection means for detecting vibration being applied to the washing machine, wherein the control device determines that the detected vibration detected by the vibration detection means is at a predetermined level. When it is greater than the vibration, it is preferable that the second predetermined time is shortened.

That is, during the second predetermined time, when either the drum or the pulsator is rotated longer than the other to generate a greater inertial force on the laundry, if the laundry is tilted, the centrifugal force of the laundry increases during the second predetermined time. There is a risk that strong vibration may be applied to the washing machine. Therefore, when a vibration greater than the predetermined vibration is detected by the vibration detection means, the second predetermined time is shortened to reduce the centrifugal force caused by the rotation of the laundry. Because of this, vibration of the washing machine can be reduced.

Another sixth embodiment includes a rotatable drum that accommodates laundry, a pulsator that is provided concentrically with the rotation axis of the drum and agitates the laundry in the drum, and the drum and the pulsator are each independently operated. The target is a washing machine equipped with a rotating motor and an inverter to drive the motor.

When the motor operates, load detection means for detecting a load applied to the motor, and based on the detection load detected by the load detection means, provide an electric signal to the motor through the inverter, It is further provided with a control device that controls the operation of the drum and the pulsator.

The control device includes a first half-phase drive mode that rotates the drum forward and the pulsator in reverse, and a second half-phase drive mode that rotates the drum in the reverse direction and the pulsator in the forward direction, and a stop period. At the same time, when the laundry stored in the drum is rotating in the same direction as the rotation direction of the drum, the rotation of the drum is slowed down and stopped during the stop period, and after the stop, the rotation of the drum is slowed down and stopped. It is configured to turn on the following first half-phase drive mode or second half-phase drive mode.

That is, for example, if laundry sticks to the drum, the laundry may rotate in the direction of rotation of the drum. However, in this case, the inertial force of the laundry acts on the drum in addition to the inertial force of the drum itself, so the inertial force of the laundry acts on the drum in the direction of rotation of the drum. When reversing, an excessive load is applied to the motor.

Therefore, when the laundry is rotating in the same direction as the rotation direction of the drum, the rotation of the drum is slowed down and stopped during the stop period between the first half drive mode and the second half drive mode, and after the stop, The following first half-phase drive mode or second half-phase drive mode is used. Because of this, the rotation direction of the drum is reversed while no inertial force remains in the drum, thereby preventing excessive load from being applied to the motor.

(Embodiment 7)

The washing machine of the seventh embodiment periodically changes the amount of unbalance by intentionally providing a predetermined speed difference between the drum and the pulsator during drum spin-drying operation, and then, when the amount of unbalance becomes minimum, the drum and Rotation control was performed so that the speed of the pulsator was the same.

That is, a rotatable drum that accommodates laundry, a pulsator that is provided concentrically with the rotation axis of the drum and agitates the laundry in the drum, and a motor that independently rotates the drum and the pulsator. It's a washing machine.

The motor has a first rotor for rotating the pulsator and a second rotor for rotating the drum, and includes unbalance detection means for detecting an amount of unbalance when at least one of the drum and the pulsator rotates, and a control unit that controls the rotational operation of the first and second rotors based on the detected value of the unbalance amount, wherein the control unit controls a predetermined distance between the drum and the pulsator during a spin-drying operation of laundry. The amount of unbalance is periodically changed by providing a rotation speed difference, and rotation control is performed so that the speeds of the drum and the pulsator become the same when the amount of unbalance is minimal.

According to this washing machine, the control unit periodically changes the amount of unbalance by providing a predetermined speed difference between the drum and the pulsator, and at the timing when the change in the amount of unbalance is minimal, the speed of the drum and the pulsator are the same. Perform speed control to ensure that Because of this, the drum and pulsator can be rotated at the same speed with minimal unbalance. In other words, the occurrence of imbalance can be prevented. Additionally, since the occurrence of imbalance can be prevented without stopping the rotation of the drum or pulsator, the spin-drying time can be significantly shortened.

The unbalance detection means detects the amount of unbalance of the drum and the pulsator in a state in which the drum and the pulsator are rotating at the same speed, and the control unit detects at least one of the drum and the pulsator. If the detected value of the unbalance amount is greater than a predetermined value, and the difference between the unbalance moment of the drum calculated based on the detected value of the unbalance amount and the unbalance moment of the pulsator is less than or equal to a predetermined value, the rotation control is executed. It can be configured to do so.

In such a case, whether to perform rotation control is determined based on the unbalance amount and unbalance moment. By providing such a judgment standard, rotation control can be performed under conditions of higher suitability and necessity, and thus the occurrence of unbalance can be prevented more effectively.

The unbalance detection means detects the unbalance amount of the drum and the pulsator in a state in which the drum and the pulsator are rotating at the same speed, and the control unit detects the unbalance amount according to the detected value of the unbalance amount. It may be configured to selectively change the solution method.

In such a case, in order for the control unit to selectively change the unbalance resolving method according to the detected value of the unbalance amount, an unbalance resolving method with higher suitability and necessity can be applied. As a result, it is possible to select a method that can more effectively prevent the occurrence of imbalance, and it is possible to further shorten the dehydration time.

The control unit does not perform the rotation control when the detected values of the unbalance amount of the drum and the pulsator are all less than a predetermined value, and increases the rotation speed of the drum and the pulsator while maintaining the same. You can configure it as well.

In that way, when the amount of unbalance is below a predetermined reference value, the rotation speed of the drum and pulsator is accelerated without performing rotation control, so the spin-drying time can be shortened.

In addition, the control unit detects that the detected value of any one of the unbalance amount of the drum and the pulsator is greater than a predetermined value, and determines the unbalance moment of the drum and the unbalance of the pulsator calculated based on the detected value of the unbalance amount. If the difference with the moment is greater than a predetermined value, the unbalanced state may be changed by applying a predetermined speed change to the drum or the pulsator with the larger unbalanced moment.

In that way, the control unit provides a predetermined speed control to the drum or pulsator based on the difference in unbalance moment, thereby eliminating the imbalance in a short time without stopping the drum or pulsator. Because of this, the dehydration time can be significantly shortened.

Another seventh embodiment is a washing machine having a rotatable drum that accommodates laundry and a motor that is provided concentrically with the rotation axis of the drum and independently rotates a pulsator that agitates the laundry in the drum. It is a control method.

The control method includes the steps of periodically changing the amount of unbalance by providing a predetermined speed difference between the drum and the pulsator during the spin-drying operation of laundry, and, during the relative rotation period, the drum and the pulsator. It includes detecting an amount of unbalance in at least one of the pulsators, and ensuring that the speeds of the drum and the pulsator are the same when the detected value of the amount of unbalance is minimal.

According to this control method, the detected value of unbalance can be set to the minimum, and the drum and pulsator can be rotated at the same speed. In other words, the occurrence of imbalance can be prevented. Additionally, since the occurrence of imbalance can be prevented without stopping the rotation of the drum or pulsator, the spin-drying time can be significantly shortened.

(Eighth Example)

The eighth embodiment targets a washing machine having a drum for receiving laundry, a pulsator for agitating the laundry in the drum, and a motor for independently rotating the drum and the pulsator, as follows: A solution was sought.

That is, the motor has a ring-shaped stator, an outer rotor disposed outside the stator to rotate the pulsator, and an inner rotor disposed inside the stator to rotate the drum, the outer rotor and a speed detection unit that detects the rotation speed of the inner rotor, and a control unit that controls rotation operations of the outer rotor and the inner rotor, wherein the control unit detects the speed detected by the speed detection unit during a dehydration operation of the drum. The rotation speed of the inner rotor is set as the target speed, and the rotation operation of the outer rotor is controlled so that the rotation speed of the outer rotor is approximately equal to the target speed.

In this configuration, during the drum dehydration operation, the rotation speed of the inner rotor is set as the target speed, and the rotation speed of the outer rotor is made to approximately match the target speed. In this way, damage to the fabric of laundry can be reduced by suppressing speed fluctuations by synchronizing the outer rotor and inner rotor during the spin-drying operation.

Specifically, during dehydration operation, when attempting to accelerate both the outer rotor and the inner rotor to the target rotation speed, the target rotation speed is controlled while performing different accelerations depending on the difference in performance of both motors. Therefore, it becomes difficult to increase the rotation speed of the outer rotor and the inner rotor at the same speed until the target rotation speed is reached.

On the other hand, in this washing machine, while the inner rotor is accelerated to the target rotation speed, the outer rotor is controlled to follow the rotation speed of the reference inner rotor as the target speed, so that the outer rotor and the inner rotor The speed difference can be reduced. In addition, since the outer rotor is followed using the inner rotor as a reference, the control target rotor does not change at random cycles, improving control safety.

a phase calculation unit that calculates a phase difference of the outer rotor with respect to the inner rotor based on the rotational speeds of the outer rotor and the inner rotor detected by the speed detection unit; , when the phase difference calculated by the phase calculation unit is greater than a predetermined value, the rotation operation of the outer rotor may be controlled so that the phase difference is smaller than the predetermined value.

In this configuration, when the phase difference between the outer rotor and the inner rotor becomes greater than a predetermined value, the rotational operation of the outer rotor is controlled to eliminate the phase difference.

For this reason, damage to the fabric of the laundry can be reduced by resolving the misalignment of the laundry that has been placed across the drum and the pulsator before it is pulled due to the misalignment between the drum and the pulsator.

(Example 9)

The ninth embodiment is a washing machine equipped with a drum for receiving laundry, a pulsator for agitating the laundry in the drum, and a motor for independently rotating the drum and the pulsator, and provides the following solutions. Means were sought.

That is, the motor has a ring-shaped stator, an outer rotor disposed outside the stator to rotate the pulsator, and an inner rotor disposed inside the stator to rotate the drum, the outer rotor and A speed detector for detecting the rotational speed of the inner rotor and a control unit for controlling the rotational operation of the outer rotor and the inner rotor, wherein the control unit is configured to operate the outer rotor and the inner rotor during a dehydration operation of the drum. When it is determined that the phenomenon of the laundry rotating along the drum of the pulsator due to the laundry has disappeared while the rotation speed is accelerating by synchronizing the operation, the supply of electricity to the motor that rotates the outer rotor is stopped to rotate the pulsator. It is characterized by being configured to be rotation free.

In this configuration, when it is determined that the phenomenon of the pulsator spinning due to laundry has disappeared during the spin-drying operation of the drum, the pulsator is set to rotation free.

As a result, the laundry rotating along the drum rubs against the free pulsator and causes it to rotate along the pulsator, preventing damage to the laundry. At the same time, power consumption is reduced by stopping the supply of electricity to the motor that rotates the outer rotor. can do.

The control unit, when the variation of the rotation speed of the outer rotor detected by the speed detection unit with respect to the set rotation speed of the outer rotor becomes greater than a predetermined value, there is no phenomenon of the laundry rotating along the drum of the pulsator. You can configure it to judge that you lost.

In this configuration, the presence or absence of the pulsator spinning phenomenon is determined from the variation in the rotational speed of the outer rotor.

Because of this, it is possible to easily determine the presence or absence of the pulsator spinning phenomenon.

In addition, it is provided with a current detection unit that detects a current flowing through the motor, and the control unit is configured to convert the current detected by the current detection unit into a rotation coordinate system when the rotation coordinate system current becomes smaller than a predetermined amount, and the laundry is detected by the laundry. It may be configured to determine that the phenomenon of the pulsator rotating along the drum has disappeared.

In this configuration, the presence or absence of the pulsator rotation phenomenon is determined from the current supplied to the motor.

Because of this, it is possible to easily determine the presence or absence of the pulsator spinning phenomenon.

In addition, when the inner rotor decelerates from the maximum rotation speed to a predetermined rotation speed, this control unit resumes control of the rotation operation of the outer rotor and operates the outer rotor and the inner rotor synchronously to reduce the rotation speed. You can also configure it as follows.

In this configuration, after the pulsator is set to rotation-free, synchronous operation of the outer rotor and the inner rotor is resumed when the inner rotor that rotates the drum decelerates to a predetermined rotation speed.

As a result, at the end of the dehydration process, it is possible to prevent the laundry rotating along the drum from rubbing against the rotating pulsator and damaging the laundry by rotating the pulsator together.

In this case, the control unit is preferably configured to use the rotational speed of the outer rotor when it is determined that the phenomenon of the laundry rotating along the drum of the pulsator has disappeared as the predetermined rotational speed.

In this configuration, the pulsator is rotated again at the rotation speed when the pulsator was set to rotation free to start.

As a result, rotation of the pulsator can be resumed at a corrected timing according to the weight, condition, type, etc. of the laundry, and damage to the fabric of the laundry can be reduced.

(Example 10)

In the washing machine of the tenth embodiment, the drum and the pulsator are configured to rotate independently, and during the spin-drying operation of laundry, the rotation of the drum is controlled with the pulsator in the rotation free state, while the pulsator is rotated by the laundry. When it was determined that rotation along the drum was occurring, the pulsator was switched from the rotation free state to the torque control mode.

That is, the washing machine includes a rotatable drum that accommodates laundry, a pulsator that is provided concentrically with the rotation axis of the drum and agitates the laundry in the drum, and a pulsator that rotates the drum and the pulsator independently. It is provided with a motor and a control unit that controls the rotation of the motor, and the control unit stops driving the pulsator according to the motor during spin-drying operation of laundry and sets the pulsator to rotation free. While the rotation of the drum is controlled, when it is determined that the laundry is causing the pulsator to rotate along the drum, a torque command value is given to the pulsator from the rotation-free state to control the torque of the pulsator. Switch to torque control mode.

According to the washing machine of this configuration, the control unit controls the rotation of the drum with the pulsator in the rotation-free state during the spin-drying operation, so that energy consumption due to driving the pulsator can be significantly reduced.

Additionally, the control unit is configured to switch the pulsator from a rotation-free state to active torque control when it is determined that the pulsator is rotating along the drum. When a phenomenon in which the pulsator rotates along the drum occurs, the load on the drum side motor increases due to the resistance generated when the counter electromotive force on the pulsator side and the control current on the drum side influence each other, and the consumption of the washing machine increases. Energy is increasing. Therefore, by actively controlling the torque of the pulsator, it becomes possible to reduce the total energy consumption of the washing machine.

The control unit may be configured to set the torque command value according to the torque control to less than or equal to the driven torque of the pulsator and apply a predetermined d-axis current to perform field weakening control.

In addition, the control unit determines a torque command value according to the torque control,

Torque command value = 0

You can configure it to be controlled by .

In this way, when the torque command value is given below the driven torque of the pulsator, for example, if the torque command value of the driven torque is given, the rotation of the pulsator that is rotating can be actively supported, and the rotation of the pulsator can be actively supported. The load is reduced.

By doing so, the energy consumption of the washing machine as a whole can be reduced. In addition, by setting the driven torque of the pulsator to less than or equal to the driven torque, energy consumed more than the driven torque is not required, so the consumed energy does not increase.

In addition, since field weakening control is performed, the back electromotive force induced by the pulsator drum rotation phenomenon (hereinafter simply referred to as pulsator rotation) can be suppressed, allowing the motor to rotate at a higher speed. There will be. In other words, it is possible to realize a washing machine capable of stable operation up to a high speed range during spin-drying operation.

In addition, as described above, by setting the torque command value on the pulsator side to "0", the resistance generated by the influence of the counter electromotive force on the pulsator side and the control current on the drum side is suppressed, and the motor (drum side) Since the load on the furnace can be reduced, it becomes possible to reduce the total energy consumption of the washing machine.

In addition, it is provided with a speed detection means for detecting the rotation speed of the pulsator, and the control unit detects the rotation speed of the pulsator by the speed detection means when the rotation speed of the pulsator reaches a predetermined threshold value. It may be configured to determine that a spinning phenomenon is occurring.

In addition, the predetermined threshold value is preferably as low as possible, as long as it is a rotation speed at which the pulsator can be controlled. For example, in the case of control using a Hall sensor, set 10 [rpm] as a predetermined threshold. However, it is not limited to 10 [rpm], and the predetermined threshold value can be set arbitrarily.

In this way, by using the speed detection means to determine whether or not a pulse is occurring along the pulsator, a decision based on the detected value becomes possible more directly.

In this case, the control unit returns the pulsator to a rotation-free state when the rotation speed of the pulsator detected by the speed detection means becomes less than or equal to a predetermined threshold value after switching to the torque control mode. It is desirable to configure

According to this configuration, after the control unit switches to the torque control mode, for example, when the laundry is released from the spinning state and the rotation speed of the pulsator becomes a predetermined speed or less, the pulsator is returned to the rotation-free state. Consists of. For this reason, control instability at extremely low rotation speeds can be prevented.

According to the first embodiment, torque can be efficiently generated by improving the winding coefficient of the coil.

According to the second embodiment, cogging torque and mutual ripple can be reduced, and two axes can be driven at high torque while effectively suppressing noise and vibration.

According to the third embodiment, even the stator of a dual-rotor type motor with a large number of poles can be manufactured efficiently, making it possible to provide a washing machine capable of supporting various operation controls at low cost.

According to the fourth embodiment, while performing synchronous control, the regenerative power from the motor is appropriately consumed by the lower arm short-circuit brake, which has a greater braking effect than the upper arm short-circuit brake, and the drum and pulser are braked on the motor. The data can be stopped relatively quickly. As a result, the deceleration time when decelerating by synchronously controlling the drum and pulsator can be shortened while appropriately consuming regenerative power from the motor.

According to the fifth embodiment, a wide variety of laundry can be washed appropriately and effectively.

According to the sixth embodiment, the rotation direction of the drum or pulsator can be reversed by using the inertial force of the laundry in the drum. For this reason, when the rotation direction of the drum or pulsator is reversed, the load applied to the motor is reduced. As a result, poor starting of the motor can be prevented.

According to the seventh embodiment, by controlling the imbalance by controlling the rotation of the drum and the pulsator, the occurrence of imbalance can be prevented more stably.

According to the eighth embodiment, damage to laundry can be reduced by suppressing speed fluctuations by synchronizing the outer rotor and inner rotor during the spin-drying operation.

According to the ninth embodiment, when it is determined that the phenomenon of the pulsator spinning due to the laundry has disappeared during the drum spin-drying operation, the pulsator is set to rotation-free, thereby reducing damage to the fabric of the laundry and dehydrating while saving power. I can drive.

According to the tenth embodiment, when it is determined that the pulsator is spinning during the spin-dry operation of the washing machine, the pulsator is switched from the rotation-free state to the torque control mode, thereby increasing energy efficiency during the spin-dry operation and Control safety in the area can be improved.

1 is a schematic perspective view of a washing machine.
FIG. 2 is a schematic cross-sectional view taken along line X-X in FIG. 1.
Figure 3 is an exploded perspective view showing the main members of the motor.
Figure 4 is a schematic longitudinal cross-sectional view showing the assembly structure of the motor.
Figure 5 is a schematic cross-sectional view showing the assembly structure of the motor.
Figure 6 is a schematic diagram showing the structure of the stator.
Figure 7 is a diagram showing the relationship between constants, number of slots, and number of poles of the motor according to the first embodiment.
Fig. 8 is a diagram showing the relationship between the number of rotating magnetic fields generated by the stator and the number of magnetic poles of the inner rotor in a conventional motor.
Fig. 9 is a diagram showing the relationship between the number of rotating magnetic fields generated by the stator and the number of magnetic poles of the inner rotor in the motor of the embodiment according to the first embodiment.
Figure 10 is a diagram showing the winding coefficient of a conventional motor with respect to the fundamental wave of the magnetic flux distribution of the rotor.
Fig. 11 is a diagram showing the winding coefficient of the motor of this embodiment with respect to the fundamental wave of the magnetic flux distribution of the rotor in the motor according to the first embodiment.
Figure 12 is a diagram explaining the magnetic flux received from the teeth of a conventional motor.
Figure 13 is a diagram showing the synthesis of magnetic flux received from two teeth of a conventional motor.
Figure 14 is a diagram explaining the magnetic flux received from the teeth of the motor according to the first embodiment.
Figure 15 is a diagram showing the synthesis of magnetic flux received from the two outer teeth of the motor according to the first embodiment.
Figure 16 is a diagram comparing the disconnection coefficient for harmonics of the magnetic flux distribution of the rotor.
Figure 17 is a graph showing the waveform of the induced voltage in a conventional motor.
Figure 18 is a graph showing the waveform of the induced voltage in the motor according to the first embodiment.
Figure 19 is a graph showing changes in induced voltage and cogging torque occurring in the outer rotor driven under no load in the motor according to the second embodiment.
Figure 20 is a diagram explaining tooth opening of a motor according to the second embodiment.
Figure 21 is a graph showing changes in induced voltage and cogging torque occurring in the inner rotor driven under no load in the motor according to the second embodiment.
Figure 22 is a graph showing the change in mutual ripple occurring in the inner rotor when the outer rotor is driven in the motor according to the second embodiment.
Figure 23 is a graph showing the change in mutual ripple occurring in the inner rotor due to inner tooth opening for each outer tooth opening in the motor according to the second embodiment.
FIG. 24 is a graph corresponding to FIG. 19 in another slot combination, relating to the second embodiment.
FIG. 25 is a graph corresponding to FIG. 19 in another slot combination, relating to the second embodiment.
Figure 26 is an exploded perspective view schematically showing the core holding structure in the motor according to the third embodiment.
Fig. 27 is a schematic perspective view of a part of the core holding structure viewed from the center side in the motor according to the third embodiment.
Fig. 28 is a schematic perspective view of a part of the core holding structure viewed from the outer peripheral side in the motor according to the third embodiment.
Figure 29 is a schematic cross-sectional view of a portion of the core holding structure, in a motor according to the third embodiment.
Figure 30 is a diagram for explaining winding processing in relation to the motor according to the third embodiment.
31 is a diagram for explaining winding processing in relation to the motor according to the third embodiment.
Figure 32 is a diagram for explaining a winding pattern in relation to a motor according to the third embodiment.
33 is a diagram for explaining a winding pattern in relation to a motor according to the third embodiment.
Fig. 34 is a schematic perspective view of a part of the winding body viewed from the outer circumference side, relating to the motor according to the third embodiment.
Figure 35 is a diagram for explaining the positioning structure in relation to the motor according to the third embodiment.
Figure 36 is a diagram for explaining a modified example of the positioning structure in relation to the motor according to the third embodiment.
Figure 37 is a diagram for explaining a modified example of the motor manufacturing method according to the third embodiment.
Figure 38 is a diagram for explaining a modified example of the motor manufacturing method according to the third embodiment.
FIG. 39 is a diagram corresponding to FIG. 26 showing a modified example of the motor according to the third embodiment.
Figure 40 is a schematic diagram showing the structure of the motor, drum-side inverter circuit, pulsator-side inverter circuit, and control device of the washing machine according to the fourth embodiment.
Figure 41 is a schematic diagram showing the relationship between a command signal and a carrier wave, and signals to the upper arm and lower arm switching elements based thereon, in relation to the washing machine according to the fourth embodiment.
42 shows the relationship between a command signal and a carrier wave when lower arm short-circuit brake period expansion control is executed, and signals to the upper arm and lower arm switching elements based thereon, with respect to the washing machine according to the fourth embodiment. This is a schematic diagram representing:
Fig. 43 is a graph showing the relationship between the detected rotation speed of the drum and the target rotation speed in the washing machine equipped with the motor control device according to Embodiment 2, in relation to the washing machine according to the fourth embodiment.
Fig. 44 is a flowchart showing processing operations in a speed reduction process according to the control device in the washing machine provided with the motor control device according to Embodiment 2, in relation to the washing machine according to the fourth embodiment.
Figure 45 is a schematic diagram showing the configuration of a motor, a drum-side inverter circuit, a pulsator-side inverter circuit, and a control device in a washing machine equipped with a motor control device according to Embodiment 3, in relation to the washing machine according to the fourth embodiment.
46 shows the relationship between the direct current voltage applied to the drum-side inverter circuit, the detected rotation speed of the drum, and the target rotation speed in the washing machine equipped with the motor control device according to Embodiment 3, in relation to the washing machine according to the fourth embodiment. This is a graph representing .
Fig. 47 is a flowchart showing processing operations in a speed reduction process according to the control device in the washing machine provided with the motor control device according to Embodiment 3, with respect to the washing machine according to the fourth embodiment.
Figure 48 is a block diagram of rotation control of the drum and pulsator in relation to the washing machine according to the fifth embodiment.
Figure 49 is a time chart showing an example of rotation control of the first control pattern in relation to the washing machine according to the fifth embodiment.
Figure 50 is a time chart showing an example of rotation control of the second control pattern in relation to the washing machine according to the fifth embodiment.
Figure 51 is a time chart showing an example of rotation control of the third control pattern in relation to the washing machine according to the fifth embodiment.
Figure 52 is a time chart showing an example of rotation control of the fourth control pattern in relation to the washing machine according to the fifth embodiment.
Figure 53 is a time chart showing an example of rotation control of the fifth control pattern in relation to the washing machine according to the fifth embodiment.
Figure 54 is a time chart showing an example of rotation control of the sixth control pattern in relation to the washing machine according to the fifth embodiment.
Figure 55 is a time chart showing an example of rotation control of the seventh control pattern in relation to the washing machine according to the fifth embodiment.
Figure 56 is a time chart showing an example of rotation control of the eighth control pattern in relation to the washing machine according to the fifth embodiment.
Figure 57 is a time chart showing an example of rotation control of the ninth control pattern in relation to the washing machine according to the fifth embodiment.
Figure 58 is a block diagram showing the configuration of a motor and a control device in relation to a washing machine according to the sixth embodiment.
FIG. 59 is a graph showing electrical signals provided to the motor when driving the drum and pulsator when executing the first correction control in relation to the washing machine according to the sixth embodiment.
FIG. 60 is a graph showing electrical signals provided to the motor when driving the drum and pulsator when executing the second correction control in relation to the washing machine according to the sixth embodiment.
Figure 61 is a flowchart showing processing operations during operation of the washing machine according to the control device, in relation to the washing machine according to the sixth embodiment.
62 is a graph showing electrical signals given to the motor when driving the drum and pulsator when executing the third correction control in the washing machine according to Embodiment 2, in relation to the washing machine according to the sixth embodiment. am.
Figure 63 is a block diagram showing the configuration of a motor and a control device in relation to a washing machine according to the seventh embodiment.
Figure 64 is a flowchart showing the procedure for controlling the rotation operation of the motor in relation to the washing machine according to the seventh embodiment.
Figure 65 is a graph showing time changes in the rotation speed of the drum and pulsator in relation to the washing machine according to the seventh embodiment.
Figure 66 is a graph showing time changes in the rotation speed of the drum and pulsator in relation to the washing machine according to the seventh embodiment.
Figure 67 is a waveform diagram showing the detection signal of the unbalance detection means in relation to the washing machine according to the seventh embodiment.
Figure 68 is a schematic diagram showing the unbalanced position of the drum and pulsator at point A in Figure 67.
Figure 69 is a schematic diagram showing the unbalanced position of the drum and pulsator at point B in Figure 67.
Figure 70 is a graph showing time changes in the rotation speed of the drum and pulsator in relation to the washing machine according to the seventh embodiment.
Figure 71 is a block diagram showing the configuration of a motor and a control device in relation to a washing machine according to the eighth embodiment.
Figure 72 is a flowchart showing a procedure for controlling the rotation operation of a motor in relation to a washing machine according to the eighth embodiment.
Figure 73 is a graph showing the relationship between the phase difference between the drum and the pulsator and the rotation speed of the drum and the pulsator, in relation to the washing machine according to the eighth embodiment.
Figure 74 is a block diagram showing the configuration of a motor and a control device in relation to a washing machine according to the ninth embodiment.
Figure 75 is a graph showing the rotational speed variation of the outer rotor at heavy load and light load in relation to the washing machine according to the ninth embodiment.
Figure 76 is a graph showing time changes in the rotational speed of the outer rotor and the motor current in relation to the washing machine according to the ninth embodiment.
Figure 77 is a flowchart showing a procedure for controlling the rotation operation of a motor in relation to a washing machine according to the ninth embodiment.
Figure 78 is a block diagram showing the configuration of a motor and a control device in relation to a washing machine according to the tenth embodiment.
Figure 79 is a block diagram showing the configuration of a motor and a control device in relation to a washing machine according to the tenth embodiment.
Figure 80 is a graph showing time changes in the rotation speed, Iq, and Id of the drum and pulsator in a free rotation state, with respect to the washing machine according to the tenth embodiment.
Figure 81 is a graph showing time changes in the rotation speed, Iq, and Id of the drum and pulsator in the torque control mode, with respect to the washing machine according to the tenth embodiment.
Figure 82 is a graph showing the time change of the phase current of the inverter in the spin-free state with respect to the washing machine according to the tenth embodiment.
Figure 83 is a graph showing the time change of the phase current of the inverter in the torque control mode, with respect to the washing machine according to the tenth embodiment.

Hereinafter, embodiments of the present invention will be described in detail based on the drawings. However, the following description is essentially merely illustrative and does not limit the present invention, its applications, or its uses.

First, the configuration of the washing machine and motor common to the first to tenth embodiments will be described. Afterwards, each of the first to tenth embodiments will be described individually.

(Full configuration of the washing machine)

Figure 1 shows a washing machine 1 of this embodiment. This washing machine 1 is a fully automatic washing machine in which each process from washing to rinsing and dehydration is performed by automatic control. The washing machine 1 has a main body 2 in the shape of a vertically long rectangular box, and an inlet 4 that is opened and closed with a lid 3 is formed on the top of the main body 2. Loading and unloading of laundry is performed through this inlet 4 (so-called vertical washing machine). At the rear of the inlet 4, various switches and display units are provided to be operated by the user.

As shown in FIG. 2, inside the main body 2, there is a water tub 10, a drum 11, a motor 12, a pulsator 13, a balancer 14, and a control device 15. etc. are provided. In particular, the motor 12 is being studied in this washing machine 1, and is compact in size to provide appropriate performance for each process of the washing machine 1, so this motor 12 will be described in detail below. Explain.

The water tank 10 is a cylindrical container with a bottom capable of storing water, and is suspended inside the main body 2 by a plurality of suspension members 16 with the opening facing the upper inlet 4. The inside of the water tank 10 is capable of pouring water through a water pouring mechanism (not shown). A drain pipe 17 whose opening and closing is controlled by a valve is connected to the lower part of the water tank 10, and unnecessary water is drained to the outside of the washing machine 1 through this drain pipe 17.

The drum 11 is a bottomed cylindrical container that is one size smaller than the water tank 10. The drum 11 has its opening facing the inlet 4 and is accommodated in the water tank 10 so that it can rotate around a vertical axis J extending in the vertical direction. All processing of laundry is carried out inside this drum 11. A large number of drain holes 11a are formed on the entire cylindrical wall of the drum 11 (only a portion is shown in FIG. 2). A balancer 14 is installed in the opening of the drum 11. The balancer 14 is a ring-shaped member containing a plurality of balls or viscous fluid inside, and adjusts the imbalance in weight balance caused by the bias of the laundry when the drum 11 rotates. At the bottom of the drum 11, a disk-shaped pulsator 13 having a stirring blade on the upper surface is rotatably installed.

The control device 15 is composed of hardware such as a CPU or ROM and software such as a control program, and comprehensively controls each process performed in the washing machine 1. The control device 15 is electrically connected to various switches, motors 12, valves, etc., and according to the user's instructions, the control program performs washing or spin-drying operations and performs washing, rinsing, and spin-drying processes.

For example, in general, in washing or rinsing processing, the motor 12 rotates the pulsator 13 while reversing it at regular intervals to agitate the laundry with water or detergent. In the dewatering process, the motor 12 drives the drum 11 to rotate at high speed in a certain direction, and the laundry is pushed against the circumferential wall by the action of centrifugal force to dehydrate.

On the other hand, the washing machine 1 is configured so that the drum 11 along with the pulsator 13 can be rotated during washing or rinsing to enable more advanced operation control.

(motor)

The motor 12 has a flat, cylindrical appearance with a diameter smaller than that of the water tank 10, and is assembled on the lower side of the water tank 10 so that the vertical axis J passes through its center.

As shown in FIGS. 3 and 4, the motor 12 is composed of an outer rotor 20, an inner rotor 30, an inner shaft 40, an outer shaft 50, and a stator 60. That is, this motor 12 is equipped with two rotors 20, 30 inside and outside one stator 60 (dual rotor), and these rotors 20, 30 operate a clutch, accelerator/decelerator, etc. It is connected to the pulsator 13 or drum 11 without intervening, and is configured to drive them directly (direct drive). The rotors 20 and 30 share the coils 63 of the stator 60, and by supplying a controlled composite current to these coils 63, the motor 12 operates each of the rotors 20 and 30. It is designed to operate independently.

The outer rotor 20 is a cylindrical member with a flat bottom, and includes a disc-shaped bottom wall 21 with an open center portion, a cylindrical peripheral wall 22 provided at the peripheral edge of the bottom wall 21, and It includes a boss portion (23) integrated into the center portion of the bottom wall portion (21) and a plurality of outer magnets (24). The bottom wall portion 21 and the peripheral wall portion 22 are formed by pressing an iron plate to function as a back yoke, and the boss portion 23 is formed of a sintered alloy or the like. At the center of the boss portion 23, an axial hole is formed whose inner peripheral surface is serrated into a sawtooth shape.

A plurality of slits 21a for dissipating heat are formed in the bottom wall portion 21. Each outer magnet 24 is made of a permanent magnet in the shape of a rectangular plate or tile, and is fixed to the inner surface of the peripheral wall portion 22. In this embodiment, as shown in Fig. 5, 48 outer magnets 24 are arranged continuously in the circumferential direction so that the N poles and S poles are arranged alternately.

The inner rotor 30 is a flat-bottomed cylindrical member with a smaller outer diameter than the outer rotor 20, and has a trapezoidal inner bottom wall portion 31 with an open center portion and a surrounding inner bottom wall portion 31. It includes an installed cylindrical inner peripheral wall portion 32, an inner boss portion 33 integrated into the center portion of the inner bottom wall portion 31, and a plurality of inner magnets 34. Like the outer rotor 20, the inner bottom wall portion 31 and the inner peripheral wall portion 32 are formed by pressing an iron plate, and the inner boss portion 33 is formed of a sintered alloy or the like. At the center of the inner boss portion 33, an axial hole is formed that has an inner diameter larger than that of the boss portion 23 and is serrated on the inner peripheral surface.

A plurality of working openings 31a for fastening the stator 60 to the water tank 10 are formed in the inner bottom wall portion 31. Each inner magnet 34 is made of a permanent magnet in the shape of a rectangular plate or tile, and is fixed to the outer surface of the inner peripheral wall portion 32. In this embodiment, as shown in Fig. 5, 42 inner magnets 34 are arranged continuously in the circumferential direction so that the N poles and S poles are arranged alternately.

The inner shaft 40 is an elongated, cylindrical shaft member, and installation portions 41 and 41 having engaging portions in which serrations are processed on the outer peripheral surface are formed at the upper and lower ends thereof. The lower mounting portion 41 is fixed to the boss portion 23 by press-fitting or bolting the engaging portion into the shaft hole, and the lower end of the inner shaft 40 is fixed to the outer rotor 20.

The outer shaft 50 is an elongated cylindrical shaft member that is shorter than the inner shaft 40 and has an inner diameter larger than the outer diameter of the inner shaft 40. At the upper and lower ends of the outer shaft 50, installation portions 51 and 51 having engaging portions in which serration processing is performed on the outer peripheral surface are formed. The lower installation portion 51 is fixed to the inner boss portion 33 by press-fitting or bolting the engaging portion into the shaft hole, and the lower end of the outer shaft 50 is fixed to the inner rotor 30.

The stator 60 includes a ring-shaped body portion 60a having an outer diameter smaller than the inner diameter of the outer rotor 20 and a larger inner diameter than the outer diameter of the inner rotor 30, and a flange portion protruding from the inner peripheral edge of the upper portion toward the center. It is provided with (60b) and is formed by resin mold molding. The detailed structure of the stator 60 will be described later.

(assembly of the motor)

As shown in FIG. 4, the stator 60 is installed by fastening the flange portion 60b to the motor bracket 70 provided on the bottom of the water tank 10. The outer shaft 50 to which the inner rotor 30 is connected is rotatably supported on the motor bracket 70 through a bearing 71 and a ball bearing 72. The upper end of the outer shaft 50 is fixed to the drum 11 by installing a bracket fixed to the drum 11 on the upper installation portion 51 protruding inside the water tank 10.

The inner shaft 40 to which the outer rotor 20 is connected is inserted into the lower end of the outer shaft 50 so that its upper end protrudes into the inside of the drum 11. The inner shaft 40 is rotatably supported by the drum 11 and the outer shaft 50 via upper and lower inner bearings 73 and 73. The upper end of the inner shaft 40 is fixed to the pulsator 13 by fastening the coupling portion of the upper installation portion 41 to the installation hole formed in the center of the pulsator 13.

The stator 60, the inner rotor 30, and the outer rotor 20 are assembled so that the inner rotor 30 and the outer rotor 20 face the stator 60 with a slight gap. In this motor 12, a controlled composite current is supplied to the stator 60, thereby forming a magnetic field that varies periodically in each coil 63.

In the case of this motor 12, a composite current consisting of 3 phases and 6 phases is supplied, the inner rotor 30 with a small number of poles is driven in 3 phases, and the outer rotor 20 with a large number of poles is driven in three phases. It is composed of 6 phases.

This periodic fluctuation of the magnetic field acts on each of the inner magnet 34 and the outer magnet 24, thereby forming an integrated structure consisting of the inner rotor 30, the outer shaft 50, and the drum 11, and the outer rotor 20. ), the inner shaft 40, and the pulsator 13 are individually driven to rotate around the vertical axis (J).

(Detailed structure of the stator)

As shown in FIG. 6, the body portion 60a, which is the main body portion of the stator 60, includes a plurality of I-shaped cores (core elements) 61, an insulator 62, a plurality of coils 63, and a resin molded body ( 75), etc. As shown in FIG. 5, the stator 60 of this embodiment is provided with 36 I-shaped cores 61 and coils 63.

As shown in Figures 26 and 29, the I-shaped core 61 is a thin plate-shaped iron member whose cross-section in the axial direction has an I shape. At the end of the inner circumference of the I-shaped core 61, both corners protrude in the shape of a knife in the circumferential direction, providing inner teeth 61a that are vertically long and horizontally wide. Additionally, at the outer peripheral end of the I-shaped core 61, outer teeth 61b are provided that are vertically long and horizontally wide, with both corners protruding in a knife-like shape in the circumferential direction. These I-shaped cores are arranged radially at equal intervals around the entire circumference of the body portion 60a, and each is arranged independently.

By continuously winding the wire W (conductive wire coated with an insulating material) around each of these I-type cores 61 via the insulator 62 in a predetermined order and configuration, the I-type core 61 is formed. A coil 63 is formed for each. The I-shaped core 61, the insulator 62, and the coil 63 are embedded in a resin molded body 75 formed into a circular ring shape by molding, and the inner teeth 61a and the outer teeth 61b are formed. Only each cross-sectional portion is exposed to the inner and outer peripheral surfaces of the resin molded body 75. A connector 76 is provided at the top of the body portion 60a to which electrical wiring for a control device or power source is connected.

<First Embodiment>

The first embodiment relates to a motor for a washing machine suitable for a washing machine.

(Relationship between number of slots and number of poles of rotor)

As shown in FIG. 7, in the first embodiment, the motor 12 that drives the inner rotor 30 side in three phases and drives the outer rotor 20 side in six phases is the object. That is, the outer rotor 20 is the first rotor, and the inner rotor 30 is the second rotor. And, the winding is formed as a fractional slot winding. A composite current obtained by overlapping currents corresponding to each of the outer rotor 20 and the inner rotor 30 is supplied to the coil 63 of the stator 60. Because of this, the coil 63 generates separate rotating magnetic fields to independently drive the outer rotor 20 and the inner rotor 30.

In addition, in this motor 12, the number of rotating magnetic fields generated by the stator 60 and the number of magnetic poles of the outer rotor 20 and the inner rotor 30 are configured to be different. Specifically, since the number of slots (S) of the stator 60 is 36, the number of poles (P1) of the inner rotor 30 is 42, and the number of poles (P2) of the outer rotor 20 is 48, the ratio is S:P1:P2 = 6:7:8 (see Figure 5). At this time, the width of the teeth of the core element 61 inserted into the slot of the stator 60 may be larger than the width of the magnet of the rotor. Specifically, the inner rotor 30 includes a plurality of inner magnets 34 arranged circumferentially to face the inner peripheral surface of the stator 60, and the core element of the stator 60 facing the inner rotor 30 ( The width of the teeth (inner teeth) 61a of 61) is greater than 1/2 of the width of each of the plurality of inner magnets 34. As another example, the width of the teeth 61a of the core element 61 of the stator 60 facing the inner rotor 30 may be larger than the width of each of the plurality of inner magnets 34. In addition, the outer rotor 20 includes a plurality of outer magnets 24 arranged circumferentially to face the outer peripheral surface of the stator 60, and the core element 61 of the stator 60 faces the outer rotor 20. ) The width of the teeth (outer teeth) 61b is greater than 1/2 of the width of each of the plurality of outer magnets 24. As another example, as shown in FIG. 12, the width of the teeth 61b of the core element 61 of the stator 60 facing the outer rotor 20 is larger than the width of each of the plurality of outer magnets 24. can be formed.

Figure 8 is a diagram showing the relationship between the number of rotating magnetic fields generated by the stator and the number of magnetic poles of the inner rotor in a conventional motor. As shown in Fig. 8, the conventional motor is a motor configured so that S:P1:P2 = 6:4:2. In the motor configured in this way, the number of rotating magnetic fields generated by the stator 60 and the number of magnetic poles of the inner rotor 30 are the same. In addition, although not shown, the number of rotating magnetic fields generated by the stator 60 is the same as the number of magnetic poles of the outer rotor.

Fig. 9 is a diagram showing the relationship between the number of rotating magnetic fields generated by the stator and the number of magnetic poles of the inner rotor in the motor of this embodiment. As shown in FIG. 9, in the motor 12 of this embodiment, the number of rotating magnetic fields generated by the stator 60 and the number of magnetic poles of the inner rotor 30 are configured to be different. In addition, although not shown, the number of magnetic poles of the outer rotor 20 is also different from the number of rotating magnetic fields generated by the stator 60.

(winding factor)

Hereinafter, the winding coefficient of the motor 12 of this embodiment will be explained by comparing it with the winding coefficient of a conventional motor. Figure 10 is a table showing the winding coefficient of a conventional motor. Fig. 11 is a table showing the winding coefficient of the motor of this embodiment. On the other hand, if the disconnected winding coefficient is Kp, the distributed winding coefficient is Kd, and the winding coefficient is Kw, then Kw = Kp·Kd.

As shown in Figure 10, when driving the inner side (4 Pole in Figure 10) in a conventional motor, it can be driven in three phases with Kp = 0.87, Kd = 1, and Kw = 0.87. In 6-phase, Kp = 0.87, Kd = 0, Kw = 0 and cannot be driven.

On the other hand, when driving the outer side (2 Pole in FIG. 10), in three phases, Kp = 0.5, Kd = 0, Kw = 0 and cannot be driven. In 6-phase, it can be driven with Kp = 0.5, Kd = 1, and Kw = 0.5.

In other words, three-phase driving only affects the inner side and does not affect the outer side. In 6-phase drive, it only affects the outer side and does not affect the inner side.

As shown in FIG. 11, in the motor 12 of this embodiment, when driving the inner side (7 Pole in FIG. 11), it can be driven with Kp = 0.97, Kd = 0.97, and Kw = 0.93 in three phases. . In 6-phase, Kp = 0.97, Kd = 0, Kw = 0 and cannot be driven.

On the other hand, when driving the outer side (8 Pole in Figure 11), in three phases, Kp = 0.87, Kd = 0, Kw = 0 and cannot be driven. In 6-phase, it can be driven with Kp = 0.87, Kd = 0.87, and Kw = 0.75.

In other words, three-phase driving only affects the inner side and does not affect the outer side. In 6-phase drive, it only affects the outer side and does not affect the inner side.

In this way, in the motor 12 of this embodiment, the winding coefficient of the coil 63 with respect to the fundamental wave of the magnetic flux distribution of the rotor is larger than that of the conventional motor. In particular, on the outer rotor 20 side, while the winding coefficient of the conventional motor is Kw = 0.5, the winding coefficient of the motor 12 of the present embodiment is Kw = 0.75, so it can be seen that the winding coefficient is improved by 50%. Because of this, torque can be efficiently generated by improving the winding coefficient.

Hereinafter, using FIGS. 12 to 15, the principle by which torque can be efficiently generated when the configuration of the motor 12 of this embodiment is adopted will be explained.

As shown in Fig. 12, in a conventional motor, three outer teeth 61b face one outer magnet 24 of the outer rotor 20. Therefore, the teeth 61b at the central position can receive a magnetic flux equivalent to 60° of the magnetic flux waveform including the central part of the outer magnet 24. Because of this, 50% of the total magnetic flux of one outer magnet 24 can be used, so Kp = 0.5.

Here, when the tooth 61b at the center position is the A phase, the next tooth 61b of the A phase can also use 50% of the magnetic flux of the entire outer magnet 24, and Kp = 0.5.

Additionally, the general formula for Kp can be expressed as follows.

Kp=sin(β/2), β is slot width (electrical angle)

And, as shown in the vector diagram of each phase in FIG. 13, if the magnetic flux received from the two teeth 61b of phase A is combined, 0.5cos0°+0.5cos0°=1. That is, the magnetic flux vector of the two teeth 61b for the A phase has a magnitude of 0.5, and since each is in the same phase as the A phase, the magnitude becomes 1 when combined. Since this deviation of 0° with respect to the A phase represents Kd, in a conventional motor, Kd=cos0°=1.

On the other hand, as shown in FIG. 14, in the motor 12 of the present embodiment, the central portion of the teeth 61b faces each other at a position deviated by 30° from the central portion of one outer magnet 24 of the outer rotor 20. . This tooth 61b can receive a magnetic flux equivalent to 120° of the magnetic flux waveform, excluding the magnetic flux canceled from the N and S poles of the adjacent outer magnet 24. Because of this, 87% of the total magnetic flux of one outer magnet 24 can be used, so Kp = 0.87.

Here, when the above-mentioned tooth 61b is the A phase, the next A-phase tooth 61b can also use 87% of the entire magnetic flux of one outer magnet 24, and Kp = 0.87.

Therefore, as shown in the vector diagram of each phase in Fig. 15, if the magnetic flux received from the two teeth 61b of phase A is combined, 0.87cos30°+0.87cos30°=1.5. In other words, the magnetic flux vector of the two teeth 61b has a magnitude of 0.87 with respect to the A phase, which is 30° ahead or behind each, so when combined, the magnitude becomes 1.5 in the phase of the A phase. Since this deviation of 30° with respect to the A phase represents Kd, in the motor 12 of this embodiment, Kd=cos30°=0.87.

As described above, when the configuration of the motor 12 of this embodiment is adopted, more magnetic flux can be used and torque can be generated efficiently compared to the configuration of a conventional motor.

Additionally, in this embodiment, the magnetic flux is compared only for the A phase, but since the magnetic fluxes for the B to F phases are the same as the A phase, detailed description is omitted.

(Cut-off winding coefficient for harmonics of the rotor’s magnetic flux distribution)

Figure 16 is a table comparing the disconnection coefficients for harmonics of the magnetic flux distribution of the rotor.

As shown in Fig. 16, in a conventional motor, the maximum disconnection coefficient for harmonics of the 3rd, 5th, and 7th orders is Kp = 1 at the 3rd order on the 6-phase side. On the other hand, in the motor 12 of this embodiment, the maximum disconnection coefficient for the 3rd, 5th, and 7th harmonics is Kp = 0.87 at the 5th and 7th orders on the 6-phase side. That is, in this embodiment, the disconnection coefficient for harmonics can be set to less than 1.

Here, as shown in the graph of FIG. 17, the waveform of the induced voltage is distorted in the conventional motor, and the distortion factor (Klirrfaktor) at this time is about 31%. On the other hand, as shown in the graph of FIG. 18, in the motor 12 of this embodiment, the waveform of the induced voltage is hardly distorted, and the distortion rate at this time is about 4.9%.

As described above, in the motor 12 of this embodiment, the disconnection coefficient of the coil 63 with respect to the harmonics of the magnetic flux distribution of the rotor is smaller than that of the conventional motor. Additionally, in the motor 12 of this embodiment, the distortion rate of the waveform of the induced voltage is lowered by about 84% compared to the conventional motor. As a result, torque ripple is reduced, thereby reducing vibration and noise.

(variation examples, etc.)

In this embodiment, the number of slots of the stator 60 is 36, the number of poles of the inner rotor 30 is 42, and the number of poles of the outer rotor 20 is 48 (S:P1:P2 = 6:7:8). has been explained, but it is not limited to this form. For example, even if the number of slots of the stator 60 is 36, the number of poles of the inner rotor 30 is 48, and the number of poles of the outer rotor 20 is 42 (S:P1:P2 = 6:8:7), good night.

If the ratio of the number of slots of the stator 60, the number of poles of the inner rotor 30, and the number of poles of the outer rotor 20 described above is satisfied, the number of stator slots and the number of poles of the rotor can be generalized as follows.

S=12n

P1=(6±1)·2n

P2=(6±2)·2n

Here, S is the number of slots of the stator, P1 is the number of poles (P1) of one of the first rotor or the second rotor, P2 is the number of poles (P2) of the other, and n is an integer of 1 or more.

In addition, in this embodiment, the motor 12 in which magnets are attached at equal intervals to the outer periphery of the outer rotor 20 and the inner rotor 30 has been described, but the motor is not limited to this form. For example, the outer rotor 20 and the inner rotor 30 may be configured as a so-called magnetic flux concentration type motor in which magnetic materials and magnets are alternately arranged in the circumferential direction while being in close contact with each other.

<Second Embodiment>

The second embodiment relates to a dual rotor type motor having two rotors inside and outside one stator suitable for a washing machine, and in particular, the core of the stator is composed of a plurality of core elements that are independent of each other, It relates to motors in which the number of these core elements is less than the number of poles of two rotors.

(Configuration of the main parts of the motor)

In the washing machine 1, large cogging torque (torque generated by the magnetic attraction force acting between the magnet and the core when moving the rotor in a deenergized state) causes noise and vibration, so cogging It is desirable that the torque be small.

In addition, in the case of a dual-rotor type motor in which the inner rotor 30 and the outer rotor 20 share one stator 60, like this motor 12, the inner rotor 30 and the outer rotor 20 There is a unique problem that when one of the rotors is driven, a torque ripple occurs in the other rotor due to the influence of the magnetic field formed by the rotor's drive (mutual ripple).

When this mutual ripple becomes large, it becomes a cause of noise and vibration, similar to cogging torque. Therefore, when using such a dual rotor type motor in the washing machine 1, it is necessary to reduce not only the cogging torque but also the mutual ripple.

Therefore, by performing electromagnetic field analysis, a combination of the number of poles of the inner rotor 30, the number of poles of the outer rotor 20, and the number of slots of the stator 60 (the same number as the number of I-type cores 61) (so-called slot combination) ), by examining the tooth opening of the I-shaped core 61, conditions were found that could effectively reduce both the cogging torque and the mutual ripple.

Next, the above will be explained in detail using the above-described motor 12 as an example. For reference, the slot combination of the motor 12 is the number of poles of the inner rotor 30: 42, the number of poles of the outer rotor 20: 48, the number of slots of the stator 60: 36, and the number of I-type cores 61. is less than the number of poles of each of the inner rotor 30 and the outer rotor 20, and the outer rotor 20 has more poles than the inner rotor 30.

In Figure 19, the outer rotor 20 with a large number of poles is driven without load, and the outer rotor ( 20) shows the results of an investigation into how the induced voltage and cogging torque generated change.

Meanwhile, the tooth opening angle referred to here is an angle (center angle) created by a line connecting both ends of the tooth in the circumferential direction and the center (J) of the stator. Figure 20 shows the tooth opening angle of the inner tooth 61a (inner tooth opening angle θ1) and the tooth opening angle of the outer tooth 61b (outer tooth opening angle θ2).

In the case of the motor 12, since the number of I-shaped cores 61 is 36, the physical upper limit of the tooth opening angle is 10° (when the gap between adjacent teeth is 0), approximately 3° to approximately 9°. An interpretation was carried out in the scope of the reshuffle of the Thirst.

As shown in FIG. 19, the induced voltage generated in the outer rotor 20 is influenced by the change in the outer tooth opening angle θ2, and has a maximum peak at about the middle of the analysis range of the outer tooth opening angle θ2. It changes into the curve shape shown. Additionally, the induced voltage generated in the outer rotor 20 is affected by the inner tooth opening angle θ1 and tends to increase as the inner tooth opening angle θ1 increases.

The cogging torque generated in the outer rotor 20 changes in a curved shape showing two peaks with troughs approximately in the middle of the analysis range of the outer tooth opening angle θ2 according to the change in the outer tooth opening angle θ2. On the other hand, the cogging torque generated in the outer rotor 20 does not change even if the inner tooth opening angle θ1 changes, so the influence of the inner tooth opening angle θ1 is extremely small.

In Figure 21, the inner rotor 30 with a small number of poles is driven without load, and the inner rotor 30 is rotated according to the outer tooth opening angle θ2 (5.42°, 6.25°, 7.08°) and the inner tooth opening angle θ1. The results of an investigation into how the generated induced voltage and cogging torque change are shown.

As shown in FIG. 21, the induced voltage generated in the inner rotor 30 is influenced by the change in the inner tooth opening angle θ1, and has a maximum peak at about the middle of the analysis range of the inner tooth opening angle θ1. It changes into the curved shape shown. Additionally, the induced voltage generated in the inner rotor 30 tends to increase as the outer tooth opening angle θ2 increases under the influence of the outer tooth opening angle θ2.

The cogging torque generated by the inner rotor 30 is not only very small compared to the cogging torque generated by the outer rotor 20, but also does not change even if the inner tooth opening angle θ1 changes, so the influence of the inner tooth opening angle θ1 is Very small. Additionally, the cogging torque generated in the inner rotor 30 does not change even if the outer tooth opening angle θ2 changes, so the influence of the outer tooth opening angle θ2 is also very small.

Therefore, with regard to cogging torque, the outer rotor 20 is a problem and the inner rotor 30 can be ignored. However, in the case of this motor 12, since mutual ripple occurs in the inner rotor 30 when the outer rotor 20 is driven, this mutual ripple may become a problem. So, we also reviewed this mutual reply.

In Figure 22, when the outer rotor 20 is driven, the mutual ripples generated in the inner rotor 30 according to the inner tooth opening angle θ1 (4.76°, 6.19°, 7.62°) and the outer tooth opening angle θ2 are shown. It shows the results of an investigation into how things are changing. As a result, the mutual ripple occurring in the inner rotor 30 is influenced by the outer tooth opening angle θ2 and tends to increase as the outer tooth opening angle θ2 increases.

In Figure 23, in this case, how the mutual ripple occurring in the inner rotor 30 changes depending on the inner tooth opening angle θ1 for each outer tooth opening angle θ2 (5.00°, 6.25°, 7.14°) is investigated. Shows the results. The mutual ripple occurring in the inner rotor 30 is influenced by the inner tooth opening angle θ1 and changes into a curved shape that becomes minimum at about the middle of the analysis range of the inner tooth opening angle θ1.

In Figure 19, the current reference value is shown by a dashed-dotted line. It can be seen that in order to secure a high induced voltage and suppress the cogging torque generated in the outer rotor 20 below the current standard value, the outer tooth opening angle θ2 can be set in the range of 5.0° to 7.14°. Moreover, within this range, as shown in FIG. 22, mutual ripple occurring in the inner rotor 30 can also be suppressed.

Additionally, in Figure 23, the current standard value is indicated by a dashed-dotted line. Since the mutual ripple occurring in the inner rotor 30 may exceed the current standard value, it is desirable to suppress it below the standard value. It can be seen that in order to keep the mutual ripple occurring in the inner rotor 30 below the standard value, the inner tooth opening angle θ1 can be set in the range of 2.67° to 9.5°.

In addition, in the case of the motor 12, since the number of poles of the outer rotor 20 is greater than that of the inner rotor 30, the inner tooth opening angle θ1 and the outer tooth opening angle θ2 have the above-mentioned relationship, but the outer rotor 20 ) and the number of poles of the inner rotor 30 are opposite, that is, when the number of poles of the inner rotor 30 is greater than that of the outer rotor 20, the above-mentioned relationship is reversed.

In addition, since the ranges of the above-mentioned inner tooth opening angle θ1 and outer tooth opening angle θ2 are determined by the number of I-shaped cores 61 (number of core elements), their ranges are based on the number of core elements. It can be generalized.

That is, for the range of 5.0° to 7.14° of the outer tooth opening angle θ2 described above, the inner teeth 61a and the outer teeth 61b facing the rotor with the greater number of poles among the inner rotor 30 and the outer rotor 20. ), the tooth opening angle of this tooth can be generalized to the range of 180°/Nc to 257°/Nc (Nc is the number of core elements).

In addition, for the range of the inner tooth opening angle θ1 described above of 2.67° to 9.5°, the inner teeth 61a and the outer teeth 61b facing the rotor with fewer poles among the inner rotor 30 and the outer rotor 20 ), the tooth opening angle of this tooth can be generalized to the range of 96°/Nc to 342°/Nc (Nc is the number of core elements).

In addition, the above-mentioned relationship is not limited to the slot combination of the motor 12 (number of poles of the inner rotor 30: 42, number of poles of the outer rotor 20: 48, number of slots of the stator 60: 36), and is not limited to a predetermined This can also be true for slot combinations.

Specifically, among the inner rotor 30 and the outer rotor 20, when the number of poles of the rotor with a small number of poles is set to P1 and the number of poles of the rotor with a large number of poles is set to P2, a slot combination that satisfies the following conditions is provided. It can be established for this.

Nc＝12n

P1=(6±1)·2n

P2=(6±2)·2n

(n is an integer greater than or equal to 1)

In addition, although the effect is weaker compared to the above-described slot combination, it can also be established for slot combinations that satisfy the following conditions.

Nc＝6n

P1=6n±2

P2=6n±4

(n is an integer greater than or equal to 2)

Figure 24 shows an example of the electromagnetic field analysis result corresponding to Figure 19 in this slot combination.

Likewise, it can also be established in slot combinations that satisfy the following conditions.

Nc＝6n

P1=6n±4

P2=6n±8

(n is an integer greater than or equal to 2)

Figure 25 shows an example of the electromagnetic field analysis result corresponding to Figure 19 in this slot combination.

In this way, according to the motor of the second embodiment, cogging torque and mutual ripple can be effectively reduced, so when used in a washing machine, the drum and pulsator can be driven at high torque while effectively suppressing noise and vibration. .

<Third Embodiment>

The third embodiment relates to a dual rotor type motor that rotates a washing machine drum, etc. in a direct drive format, and in particular, relates to the structure of a stator formed by mold forming.

(Details of insulators, etc., stator manufacturing method)

Manufacturing the stator 60 not only requires a lot of work, but also requires a high degree of difficulty, as it is necessary to accurately place a plurality of independently formed I-shaped cores 61 at a predetermined position. Therefore, insulators 62 and the like that can be manufactured efficiently while ensuring high quality are being studied. Hereinafter, the structure of the insulator 62 will be described in detail while explaining the manufacturing method of the stator 60.

26 shows an exploded perspective view of the I-shaped core 61 and the insulator 62. The insulator 62 is a structure with thin walls connected, and is formed by injection molding of resin, etc. The insulator 62 is composed of a pair of ring-shaped connectors 81 and 82 connected by touching each other in the axial direction with all I-shaped cores 61 sandwiched between them.

In the case of the insulator 62 of this embodiment, the lower ring-shaped connecting body 81 is made of one body formed in a circular ring shape (main connecting body 81). The upper ring-shaped connecting body 82 is composed of a plurality of arc-shaped connecting elements 82a (three in this embodiment), and by connecting them, it forms a circular shape that is vertically symmetrical with the main connecting body 81. It is formed in a ring shape (subconnector 82). However, unlike the main connector 81, the sub-connector 82 is provided with a terminal portion 83 constituting the connector 76. All ends of the wire W leading from the coil 63 are connected to this terminal portion 83.

The main connection body 81 is provided with 36 core insertion portions 84 into which each of the I-shaped cores 61 is inserted at equal intervals in the circumferential direction. The core insertion portion 84 accommodates approximately half of the lower side of the I-shaped core 61, and is formed into a shape according to the external shape of the I-shaped core 61 with a thin wall. Each core insertion portion 84 is connected by a wall (connecting wall portion 84a) between its two outer peripheral edges.

The basic structure of each connection element 82a is the same as that of the main connection body 81, and twelve core insertion portions 84 into which each of the I-type cores 61 are inserted are provided at equal intervals in the circumferential direction. The core insertion portion 84 accommodates approximately half of the upper side of the I-shaped core 61, and is formed with a thin wall in a shape according to the external shape of the I-shaped core 61. The core insertion portions 84 are connected to each other by extending the outer wall (connection wall portion 84a) of each core insertion portion 84.

The main connector 81 and the secondary connector 82, which are the insulator 62, need to ensure insulation between the I-type core 61 and the coil 63. Therefore, the main connecting body 81 and the secondary connecting body 82 are formed using an insulating resin (resin with excellent insulating properties). In particular, the main connector 81 may be composed of insulating resin and CFRP (carbon fiber reinforced plastic). Then, the rigidity is further strengthened, and as a result, deformation or damage of the main connecting body 81 can be suppressed, making handling easier.

However, since CFRP has low insulating properties, in the present embodiment, for example, the portion of the main connecting body 81, such as the connecting wall portion 84a, where the coil 63 is not wound, is made of CFRP and the coil 63 The area around the I-shaped core 61 is formed into a double structure made of insulating resin. As another example, rather than molding CFRP and insulating resin separately for each part, CFRP may be molded so that it is covered with insulating resin, and the entire main connector 81 may be composed of CFRP and insulating resin.

It is preferable to use a resin of the same type as the insulating resin as the base resin constituting CFRP. By making the base resin the same as the insulating resin, the integrity of CFRP and the insulating resin by double molding can be improved, and the rigidity can be further improved.

(Step 1)

During manufacturing, first, place the main connector 81 on a workbench or the like and support it stably, then insert one I-shaped core 61 into each of the core insertion portions 84 of the main connector 81. . Because it is a repetition of a simple task, the insertion task can be performed simply and is easy to automate. Each I-shaped core 61 can be placed in an appropriate position simply by inserting it into the core insertion section 84.

Then, the sub-connector 82 is connected to the main connector 81 so that it touches each other, so that the core holding structure C1 (the I-shaped core 61 is attached to the pair of connected ring-shaped connectors 81 and 82) form an embedded structure. At this time, if both the ring-shaped connectors 81 and 82 are formed as one piece, insertion is difficult unless the positions of all I-shaped cores 61 and the core insertion portion 84 are aligned, making connection difficult. However, in the case of this embodiment, since the sub-connector 82 to be connected later is divided into a plurality of connection elements 82a, connection can be made relatively easily. In addition, since the main connecting body 81, which is formed as one piece and has excellent rigidity, is handled with the lower side, the core holding structure C1 can be handled stably.

Figures 27, 28, and 29 show the core holding structure C1. In the core holding structure C1, 36 tooth bodies 61c and 36 slots 85 are formed. The tooth body 61c is a part where the I-shaped core 61 is covered with an insulator 62, and the wire W is wound around it. The slot 85 is a space penetrating in the axial direction between adjacent tooth bodies 61c and 61c, and the wound wire W is accommodated therein.

External flange portions 86 and 86 protruding in the axial direction are provided on both edges of the outer peripheral side of the core holding structure C1. Similarly, inner flange portions 87 and 87 protruding in the axial direction are provided on both edges of the inner circumference side of the core holding structure C1. The outer flange portion 86 and the inner flange portion 87 prevent the winding of the wound wire W from being damaged, and are formed slightly higher than the axial height of the coil 63.

On the inner peripheral surface of the core holding structure C1, 36 slot openings 85a communicating with each slot 85 are opened in a slit shape. The I-shaped core 61 is exposed on the inner and outer peripheral surfaces of the core holding structure C1, and an inner core surface portion 88 and an outer core surface portion 89 are formed.

As shown in Fig. 29, when viewed in the axial direction, the thickness t of the central portion of the connecting wall portion 84a is formed to be thicker than that of both ends. Therefore, the rigidity of the main connection body 81 or the core holding structure C1 can be improved.

Similarly, when viewed in the axial direction, the inner core surface portion 88 is located inside the inner peripheral surface of the insulator 62, and the outer core surface portion 89 is located outside the outer peripheral surface of the insulator 62. With this configuration, when forming the mold, the inner core surface portion 88 and the outer core surface portion 89 come into contact with the mold D, so that the I-shaped core 61 can be positioned with high precision in the radial direction, The roundness of the stator 60 can be increased. As a result, the gap between the inner rotor 30 and the outer rotor 20 can be reduced, thereby improving motor performance.

(2nd stage)

The core holding structure C1 is set on the winding machine M, and the winding process of forming the coil 63 by winding the wire W around each of the I-type cores 61 covered with the insulator 62 is mechanically performed. . As a result, a structure (winding body C2) in which the coil 63 is formed on the core holding structure C1 is formed.

As shown in FIG. 30, the winding machine M includes a support member Ms that supports the core holding structure C1 in a rotationally controllable manner, and is capable of being displaced in the axial direction with respect to the core holding structure C1 and is positioned from the tip of the winding machine M. There are three nozzles (Mn) that output the wire (W). In the winding machine M, the rotation of the support member Ms supporting the outer circumference of the core holding structure C1 is controlled, and the displacement of the three nozzles Mn is synchronized on the inner circumferential side of the core holding structure C1, thereby performing winding. Processing is performed.

In order to firmly support the core holding structure C1 on the support member Ms, as shown in FIG. 28, grooves 89a (nipping structure) extending in the axial direction are provided at the upper and lower parts of the outer core surface portion 89. An example of ) is formed. As shown in FIG. 30, the support member Ms is provided with a clamping mechanism Mp that fits into each of the grooves 89a. Therefore, during the winding process, the clamping mechanism Mp is inserted into each groove 89a. , the core holding structure C1 is firmly supported by the support member Ms, so that winding processing can be performed stably.

In addition, when the edge portions on both sides (circumferential direction) of the outer core surface portion 89 protrude from the outer surface of the insulator 62, the groove portion 89a is not inserted into the clamping mechanism Mp, but the outer core surface portion ( 89), the edges of both sides (circumferential direction) may be inserted into the clamping mechanism Mp.

In order to individually drive both the inner rotor 30 and the outer rotor 20 by supplying a composite current, each coil 63 has a 6-phase configuration corresponding to both 3 and 6 phases (phases A to F). ). Specifically, each coil 63 is formed by winding each of the six wires W around each of the 36 I-shaped cores 61 in a certain order, and in the winding process, the three nozzles Mn are synchronized to achieve displacement. By controlling, the process of winding the three wires W simultaneously with the same operation is performed twice. Therefore, the coil 63 can be formed with a small number of steps, resulting in excellent productivity.

When the winding process starts, the winding machine M is controlled to wind the wire W around a predetermined tooth body 61c and automatically form a three-phase coil group in a predetermined winding pattern. In detail, after each nozzle Mn is positioned with respect to a predetermined tooth body 61c on each phase, winding of the wire W begins. In this way, as indicated by arrows in FIGS. 30 and 31, the axial displacement of each nozzle Mn and the rotation of the core holding structure C1 are alternately repeated in a predetermined order while each nozzle Mn is rotated along the diameter. By displacing in this direction, the wire W drawn out from the nozzle Mn is wound around the tooth body 61c.

The winding pattern will be described with reference to FIGS. 32 and 33. The core holding structure C1 can be divided into three sections I to III made of the same winding pattern. One section is composed of 12 tooth bodies 61c, and in FIG. 32, each tooth body 61c is numbered 1 to 12 in a clockwise direction to distinguish them.

Figure 33 shows the winding pattern of division I. The tooth body 61c indicated by a white circle indicates that it is wound counterclockwise (CCW), and the tooth body 61c indicated by a black circle indicates that it is wound clockwise (CW). For example, in the first winding process, it is assumed that winding of the wire W starts from the tooth body 61c of numbers 2, 4, and 6 of section I. When the wire W is wound counterclockwise a predetermined number of times around the tooth body 61c to form the coil 63, the wire W is pulled out upward. Next, the wire W is wound clockwise around the tooth bodies 61c numbered 1, 3, and 5 a predetermined number of times to form the coil 63, and the wire W is pulled upward.

The wire W thus drawn out begins to be wound from the tooth body 61c of numbers 2, 4, and 6 of division II, and the winding process is performed in the same manner as in division I. Next, it moves to division III, and winding processing is performed in the same way as divisions I and II. As a result, 18 coils 63 (D, E, F) of the same winding pattern are formed in each section I to III.

Next, a new wire W is pulled out from each nozzle Mn and a second winding process is performed.

Ⅰ Winding of the wire W starts from the tooth bodies 61c of numbers 7, 9, and 11 of the section, and the wire W is wound counterclockwise a predetermined number of times on these tooth bodies 61c, so that the wire W is It is drawn downward. Next, the wire W is wound clockwise around the tooth bodies 61c numbered 8, 10, and 12 a predetermined number of times, and then the wire W is pulled out downward.

The wire W thus drawn out is transferred to division II, and winding of the wire W is started from the tooth body 61c of numbers 7, 9, and 11 of division II, and winding processing is performed in the same manner as in division I. It is carried out. Next, the process moves to section III, and winding processing is performed in the same way as sections I and II. As a result, 18 coils 63 (A, B, C) of the same winding pattern are formed in each section of I to III, and the winding process is completed.

As shown in FIG. 34, during the winding process, the jumper wire Wa (portion spanning between sections) of the three wires W processed in the first time is of the outer flange portion 86 located on the upper side. The jumper wires Wa of the three wires W, which are arranged along the outer surface and are processed secondly, are arranged along the outer surface of the outer flange portion 86 located below. Since a notch portion 86a is formed in a predetermined portion of the outer flange portion 86, the wire W can be drawn out to the outer surface side of the outer flange portion 86 through this notch portion 86a.

In this way, by arranging three jumper wires Wa on the upper and lower outer flange portions 86, the axial height of the insulator 62 and the stator 60 can be suppressed, thereby miniaturizing the motor 12. can be promoted. Since the jumper wire Wa is arranged on the same side of the outer flange portion 86 for each winding process, the arrangement structure of the wire W is simplified, and the processing efficiency of the winding machine M can be improved.

After the winding process is completed, the winding body C2 is removed from the winding machine M and placed on a work table, and the start and end ends of each wire W are connected to predetermined terminals of the terminal portion 83. At this time, the winding body C2 is handled with the main connecting body 81 at the lower side, and the terminal portion 83 disposed in the sub connecting body 82 is located at the upper side, so the connection process can be easily performed. You can.

(Step 3)

The winding body C2 is set in the mold D, and mold forming is performed using a thermosetting resin.

As shown in FIG. 35, the mold D is composed of a pair of upper and lower molds that contact each other in the axial direction, and inside the mold D is a ring-shaped cavity (C2) that accommodates the winding body C2. Dc) is formed. In order to expose the inner core surface portion 88 and the outer core surface portion 89 from the resin molded body 75, the inner core surface portion 88 is in surface contact with the inner peripheral surface of the cavity Dc and the outer peripheral surface of the cavity Dc is The dimensions of the cavity Dc are set so that the outer core surface portion 89 makes surface contact.

Since the inner peripheral surface of the winding body C2 is divided into a plurality of parts by the slot opening 85a, positional misalignment or deformation is likely to occur due to the winding process. Furthermore, in this motor 12, the inner circumference of the stator 60 rotates at high speed and is prone to generating noise, so if the roundness of the inner circumference of the winding body C2 or the accuracy of the arrangement of the magnetic poles is low, the noise will increase. There is a possibility.

Therefore, a positioning structure is provided between the inner peripheral surface of the winding body C2 and the opposing surface of the mold D opposing it. This positioning structure allows the winding body C2 to be molded while positioned in the circumferential direction with respect to the mold D.

Specifically, on the inner peripheral surface of the winding body C2, as shown in FIG. 27, a plurality of concave portions 90 extending in the axial direction from each of the upper edge and the lower edge are provided with the inner core face portion 88 and the insulator ( 62). And, as shown in FIG. 35, a plurality of convex portions D1 inserted into these concave portions 90 are formed on the opposing surfaces of the upper mold and the lower mold. By inserting and joining each convex part D1 into each concave part 90 and mounting the winding body C2 on the upper and lower molds, the winding body C2 is positioned in the circumferential direction with high precision with respect to the mold D. You can decide.

Additionally, a positioning structure can be provided using a plurality of slot openings 85a facing the inner peripheral surface of the winding body C2. That is, as shown in FIG. 36, a plurality of engaging protrusions D2 are provided on the mold D so as to fit into each slot opening 85a, and these engaging protrusions D2 are fitted into each slot opening 85a. Insert and attach the winding body (C2) to the upper and lower molds. Even by doing this, the winding body C2 can be positioned in the circumferential direction with respect to the mold D with high precision.

Also, at this time, the dimensions may be set so that a portion of the entire circumference of the insulator 62 facing the outer circumference of the winding body C2 contacts the outer circumference of the mold D and presses the winding body C2 toward the inner circumference side. . Because of this, the adhesion between the inner peripheral surface of the winding body C2 and the mold D increases, and thus the roundness of the inner peripheral side of the winding body C2 can be improved. By setting the winding body C2 in the mold D and performing mold forming in this way, the resin molded body 75 is formed, and the stator 60 with the structure shown in FIG. 6 is formed.

(variation examples, etc.)

For example, as shown in FIGS. 37 and 38, a plurality of small rod-shaped temporary connecting portions 92 are provided around the connecting portion of the sub connecting body 82 and the main connecting body 81 that contacts each other. In this way, a ring-shaped support portion 93 connecting each of the plurality of core insertion portions 84 can be provided. At this time, after the third step, a fourth step of removing the ring-shaped support portion 93 by cutting the temporary connection portion 92 may be further included.

In this way, the rigidity of the main connecting body 81 can be strengthened by the annular support portion 93, so that handling of the core holding structure C1 and the winding body C2 is facilitated during winding processing and forming processing. It gets easier. Additionally, since mold forming can be performed while suppressing deformation of the core holding structure C1, the quality of the motor can be improved.

As shown in FIG. 39, instead of using the main connecting body 81, both sides of the ring-shaped connecting body can be formed with a plurality of sub-connecting bodies 82. In this case, the connection portion 95 between each of the plurality of connection elements 82a in one subconnection body 82, and each connection element 82a in the other subconnection body 82. The connecting portions 95 are arranged so that they are offset in the circumferential direction and do not coincide with each other (do not overlap top and bottom). In this way, even if the two ring-shaped connecting bodies are composed of a plurality of connecting elements, they can be integrated and stably supported. Compared to a mold for molding the integrated main connection body 81, the mold can be made smaller by dividing it, so there is an advantage of significantly reducing mold costs.

In particular, in this case, as shown in FIG. 39, the number of sub-connectors 82 on the side corresponding to the main connector 81 is greater than the number of sub-connectors 82 on the upper side where the terminal portion 83 is arranged. It is better to reduce it. In this way, the connection portion 95 can be easily moved, and since the subconnection body 82, which has a small number of divisions and is strong, is positioned at the lower side, it can be stably supported, and connection processing can also be facilitated.

The slot opening 85a of the stator 60 may be provided on the outer peripheral side. The number of poles of the stator 60, inner rotor 30, and outer rotor 20 can be appropriately changed depending on specifications. The arrangement or configuration of the coil 63 can also be changed. The current that drives the motor 12 is not limited to the composite current.

<Embodiment 4>

The fourth embodiment relates to a motor control device used in a washing machine.

(Control of the rotational motion of the motor)

As shown in FIG. 40, the control device 15 and the inner rotor 30 provided in the washing machine 1 are connected through the drum side inverter circuit 101, and the control device 15 and the outer rotor ( 20) is connected through the pulsator side inverter circuit 102. Additionally, the inverter circuits 101 and 102 are connected in parallel to each other and to a common DC power supply 100.

The control device 15 uses a predetermined command signal and a carrier wave consisting of a triangle wave to input pulse width modulated (PWM controlled) electrical signals to the drum and pulsator side inverter circuits 101 and 102, and drives the motor ( Apply direct current voltage to 12).

The drum side inverter circuit 101 is a three-phase inverter circuit, and three upper arm switching elements (hereinafter referred to as upper arm SW elements) 80a, 80b, 80c are provided on the upper arm side, which is the high potential side, and the upper arm side, which is the high potential side, is provided. Three lower arm switching elements (hereinafter referred to as lower arm SW elements (80d, 80e, 80f)) are provided on the lower arm side, making a total of 6 SW elements.

The upper arm SW element 80a and the lower arm SW element 80d are connected in series to form an inverter, and similarly, the upper arm SW element 80b and the lower arm SW element 80e, and the upper arm SW. The element 80c and the lower arm SW element 80f are also connected in series to each other to form an inverter. Then, these three inverters are connected in parallel to form the drum side inverter circuit 101.

Each SW element 80a to 80f is controlled on or off based on the electric signal from the control device 15, and the power supplied to the motor 12 is controlled by the combination of this on and off. Due to this, the rotation speed of the inner rotor 30, that is, the rotation speed of the drum 11 is controlled. Additionally, each SW element 80a to 80f is an IGBT in this embodiment.

A drum-side current sensor 103 for detecting the rectification supplied from the drum-side inverter circuit 101 to the motor 12 is connected to the drum-side inverter circuit 101. The detection current detected by the drum side current sensor 103 is transmitted to the control device 15.

Meanwhile, the pulsator side inverter circuit 102, like the drum side inverter circuit 101, is a three-phase inverter circuit, and three upper arm side SW elements 90a, 90b, and 90c are provided on the upper arm side, which is the high potential side, Three lower arm side SW elements (90d, 90e, 90f) are provided on the lower arm side, which is the low potential side, for a total of 6 SW elements. The upper arm SW element 90a and the lower arm SW element 90d are connected in series to each other to form an inverter, and similarly, the upper arm SW element 90b and the lower arm SW element 90e, and the upper arm SW. The element 90c and the lower arm SW element 90f are also connected in series to each other to form an inverter.

Then, these three inverters are connected in parallel to form the pulsator side inverter circuit 102. Also, like the drum inverter circuit 101, each SW element 90a to 90f is controlled to be on or off based on the electric signal from the control device 15, and the combination of this on and off causes the motor to operate. The power supplied to (12) is controlled to control the rotational speed of the outer rotor 20, that is, the rotational speed of the pulsator 13. Additionally, each SW element 90a to 90f is an IGBT in this embodiment.

Additionally, a pulsator-side current sensor 104 for detecting the current supplied from the pulsator-side inverter circuit 102 to the motor 12 is connected to the pulsator-side inverter circuit 102. The detection current detected by the pulsator side current sensor 104 is transmitted to the control device 15.

Additionally, the washing machine 1 is equipped with a drum side position sensor 105 that detects the rotation speed of the inner rotor 30 and a pulsator side position sensor 106 that detects the rotation speed of the outer rotor 20. The drum side position sensor 105 detects the actual rotation speed of the inner rotor 30, thereby detecting the rotation speed of the drum 11, while the pulsator side position sensor 106 detects the actual rotation speed of the outer rotor 20. By detecting the speed, the rotational speed of the pulsator 13 is detected. The detected rotation speed detected by each position sensor (105, 106) is transmitted to the control device (15).

The control device 15 calculates the rotational speed of the drum 11 and the pulsator 13 calculated from the detection current detected from the drum and pulsator side current sensors 103 and 104, and the drum and pulsator side positions. Based on the detected rotation speed detected from the sensors 105 and 106, an electrical signal input to the drum side and pulsator side inverters 101 and 102 so that the drum 11 and the pulsator 13 reach the desired rotation speed. Correct.

Due to this, the rotation speed of the drum 11 and the pulsator 13 is controlled. From the above, the drum-side and pulsator-side current sensors 103, 104 and the drum-side and pulsator-side position sensors 105, 106 constitute rotational speed detection means.

Here, the control device 15 rotates the drum 11 and the pulsator 13 at high speed in the same direction during the dehydration process, and rotates the drum 11 and the pulsator 13 at the high speed after completion of the dehydration process. A deceleration process is performed to slow down and stop. In the above-mentioned deceleration process, if a difference in rotation speed occurs between the drum 11 and the pulsator 13, the laundry rotates toward the slower speed and is pulled between the drum 11 and the pulsator 13, causing damage to the fabric. There is a risk that this will occur.

In addition, as in the present embodiment, when the inner rotor 30 and the outer rotor 20 are provided and the drum 11 and the pulsator 13 are rotated independently, the inner rotor 30 and the outer rotor 20 are rotated independently. Since regenerative power is generated based on the torque acting on each rotor 20, the regenerative power is almost twice that of the case where there is only one rotor.

For this reason, if the drum 11 and the pulsator 13 (specifically, the inner rotor 30 and the outer rotor 20) are suddenly decelerated, the regenerative power cannot be consumed all and the regenerative power is converted to direct current. There is a possibility that it may act on the power source 100 and damage the DC power source 100. To prevent this, it is necessary to gently decelerate the drum 11 and the pulsator 13 to properly process the regenerative power.

In this way, when it is necessary to gently decelerate the drum 11 and the pulsator 13 while performing synchronous control, it is desirable to adjust the rotation speed to the lower deceleration rate, that is, the higher rotation speed. However, if the rotation speed is set to the higher rotation speed, it takes time to stop the drum 11 and the pulsator 13.

So, in Embodiment 1, the drum 11 and the pulsator are detected by the drum side and pulsator side position sensors 105 and 106, which the control device 15 executes for each cycle of the carrier wave used for PWM control. (13) synchronous control that makes the detection rotation speed approximately the same, upper arm short-circuit brake control that turns on all of the upper arm SW elements and turns off all of the lower arm SW elements to apply a short-circuit brake, and In the lower arm side short-circuit brake control that turns off all of the lower arm side SW elements and turns on all of the lower arm side SW elements to apply a short circuit brake, the synchronous control set by the PWM control is performed based on the detected rotation speed for each cycle of the carrier wave. Without changing the length of the synchronous control period, which is the execution period, the upper arm short circuit brake period, which is the period for executing the upper arm short circuit brake control, is shortened, and at the same time, the lower arm short circuit brake period, which is the period for executing the lower arm short circuit brake control, is shortened. The lower arm side short-circuit break period expansion control that expands is performed.

Since the short circuit brake does not exhibit a braking effect unless regenerative current flows from the motor 12, it is connected to the ground side rather than the upper arm short circuit brake, which shorts out the upper arm SW element affected by the direct current voltage from the DC power supply 100. The lower arm short circuit brake, which shorts the lower arm SW element that is not affected by direct current voltage, has a great braking effect. For this reason, by executing the lower arm side short-circuit brake period expansion control, the deceleration time when decelerating while executing synchronous control on the drum 11 and the pulsator 13 can be shortened.

Hereinafter, the lower arm side short-circuit brake period expansion control will be described with reference to FIGS. 41 and 42. In addition, since the lower arm side short circuit break period expansion control method is substantially the same in the drum side inverter circuit 101 and the pulsator side inverter circuit 102, in the following description, the control for the drum side inverter circuit 101 It only explains.

First, referring to FIG. 41, the synchronization control period, the upper arm short-circuit break period, and the lower arm short-circuit break period are explained.

In Figure 41, the relationship between the command signals Va, Vb, Vc and the carrier wave C in PWM control before executing the lower arm short-circuit brake period expansion control, and the upper arm and lower arm SW elements 80a based thereon. It represents an electrical signal of ∼80f). In addition, a, b, c, d, e, and f in the figure correspond to each SW element, such that, for example, a is an electrical signal transmitted to the upper arm SW element 80a. In addition, in Figure 41, any part of the electric signal sent to the drum-side inverter circuit 101 is omitted, and the same or different electric signals are transmitted from the control device 15 to the drum-side inverter circuit before and after the period shown in Figure 41. It is being sent to (101).

The PWM-controlled electrical signal sent from the control device 15 to the drum-side inverter circuit 101 is determined by comparing the command signals Va, Vb, and Vc with the carrier wave C. In detail, based on the point where the command signal (Va, Vb, Vc) and the carrier wave (C) intersect, in the range where the command signal (Va, Vb, Vc) exceeds the carrier wave (C), the upper An electrical signal is sent to turn off the arm SW elements (80a to 80c) and turn on the lower arm SW elements (80d to 80f). On the other hand, in the range where the command signals (Va, Vb, Vc) are lower than the carrier wave (C), the upper arm SW elements (80a to 80c) are turned off and the lower arm SW elements (80d to 80f) are turned on. send a signal

In addition, the command signals (Va, Vb, Vc) before executing the lower arm side short-circuit brake period expansion control are determined based on the detected rotation speeds of the drum and pulsator. In addition, to simplify the explanation, in FIG. 41, switching between on and off of the upper arm SW elements 80a to 80c and switching between on and off of the lower arm SW elements 80d to 80f are performed simultaneously. Although depicted, in reality, the switching timing is shifted so that the SW elements forming the inverter (for example, the upper arm SW element 80a and the lower arm SW element 80d) do not turn on at the same time.

Specifically, in the period from to t1, the control device 15 turns off all of the upper arm side SW elements 80a to 80c because all command signals (Va, Vb, Vc) are high with respect to the carrier wave C. and all of the lower arm SW elements (80d to 80f) are turned on. At this time, the regenerative current from the motor 12 is consumed through the lower arm SW elements 80d to 80f, and a short circuit brake is applied to the inner rotor 30 of the motor 12. From here, when the carrier wave C exceeds the command signal Va at t1, the control device 15 turns on the upper arm SW element 80a and turns off the lower arm SW element 80d.

As a result, a direct current voltage from the direct current power source 100 is applied to the motor 12 to adjust the rotational speed of the inner rotor 30. Thereafter, when the carrier wave C exceeds the command signal Vb, the control device 15 turns on the upper arm SW element 80b and turns off the lower arm SW element 80e. Then, at t2, when the carrier wave C exceeds the command signal Vc, the control device 15 turns on the upper arm SW element 80c and turns off the lower arm SW element 80f. , all of the upper arm SW elements 80a to 80c are turned on and all of the lower arm SW elements 80d to 80f are turned off.

At this time, all parts connected to the motor 12 are at the same potential, and direct current voltage is not applied to the motor 12 from the drum side inverter circuit 101. At this time, the regenerative current from the motor 12 is consumed through the upper arm side SW elements 80a to 80c, and a short circuit brake is applied to the inner rotor 30.

Then, after passing the peak of the triangular wave, which is the carrier wave C, when the carrier wave C falls below the command signal Vc at time t3, the control device 15 controls the upper arm SW element 80c. ) is turned off, and at the same time, the lower arm side SW element 80f is turned on. As a result, a potential difference is created again with respect to the motor 12, and a direct current voltage is applied to the motor 12, thereby adjusting the rotational speed of the inner rotor 30.

Thereafter, when the carrier wave C falls below the command signal Vb, the control device 15 turns off the upper arm SW element 80b and simultaneously turns on the lower arm SW element 80e. Then, at t4, when the carrier wave C falls below the command signal Va, the control device 15 turns off the upper arm SW element 80a and simultaneously turns on the lower arm SW element 80d. As a result, all of the upper arm SW elements 80a to 80c are turned off again and all of the lower arm SW elements 80d to 80f are turned on. At this time, regenerative power from the motor 12 is consumed again through the lower arm side SW elements 80a to 80f, and a short circuit brake is applied to the inner rotor 30.

As described above, in the period from t1 to t4 in Figure 41, the lower arm side short-circuit brake is applied to the inner rotor 30 of the motor 12, and in the period from t1 to t2 and t3 to t4 in Figure 41, the motor A direct current voltage is applied to (12) to adjust its rotational speed, and in the period t2 to t3 in Fig. 41, the upper arm side short-circuit brake is applied to the inner rotor 30 of the motor 12. That is, the periods from t1 to t4 in Figure 41 correspond to the lower arm short-circuit brake period, the periods from t1 to t2 and t3 to t4 in Figure 41 correspond to the synchronous control period, and the periods t2 to t3 in Figure 41. The period corresponds to the upper arm side short circuit break period.

Next, referring to FIG. 42, the lower arm side short-circuit break period expansion control will be explained.

In Figure 42, the relationship between the command signals Va', Vb', and Vc' in PWM control and the carrier wave C when lower arm side short-circuit brake period expansion control is executed, and the upper arm side and lower arm side SW based thereon. Electric signals to elements 80a to 80f are shown. Additionally, the virtual lines shown in FIG. 42 correspond to the command signals Va, Vb, and Vc in FIG. 41.

When executing lower arm side short circuit break period expansion control, the control device 15 expands the lower arm side short circuit break period without changing the length of the synchronous control period. Specifically, in the PWM control, it is set by the command signals Va, Vb, and Vc before correction and the carrier wave (C). The threshold at which the upper dark side SW elements (80a to 80c) turn on is moved to the bright side of the carrier wave (C) by the same amount.

That is, the command signals Va, Vb, and Vc before correction shown by the virtual line in FIG. 42 are corrected so that the intersection point between the command signals Va, Vb, and Vc and the carrier wave C moves to the mountain side of the carrier wave C, and the command signals Va, Vb, and Vc before correction are shown in FIG. The command signals Va', Vb', and Vc' are indicated by solid lines. By moving the command signals Va, Vb, and Vc to the high side of the carrier wave (C) to create new command signals Va', Vb', and Vc', the period during which the command signal falls below the carrier wave (C) is shortened, and the command signal is transferred to the carrier wave (C). Since the period exceeding (C) is expanded, the upper arm short circuit break period in which all upper arm SW elements (80a to 80c) are turned on and all lower arm SW elements (80d to 80f) are turned off is shortened, and the upper arm SW elements (80a to 80c) are all turned on. The lower arm side short-circuit brake period in which all elements 80a to 80c are turned off and all lower arm SW elements 80d to 80f are turned on is expanded (specifically, t1 to t1' and t4' to t4 shown in FIG. 42). (can be expanded by the period).

In addition, the timing at which the upper arm SW elements (80a to 80c) and the lower arm SW elements (80d to 80f) are turned on or off is made the same as the magnitude of the threshold value of each upper arm SW element (80a to 80c) that moves toward the acid side. only changes, and the length of the synchronization control period (periods t1' to t2' and t3' to t4' in FIG. 42) can be maintained. Because of this, it is possible to expand the lower arm side short-circuit braking period, which has a large braking effect, while maintaining the length of the synchronous control period.

Here, the control device 15 determines the duty cycle in PWM control among the upper arm SW elements 80a to 80c based on the shortest period of each period during which the upper arm SW elements 80a to 80c are turned on. Based on the duty ratio of the upper arm SW element (upper arm SW element 80c in Figs. 41 and 42) with the smallest ratio, the length of the lower arm short circuit break period is determined. In the lower arm side short-circuit brake period expansion control, the ON period of the upper arm side SW elements 80a to 80c is shortened, so the duty ratio of the upper arm side SW elements 80a to 80c becomes smaller.

For this reason, the period during which the duty ratio of the upper arm SW element with the smallest duty ratio among the upper arm SW elements 80a to 80c becomes the duty ratio 0% becomes the longest period of the lower arm short circuit break period. For this reason, the control device 15 determines the length of the lower arm short-circuit break period based on the duty ratio of the upper arm SW element with the smallest duty ratio of PWM control among the upper arm SW elements 80a to 80c. Because of this, it is possible to appropriately expand the lower arm side short-circuit break period.

The control device 15 performs the above-described lower arm side short-circuit brake expansion control also on the pulsator side inverter circuit 102 to decelerate the outer rotor 20, thereby decelerating the pulsator 13. In addition, the method of controlling the expansion of the lower arm short circuit break period is the same in the drum and pulsator side inverter circuits 101 and 102, but the length of the lower arm short circuit brake period is determined by the rotation speed of the drum 11 and the pulsator 13. It is changed appropriately according to the difference. Additionally, the period of the carrier wave may be different in control of the drum-side inverter circuit 101 and control of the pulsator-side inverter circuit 102.

Therefore, in Embodiment 1, the control device 15 uses the drum-side and pulsator-side position sensors 105, 106), synchronization control for making the detection rotation speeds of the drum 11 and the pulsator 13 approximately equal, and turning on all of the upper arm SW elements 80a to 80c and turning on the lower arm SW elements. The upper arm short circuit brake control turns off all of the (80d to 80f) to apply a short circuit brake to the motor 12, and turns off all of the upper arm SW elements (80a to 80c) to apply the short circuit brake to the motor 12. At the same time as executing the lower arm side short-circuit brake control to apply the short-circuit brake to the motor 12 by turning on all of them, the synchronous control set by the PWM control is performed based on the detected rotation speed in each cycle of the carrier wave. Without changing the length of the synchronous control period, which is the execution period, the upper arm short circuit brake period, which is the period for executing the upper arm short circuit brake control, is shortened, and at the same time, the lower arm short circuit brake period, which is the period for executing the lower arm short circuit brake control, is shortened. Since it is configured to execute lower arm side short-circuit brake period expansion control to expand the period, when decelerating by synchronously controlling the drum 11 and the pulsator 13 while appropriately consuming the regenerative power from the motor 12 The deceleration time can be shortened.

Next, an embodiment (Embodiment 2) that is different from the above-described embodiment (Embodiment 1) will be described. Additionally, Embodiment 2 is common with Embodiment 1 in terms of the configuration of the washing machine 1, and only the contents of the control according to the control device 15 are different from Embodiment 1, so in the following description, only the contents of the control are explained. And description of the configuration of the washing machine 1 will be omitted. In addition, in the following description, elements common to Embodiment 1 will be described by assigning the same reference numerals.

In Embodiment 2, the target rotation speed is determined in advance, and when slowing down the drum 11 and the pulsator 13, the drum 11 and the drum 11 detected by the drum side and pulsator side position sensors 105 and 106 The detection rotation speed of the pulsator 13 is controlled to be the target rotation speed. In particular, in the lower arm side short-circuit brake period expansion control of Embodiment 1, the length of the lower arm side short-circuit brake period to be expanded is the detection rotation speed. It differs from Embodiment 1 in that it is determined based on the difference between and the target rotation speed.

In this way, by determining the target rotation speed in advance and determining the length of the lower arm side short-circuit brake period based on the difference between the detected rotation speed and the target rotation speed, the drum 11 and the pulsator 13 in the deceleration process It can be quickly and accurately decelerated and stopped.

Control in Embodiment 2 will be explained with reference to the graph in FIG. 43. In addition, since the control of the drum 11 and the control of the pulsator 13 are substantially the same, hereinafter, only the control of the drum 11 will be described, and the control of the pulsator 13 will be omitted. do.

Figure 43 is a graph showing the relationship between the detected rotation speed of the drum 11 and the target rotation speed. The vertical axis is rotation speed, and the horizontal axis is time. The drum 11 is controlled to have a substantially constant speed during the dewatering process (period from 0 to t1 in FIG. 43). And when the dehydration process ends at time t1, the deceleration process begins.

In the deceleration process, the control device 15 decelerates the drum 11 while executing the lower arm side short-circuit brake period expansion control so that the detected rotational speed of the drum 11 becomes the target rotational speed.

To describe the control in the deceleration process in detail, when the detected rotation speed is lower than the target rotation speed and at the same time the difference between the detected rotation speed and the target rotation speed becomes greater than a predetermined value, the control device 15 It is determined that there is a possibility that there may be a difference in the rotation speed of the drum 11 and the pulsator 13, and the lower arm side short circuit brake period is expanded in the lower arm side short circuit brake period expansion control based on the size of the difference in rotation speed. Control to shorten. As a result, the rotation speed of the drum 11 can be brought closer to the target rotation speed.

On the other hand, when the detected rotation speed exceeds the target rotation speed and at the same time the difference between the detected rotation speed and the target rotation speed becomes greater than a predetermined value, the control device 15 supplies regenerative power from the motor 12. When it is determined that consumption has not been achieved, the enlarged lower arm side short-circuit brake period is controlled to be extended based on the size of the difference in rotation speed. Because of this, unconsumed regenerative power may be consumed. In addition, when the expanded lower arm short-circuit brake period is lengthened, it is lengthened within the range of the longest period of the lower arm short-circuit brake period determined from the duty ratio in the PWM control of the upper arm SW elements 80a to 80c. .

Next, with reference to the flowchart in FIG. 44, the processing operation of the control device 15 in the speed reduction process of the washing machine 1 according to Embodiment 2 will be described.

In the first step S101, the rotation speed of the drum 11 (specifically, the inner rotor 30) is detected by the drum side position sensor 105.

Next, in step S102, it is determined whether the absolute value of the difference between the detected rotational speed detected in step S101 and the target rotational speed is smaller than a predetermined value. If the absolute value of the difference in rotation speed is NO, which is greater than or equal to the predetermined value, the process proceeds to step S103. On the other hand, if the absolute value of the difference in rotation speed is YES, which is less than the predetermined value, it returns.

In step S103, the lower arm short circuit brake period to be expanded in the lower arm short circuit brake period expansion control is changed. Specifically, when the detected rotation speed is greater than the target rotation speed, the expanded lower arm short-circuit brake period is lengthened, and when the detected rotation speed is smaller than the target rotation speed, the expanded lower arm short-circuit brake period is extended. Make it short. As a result, the rotation speed of the drum 11 can be brought close to the target rotation speed, and at the same time, the regenerative power from the motor 12 can be appropriately consumed. After step S103, the process returns to step S101, the rotational speed of the drum 11 is detected, and determination is made again in step S102.

Additionally, control is performed on the pulsator side inverter circuit 102 based on the same flowchart.

Therefore, in Embodiment 2, the target rotation speed of the drum 11 and the pulsator 13 is set in advance, and the lower arm side short-circuit brake period expansion control is expanded based on the difference between the detected rotation speed and the target rotation speed. Since the length of the lower arm side short-circuit brake period is determined, the same effect as in Embodiment 1 can be obtained, and at the same time, the drum 11 and the pulsator 13 can be accurately decelerated and stopped.

Another form (Embodiment 3) will be described. In addition, in the following description, elements common to Embodiment 1 are given the same reference numerals and described.

In Embodiment 3, as shown in FIG. 45, the voltage sensor 108 for detecting the direct current voltage applied to the drum-side and pulsator-side inverter circuits 101 and 102 is provided, and is similar to Embodiment 1 and Embodiment 3. It is different from 2. The voltage sensor 108 has resistors 109, 110 connected to the DC power source 100 in parallel with the drum and pulsator side inverter circuits 101 and 102, respectively. ) is measured to detect the direct current voltage applied to the drum side and pulsator side inverter circuits 101 and 102. Other configurations of the washing machine 1 are the same as those of Embodiments 1 and 2.

Additionally, Embodiment 3 differs from Embodiments 1 and 2 in the method of determining the length of the lower arm side short circuit break period to be expanded. In detail, in Embodiment 3, the length of the lower arm side short circuit break period is determined based on the difference between the detection voltage detected by the voltage sensor 108 and the preset target voltage.

Control in Embodiment 3 will be explained with reference to the graph in FIG. 46. In addition, since the control of the drum 11 and the control of the pulsator 13 are substantially the same, hereinafter, only the control of the drum 11 will be described, and the control of the pulsator 13 will be omitted. do.

Figure 46 is a graph showing the relationship between the direct current voltage applied to the drum-side inverter circuit 101, the rotation speed of the drum 11, and the target rotation speed. In Figure 46, the vertical axis on the left is the direct current voltage applied to the drum-side inverter circuit 101, the vertical axis on the right is rotation speed, and the horizontal axis is time. Additionally, the target voltage is set to a voltage based on the voltage power supply 100. Additionally, the rotation speed of the drum 11 is detected by the drum side position sensor 105 in the same way as in Embodiment 2.

The drum 11 is controlled to have a substantially constant speed during the dewatering process (period from 0 to t1 in FIG. 46). At this time, since the power supply voltage is applied to the drum side inverter circuit 101 from the DC power supply 100, the detection voltage becomes equal to the target voltage. Then, when the dehydration process ends at time t1, the deceleration process begins. In the deceleration process, the control device 15 decelerates the drum 11 while executing the lower arm side short-circuit brake period expansion control so that the detected rotational speed of the drum 11 becomes the target rotational speed.

In this deceleration process, when the detected rotation speed exceeds the target rotation speed, all the regenerative power from the motor 12 is not consumed, and the DC power supply 100 is transferred from the motor 12 to the drum side inverter circuit 101. ) is applied. At this time, as shown in FIG. 46, the detection voltage detected by the voltage sensor 108 becomes higher than the target voltage.

Therefore, when the detected voltage exceeds the target voltage, the control device 15 determines that all regenerative power from the motor 12 has not been consumed, and the lower arm side short-circuit break period is as long as the detected voltage is higher than the target voltage. Control to lengthen. As a result, the unused regenerative power can be consumed, and the detected rotation speed of the drum 11 can be set to the target rotation speed.

By determining the length of the lower arm short-circuit brake period as described above, the drum and pulsator can be decelerated while appropriately consuming the regenerative power. Additionally, when lengthening the lower arm short-circuit brake period, it is lengthened within a range that does not exceed the longest period of the lower arm short-circuit brake period determined from the duty ratio in the PWM control of the upper arm SW elements 80a to 80c.

Next, with reference to the flowchart in FIG. 47, the processing operation of the control device 15 in the speed reduction process of the washing machine 1 according to Embodiment 3 will be described.

In the first step S201, the voltage being applied to the drum side inverter circuit 101 is detected by the voltage sensor 108.

Next, in step S202, it is determined whether or not the detection voltage detected in step S201 is greater than the preset target voltage. When the decision in step S201 is NO, the process proceeds to step S203, and when the decision in step S201 is YES, it returns.

In step S203, the lower arm side short circuit break period is lengthened. At this time, the lower dark side short-circuit break period is lengthened to the extent that the detected voltage is higher than the target voltage. Because of this, the regenerative power from the motor 12 can be consumed appropriately. After step S203, the process returns to step S201, the pressure applied to the drum side inverter circuit 101 is detected, and determination is made again in step S202.

Additionally, control is performed on the pulsator side inverter circuit 102 based on the same flowchart.

Therefore, in Embodiment 3, a voltage sensor 108 is provided to detect the voltage applied to the drum-side and pulsator-side inverter circuits 101 and 102, and the detection voltage detected by the voltage sensor 108 is preset. Since it is configured to lengthen the lower arm side short-circuit brake period as much as it is higher than the target voltage, the same effect as Embodiment 1 can be obtained and the drum 11 while consuming the regenerative power of the motor 12 more appropriately. And the pulsator 13 can be slowed down.

(variation examples, etc.)

As the detected rotational speed of the drum 11 and the pulsator 13 used during the expansion control of the lower arm side short circuit brake period, the detected rotational speed detected by the drum side and pulsator side position sensors 105 and 106 is used, However, it is not limited to this, and the rotation speed calculated from the detection current detected by the drum-side and pulsator-side current sensors 103 and 104 may be used.

Additionally, the controls for determining the lower arm side short-circuit break period may be combined. For example, when the control of Embodiment 2 and the control of Embodiment 3 are combined, and the detected voltage becomes higher than the target voltage, the difference between the detected rotation speed of the drum 11 and the pulsator 13 and the target rotation speed By specifying whether it is the drum side inverter circuit 101 or the pulsator side inverter circuit 102 that is not consuming regenerative power from the motor 12, the lower arm side short-circuit brake period is set only for the side for which the regenerative power is not consumed. You can control the length.

<Embodiment 5>

The fifth embodiment relates to a washing operation or a rinsing operation, and in particular, to a technology for controlling the rotation of drums and pulsators in the washing process or rinsing process.

That is, as shown in FIG. 48, the control device 15 of the washing machine 1 simultaneously and independently controls both the drum 11 and the pulsator 13 in either the washing process or the rinsing process. A dual rotation control unit 15a that rotates is provided. The dual rotation control unit 15a rotates both the drum 11 and the pulsator 13 simultaneously and independently, so that water streams with various directions and flow speeds can be generated inside the drum 11, and the laundry can be properly immersed in the water. It is possible to wash or rinse with a soft touch while dispersing it.

(Control of rotation of drum and pulsator in washing or rinsing processing)

As described above, this washing machine 1 is equipped with a dual rotor type motor 12 in which the inner rotor 30 and the outer rotor 20 share one stator 60. For this reason, not only can both the drum 11 and the pulsator 13 be driven independently, but also the diameter of the inner rotor 30 can be brought closer to that of the outer rotor 20, so that the inner rotor 30 It is also possible to obtain high torque.

In the case of this washing machine 1, since the drum 11 can be stably driven even at high torque, the double rotation control unit 15a controls the complex current supplied to the motor 12, as shown in FIG. 48. By doing so, during washing or rinsing processing, the rotation of the drum 11 by the inner rotor 30 and the rotation of the pulsator 13 by the outer rotor 20 are individually and independently controlled, enabling advanced and delicate processing. You can perform it in a variety of ways.

(First control pattern)

Figure 49 shows an example (first control pattern) of rotation control performed by the dual rotation control unit 15a. The first control pattern is a control pattern in which the drum 11 and the pulsator 13 are driven by the motor 12 to rotate in the same direction at different rotation speeds. In the illustrated first control pattern, the drum 11 and the pulsator 13 are synchronized and rotate intermittently in the same direction, and the rotation speed R1 of the drum 11 is equal to the rotation speed R2 of the pulsator 13. ) is set to be larger than that.

The direction of rotation of the drum 11 and the pulsator 13, which is performed intermittently, may be in the same direction as indicated by an imaginary line, or may be in the opposite direction, that is, reversed. By rotating the drum 11 and the pulsator 13 in the same direction, the laundry can be rotated and gently moved to the outside or inside of the drum 11, allowing the laundry to be properly distributed in the water and washed or washed with a soft touch. Rinsing can be performed.

As an example, if the rotation speed of the drum 11 is increased than the rotation speed of the pulsator 13, the laundry can be gently moved to the outside of the drum 11, and conversely, if the rotation speed of the drum 11 is increased to pulsate. If the rotational speed of the eater 13 is lowered, the laundry can be gently moved inside the drum 11.

(second control pattern)

Figure 50 shows another example of rotation control (second control pattern) performed by the dual rotation control unit 15a. The second control pattern is a control in which among the drum 11 and the pulsator 13, only the drum 11 is driven to rotate by the motor 12, and the pulsator 13 rotates in accordance with the rotation of the drum 11. It's a pattern. The composite current that drives the inner rotor 30 and the outer rotor 20 is not supplied, and the three-phase current that drives only the inner rotor 30 is supplied to the stator 60. For this reason, the pulsator 13 can be rotated at a low rotation speed in the same direction as the drum 11 in conjunction with the rotation of the drum 11, while suppressing power consumption.

A cogging torque (torque generated due to a magnetic attraction force acting between the magnet and the core when the rotor is moved in an unexcited state) is applied to the outer rotor 20. In addition, in the case of this motor 12, mutual ripple (torque ripple generated in the outer rotor 20 due to the influence of the magnetic field formed due to the driving of the inner rotor 30) also acts on the outer rotor 20. . For this reason, a certain brake is applied to the rotation of the pulsator 13.

For this reason, since the pulsator 13 rotates at a lower rotation speed than the drum 11, the laundry can be gently moved to the outside of the drum 11 while rotating.

(Third control pattern)

Figure 51 shows another example of rotation control (third control pattern) performed by the dual rotation control unit 15a. The third control pattern is a control pattern that rotates the drum 11 and the pulsator 13 while inverting each at different cycles. In the illustrated third control pattern, each of the drum 11 and the pulsator 13 rotates while reversing at regular intervals, and the drum 11 rotates for one cycle (in the example, a period during which forward rotation, stop, and reverse rotation are performed). While ) worth of processing is being performed, the pulsator 13 is set to perform two cycles worth of processing.

By controlling the rotation in this way, it is possible to properly distribute laundry in water and perform washing or rinsing with a gentle touch. Additionally, the respective cycles of the drum 11 and the pulsator 13 may be different, and the relationship is not limited to 1:2.

(Fourth control pattern)

Figure 52 shows another example (fourth control pattern) of rotation control performed by the dual rotation control unit 15a. The fourth control pattern is a control pattern that rotates the pulsator 13 while rotating the drum 11 in the same direction. In the illustrated fourth control pattern, the drum 11 is maintained in a state of forward rotation at a constant rotation speed, and in the meantime, the pulsator 13 is set to intermittently reverse and repeat forward and reverse rotation.

In this case, the rotation speed of the pulsator 13 may be the same as or different from the rotation speed of the drum 11. Additionally, the rotation speed of the pulsator 13 during forward rotation and reverse rotation may be the same or different. When rotation is controlled in this way, centrifugal force acts on the water or laundry inside the drum 11 due to the rotation of the drum 11, so the water level around the drum 11 becomes relatively high, and the laundry also stays in the drum 11. It becomes easier to gather in the periphery of. Since the pulsator 13 rotates in this state, it is possible to effectively wash or rinse a wide variety of laundry while properly dispersing the laundry in the water, and to efficiently perform washing or rinsing processing with a small amount of laundry. You can.

(5th control pattern)

Figure 53 shows another example (fifth control pattern) of rotation control performed by the dual rotation control unit 15a. The fifth control pattern controls at least one of the start time t1 until the rotation speed reaches the target rotation speed and the end time t2 from the target rotation speed until the rotation stops in the drum 11 and the pulsator 13. It is a different control pattern.

In this rotation control, the drum 11, which has a large inertial force, is started from a stopped state at a low speed, and the speed is slowly increased to a preset target rotation speed. And, the pulsator 13, which has a small inertial force, is started from a stopped state at a high speed and quickly increases to a preset target rotation speed.

That is, the startup time t1 of the drum 11 is set longer than the startup time t1 of the pulsator 13. By doing this, efficient maneuvering corresponding to the inertial force can be performed, thereby reducing power consumption.

It is desirable that not only the start time t1 but also the end time t2 be different from the start time t1. That is, without performing braking control, the drum 11, which has a large inertial force, is terminated at a low speed from the target rotation speed and slowly decelerated to a stop state. The pulsator 13, which has a small inertial force, terminates at a high speed from the target rotation speed and quickly decelerates to a stop state. In this way, power consumption can be further reduced.

In addition, in Figure 53, for convenience, a pattern of rotating the drum 11 and the pulsator 13 in the opposite direction in the first half is shown, and a pattern of rotating the drum 11 and the pulsator 13 in the same direction in the second half is shown. The second half may be reversed by rotating the drum 11 and the pulsator 13 in the opposite direction as in the first half, and the first half may be reversed by rotating the drum 11 and the pulsator 13 in the same direction as in the second half. You can also reverse it. The rotation of the drum 11 and the pulsator 13 can be arbitrarily controlled.

(6th control pattern)

Figure 54 shows another example (sixth control pattern) of rotation control performed by the dual rotation control unit 15a. The sixth control pattern is a control pattern in which the start timing (P) of the drive by the motor 12 is different for the drum 11 and the pulsator 13 in addition to the fifth control pattern.

Since the drum 11 and the pulsator 13 can efficiently perform washing or rinsing processing by simultaneously rotating at the target rotation speed, the appropriate rotation period K is preferably long. However, in the fifth control pattern, since the start time and end time are different in the drum 11 and the pulsator 13, the driving time (Ton) by the motor 12 in the drum 11 and the pulsator 13 is the same. If this is done, a difference will occur in the appropriate rotation period (K) between the drum 11 and the pulsator 13.

Therefore, in the illustrated sixth control pattern, the drive start timing (P) by the motor 12 of the drum 11 is made faster than the drive start timing (P) by the motor 12 of the pulsator 13, The timing at which the drum 11 and the pulsator 13 reach the target rotation speed are matched to achieve the optimal combination of the appropriate rotation periods (K) of both.

(7th control pattern)

Figure 55 shows another example of rotation control (seventh control pattern) performed by the dual rotation control unit 15a. The seventh control pattern is, in addition to the fifth control pattern, control to vary at least one of the driving period (Ton) and the driving stop period (Toff) by the motor 12 in the drum 12 and the pulsator 13. It's a pattern. In addition, the drive period (Ton) is an energized period in which the drum 11, etc. is driven by the motor 12, and the drive stop period (Toff) is a non-energized period in which the drum 11, etc. is not driven by the motor 12. It's a period.

In the fifth control pattern, since the start time and end time are different for the drum 11 and the pulsator 13, the drum 11 and the pulsator 13 have a rotation period (rotating period) and a stop period (rotation period). There is a difference in the period of this stop.

Therefore, in the illustrated seventh control pattern, the driving period (Ton) and the driving stop period (Toff) are varied in the drum 11 and the pulsator 13, so that the drum 11 and the pulsator 13 rotate The length and timing of the period and stop period are set to match. Therefore, washing or rinsing processing can be performed efficiently.

(8th control pattern)

Figure 56 shows another example of rotation control (the eighth control pattern) performed by the dual rotation control unit 15a. The eighth control pattern intermittently rotates the drum 11 and the pulsator 13 in opposite directions, and in that state, each rotation is performed intermittently in at least one of the drum 11 and the pulsator 13. It is a control pattern that varies the length of at least one of the rotation period (Tr) and each stop period (Ts) between these rotation periods.

When the drum 11 and the pulsator 13 are intermittently rotated in opposite directions, a state in which the water flow stagnates inside the drum 11 occurs, which tends to generate stagnant laundry. Therefore, in the illustrated eighth control pattern, in both the drum 11 and the pulsator 13, the length and timing of the rotation period Tr and the stop period Ts are matched, while these rotation periods ( Tr) and the length of the stop period (Ts) are set differently.

Specifically, with respect to the rotation period Tr1 when the drum 11 and the pulsator 13 rotate in the first half, the rotation period Tr2 when the drum 11 and the pulsator 13 rotate in the second half is It's getting shorter. And, relative to the stop period Ts1 of the drum 11 and the pulsator 13 in the first half, the stop period Ts2 of the drum 11 and the pulsator 13 in the second half is longer.

In this way, by varying the length of each rotation period (Tr) or each stop period (Ts), it is possible to prevent the water flow from stagnating inside the drum 11 and to move the laundry as a whole. Additionally, the length of the rotation period (Tr) or the stop period (Ts) can be adjusted appropriately. In addition, the length of the rotation period (Tr) or the stop period (Ts) may be varied by either the drum 11 or the pulsator 13, and the lengths may be varied by the rotation period (Tr) and the stop period (Ts). ) may be any one of the following.

(9th control pattern)

Figure 57 shows another example of rotation control (ninth control pattern) performed by the dual rotation control unit 15a. The ninth control pattern intermittently rotates the drum 11 and the pulsator 13 in opposite directions, and at the same time, the number of rotations performed intermittently in at least one of the drum 11 and the pulsator 13 It is a control pattern that varies. Even with this ninth control pattern, the same effect as the eighth control pattern can be obtained.

In the illustrative ninth control pattern, the length and timing of each rotation period (Tr) and each stop period (Ts) of both the drum 11 and the pulsator 13 match each other, and the rotation in each rotation The number (R) is set differently.

Specifically, the drum 11 is set so that the rotation speed R2 during the second half rotation is smaller than the rotation speed R1 during the first half rotation. And in the case of the pulsator 13, about the rotation speed (R3) during the first half rotation. The rotation speed (R4) during the second half rotation is set to be large.

In this case, the rotation speed (R) can be adjusted appropriately. Additionally, only one of the drum 11 and the pulsator 13 may be used to vary the rotation speed R. In addition, by combining the eighth and ninth control patterns, both the rotation speed (R) of each rotation is varied and the length of each rotation period (Tr) and each stop period (Ts) are varied. It's okay to do it.

It is not limited to the 8th and 9th control patterns, and the 1st to 9th control patterns may be performed individually, or these control patterns may be performed in combination.

(variation examples, etc.)

For example, the type of motor is not limited to the dual rotor type motor 12 of the embodiment. A motor with the same structure as in Patent Document 2 may be used. Additionally, a motor combined with a transmission or the like may be used. In other words, any motor that can drive the drum and pulsator individually is sufficient.

<Embodiment 6>

The sixth embodiment relates to a technology that can reduce the load applied to the motor when the drum and pulsator rotate in opposite directions.

As shown in FIG. 58, the control device 15 and the motor 12 are connected through an inverter circuit 111. The inverter circuit 111 is provided with an inverter 112 and load detection means 113a and 113b.

The inverter 112 transmits the driving voltage to the motor 12 based on the electrical signal transmitted from the control device 15. The operations of the outer rotor 20 and the inner rotor 30 of the motor 12 are controlled based on the driving voltage transmitted from the inverter 112.

The load detection means (113a, 113b) detects the load applied to the motor 12 when operating the pulsator 13 driven to the outer rotor 20 and the drum 11 driven to the inner rotor 30. will be. The load detection means 113a detects the load applied to the motor 12 when driving the pulsator 13, and the load detection means 113b detects the load applied to the motor 12 when driving the drum 11. Detect load.

The load detection means 113a and 113b are not particularly limited as long as they can detect the load applied to the motor 12 when operating the drum 11 and the pulsator 13. For example, the load applied to the motor 12 may be detected by detecting the current flowing through the motor 12 using a current sensor, and the motor may be detected by detecting the rotational speed of the rotors 20 and 30 detected by a position sensor. When (12) operates, the load applied to the motor (12) may be detected. The detection load detected by the load detection means 113a and 113b is transmitted to the control device 15 as a detection signal.

Additionally, as shown in FIG. 58, the washing machine 1 is provided with vibration detection means 114 for detecting vibration of the washing machine 1. The vibration detection means 114 is arranged in the water tank 10 outside the drum 11, for example. The vibration detection means 14 is not particularly limited as long as it can detect the vibration of the washing machine 1, especially the vibration of the drum 11.

For example, the magnitude of vibration of the washing machine 1 may be detected by measuring the displacement of the washing machine 1 using a displacement sensor, and the vibration magnitude may be detected by detecting the acceleration of the vibrating washing machine 1 using an acceleration sensor. It may be configured to detect the size of . Additionally, the load detection means 113a and 113b may be used concurrently with the vibration detection means 114. The detected vibration detected by the vibration detection means 114 is transmitted to the control device 15 as a detection signal.

The control device 15 controls the operation of the drum 11 and the pulsator 13 based on the detected load detected by the load detection means 113a and 113b or the detected vibration detected by the vibration detection means 114. do. In detail, an electric signal for controlling the motor 12 is transmitted based on the detected load, detected vibration, etc. The electrical signal transmitted from the control device 15 is input to the inverter 112, and a driving voltage based on the electrical signal is provided to the motor 12 through the inverter 112.

And, the operation of the outer rotor 20 and the inner rotor 30 of the motor 12 is controlled by the driving voltage. Above, based on the electric signal transmitted from the control device 15, the operations of the pulsator 13 driven and connected to the outer rotor 20 and the drum 11 driven and connected to the inner rotor 30 are controlled.

(Control of the rotational motion of the motor)

As described above, the washing machine 1 is configured so that the rotors 20 and 30 can be driven independently, so that a different type of operation from the conventional one can be realized.

In particular, in the washing machine 1, during washing operation, the inner rotor 30 (drum 11) rotates clockwise (hereinafter referred to as normal rotation) and the outer rotor 20 (pulsator 13) A first upper half drive mode in which the inner rotor 30 (drum 11) is rotated counterclockwise (hereinafter referred to as reverse rotation) and the outer rotor 20 (pulsator 13) is rotated counterclockwise (hereinafter referred to as reverse rotation). An operation that alternately repeats the second half drive mode of forward rotation with a stop period in between may be provided.

That is, by rotating the drum 11 and the pulsator 13 in opposite directions, a twisting force is generated on the water in the drum, thereby preventing laundry from being washed. Additionally, by alternately repeating the first half-half drive mode and the second half-half drive mode with a stop period in between, the direction of the water flow can be switched and the laundry can be unpacked. As a result, improvement in washing efficiency is expected.

Here, when switching from the first half-phase drive mode to the second half-phase drive mode, or from the second half-phase drive mode to the first half-phase drive mode, in order to reverse the rotation direction of the drum 11 and the pulsator 13, A relatively large starting load is applied to the motor 12. In particular, since the drum 11 is a large part even in the washing machine 1, when the drum 11 is rotated, a relatively large inertial force is applied to the drum 11 with respect to the rotation direction. Therefore, when the rotation direction of the drum 11 is reversed, an excessive starting load is applied to the motor 12. At this time, there is a possibility that the motor 12 may cause starting failure due to this excessive starting load.

In addition, when the inertial force of the above-mentioned drum 11 and the pulsator 13 becomes the largest during the stop period after acceleration by the motor 12, the direction of rotation is reversed with a lot of inertia force remaining as the stop period is short. Therefore, the shorter the stop period, the more likely it is that the motor 12 will start malfunctioning.

Therefore, in Embodiment 1, when the stop period is set to a time shorter than a predefined reference time, the drum 11 is set so that the detected load detected by the load detection means 113a and 113b is below the preset target load. ) and load reduction correction control that controls at least one timing of On and Off of at least one of the pulsator 13.

Specifically, when the detected load becomes larger than the target load, either the first correction control or the second correction control described below is executed as load reduction correction control to reduce the starting load applied to the motor 12. In addition, the reference time is long enough for the inertial force of the drum 11 and the pulsator 13 to sufficiently decrease. Additionally, the target load is a load at which starting failure of the motor 12 does not occur.

Below, the first correction control and the second correction control will be described in detail with reference to FIGS. 59 and 60.

Figure 59 shows the electrical signal provided to the motor 12 when the first correction control is executed. The first correction control is to control the drum ( This is a control that turns on the remaining one of 11) and the pulsator (13). In addition, Figure 59 shows an electrical signal transmitted to the motor 12 when the pulsator 13 is turned on after a first predetermined time (t1 in Figure 59) has elapsed after turning on the drum 11. (pulse signal).

Here, based on FIG. 59, only the case where the pulsator 13 is turned on after the first predetermined time has elapsed after the drum 11 is turned on will be described in detail.

Referring to FIG. 59, first, the control device 15 turns on the first half drive mode to rotate the drum 11 forward and the pulsator 13 in reverse. At this time, the laundry in the drum 11 generally rotates in the rotation direction of the pulsator 13.

Next, the first upper half drive mode is turned off and the motor 12 is made to rest for a predetermined period of time (hereinafter referred to as a stop period). During this stop period, the drum 11 coasts in the forward rotation direction due to inertial force, and the pulsator 13 also coasts in the reverse rotation direction due to inertial force.

In addition, as shown in FIG. 59, an inertial force is also generated in the laundry in the drum 11 by being pulled along the rotation direction of the pulsator 13, and the laundry inertially rotates in the reverse rotation direction identical to the rotation direction of the pulsator. do. Since this stop period is shorter than the reference time, the inertial force of the laundry remains until the next second upper half drive mode is turned on.

After the stop period has elapsed, the control device 15 turns on the second half drive mode to rotate the drum 11 in reverse and rotate the pulsator 13 forward.

When turning on this second half drive mode, the load detection means 113a and 113b detect the load applied to the motor 12. Then, when the detected load is larger than the target load, the control device 15 determines that there is a possibility that a starting defect of the motor 12 may occur, and performs the first correction control when starting the next first upper half drive mode. Run.

Next, the control device 15 turns off the second upper half drive mode and makes the motor 12 idle during the stop period. During this stop period, the drum 11 and the pulsator 13 coast and rotate due to inertial force, as described above. At this time, the laundry coasts in the same forward rotation direction as the rotation direction of the pulsator 13.

Then, when turning on the first upper half drive mode after the stop period has elapsed, the control device 15 executes the first correction control, first turning on only the drum 11 to rotate the drum 11 forward. At this point, since the pulsator 13 is not rotating in reverse, an inertial force in the forward rotation direction remains on the laundry in the drum 11.

For this reason, the drum 11 is driven using the inertial force of the laundry. Because of this, it becomes easy to reverse the rotation direction of the drum 11 to the forward rotation direction, and the starting load applied to the motor 12 to rotate the drum 11 forward is reduced.

Next, after the first predetermined time has elapsed after turning on the drum 11, the control device 15 turns on the pulsator 13 to rotate it in reverse. The laundry in the drum 11 turns again along the rotation direction of the pulsator 13, changing the rotation direction from the forward rotation direction to the reverse rotation direction.

As a result, an inertial force in the reverse rotation direction is generated on the laundry in the drum 11. As a result, when starting the next second half drive mode, by executing the first correction control again, the starting load applied to the motor 12 to reverse the rotation direction of the drum 11 to the reverse rotation direction is reduced. do.

As described above, by executing the first correction control, the direction of rotation of the drum 11 can be reversed using the inertial force before the direction of the inertial force generated on the laundry in the drum 11 is switched by the pulsator 13. Therefore, the starting load applied to the motor 12 is reduced when the rotation direction of the drum 11 is reversed.

Here, for example, when the laundry sticks to the drum 11 and the laundry is rotating in the rotation direction of the drum 11, contrary to the above-mentioned, the pulsator 13 is turned on before the drum 11. Let them do it. When the laundry is rotating in the direction of rotation of the drum 11, the inertial force of the laundry acts on the drum 11 in addition to the inertial force of the drum 11 itself, so when the rotation direction of the drum 11 is reversed, the motor ( 12) Excessive load is applied.

Therefore, the pulsator 13 is first rotated, and force is applied to the laundry so that the laundry rotates along the pulsator 13. And when the laundry rotates in the direction of the pulsator 13, the drum 11 is turned on first. This prevents excessive load from being applied to the motor 12.

Additionally, whether the laundry is rotating in the rotation direction of the drum 11 can be detected by the load detection means 113a and 113b. For example, when the laundry is rotating in the rotation direction of the drum 11, the direction of the inertial force before the laundry is reversed and the direction of rotation after the pulsator 13 is reversed are the same, so when the pulsator 13 is reversed, the direction of rotation becomes the same. The load on the motor 12 (outer rotor 20) decreases.

As the load becomes smaller, the current detected by the current sensor becomes smaller. As a result, it is detected that the laundry is rotating along the rotation direction of the drum 11. Additionally, the rotation speed of the outer rotor 20 and the inner rotor 30 during the stop period can be detected using a position sensor, and it can be detected that the laundry is rotating along the rotation direction of the drum 11.

Figure 60 shows the electrical signal provided to the motor 12 when executing the second correction control. The second correction control controls the drum 11 after a second predetermined time has elapsed after turning off either the drum 11 or the pulsator 13 when the first half drive mode or the second half drive mode is turned off. ) and the remaining one of the pulsator (13) is controlled to turn off. In addition, Figure 60 shows the electric signal transmitted to the motor 12 when the pulsator 13 is turned off after a second predetermined time (t2 in Figure 60) has elapsed after turning off the drum 11. (pulse signal).

Here, based on FIG. 60, only the case where the drum 11 is first turned off and then the pulsator 13 is turned off will be described in detail.

Referring to FIG. 60, first, the control device 15 turns on the first upper half drive mode to rotate the drum 11 forward and the pulsator 13 in reverse. At this time, the laundry in the drum 11 rotates in the rotation direction of the pulsator 13.

Next, the first upper half drive mode is turned off and the motor 12 is idled during the stop period. As described above, during this stop period, the drum 11 and the pulsator 13 coast and rotate due to inertial force. At this time, the laundry coasts in the reverse rotation direction, which is the rotation direction of the pulsator 13.

After the stop period has elapsed, the control device 15 turns on the second upper half drive mode to rotate the drum 11 in reverse and rotate the pulsator 13 forward.

When turning on this second half drive mode, the load detection means 113a and 113b detect the load applied to the motor 12. When the detected load is greater than the target load, the control device 15 determines that there is a possibility that a starting defect of the motor 12 may occur, and executes the second correction control when turning off the second half-phase drive mode.

When executing the second correction control, the control device 15 first turns off only the drum 11. After the drum 11 is turned off, it coastingly rotates in the reverse rotation direction due to inertial force. Then, after a second predetermined time has elapsed after turning off the drum 11, the pulsator 13 is turned off.

By turning off the pulsator 13 late, that is, by rotating the pulsator 13 for a long time, a force is generated on the laundry in the drum 11 in the direction of rotation of the pulsator 13, so that the drum 11 ) A large inertial force remains on the laundry in the laundry compared to the case where the drum 11 and the pulsator 13 are turned off at the same time. After turning off the pulsator 13, the control device 15 idles the motor 12 for a stop period. During this stop period, the laundry in the drum 11 and the pulsator 13 coast in the forward rotation direction.

Then, after the stop period has elapsed, the control device 15 turns on the next first upper half drive mode to rotate the drum 11 forward and the pulsator 13 in reverse. At this time, since a greater inertial force remains in the laundry in the drum 11 than when the drum 11 and the pulsator 13 are turned off at the same time, the rotation direction of the drum 11 is rotated forward using the inertial force of the laundry. By reversing the direction, the starting load applied to the motor 12 is reduced.

In addition, by reversing the rotation direction of the pulsator 13 to the reverse rotation direction, the laundry in the drum 11 rotates again along the rotation direction of the pulsator 13, changing the rotation direction from the forward rotation direction to the reverse rotation direction. . For this reason, when the first upper half drive mode is turned off, an inertial force in the reverse rotation direction is generated on the laundry in the drum 11. As a result, when turning off the first half drive mode, the second correction control is executed again, and when the next second half drive mode is turned on to reverse the rotation direction of the drum 11 to the reverse rotation direction, the motor ( 12) The starting load applied to the machine is reduced.

As described above, by executing the second correction control, compared to the case where the drum 11 and the pulsator 13 are turned off at the same time, a large inertial force can be left on the laundry in the drum 11, so that the inertial force is By starting the drum 11, the starting load applied to the motor 12 can be reduced.

As described above, by executing either the first or second correction control, it is possible to reduce the load applied to the motor 12 when the first half-phase drive mode and the second half-phase drive mode are alternately executed. As a result, poor starting of the motor is prevented.

In addition, when the stop period is set to a time longer than the above reference time, the inertial force of the drum 11 and the pulsator 13 is sufficiently reduced during the stop period, so the change from the first half drive mode to the second half drive mode Alternatively, when switching from the second half drive mode to the first half drive mode, the load applied to the motor 12 is almost always less than the target load. For this reason, if the stop period is set to a time longer than the reference time, the first or second correction control is not executed.

Here, in the above-described first correction control, the rotation direction of the drum 11 is reversed using the inertial force of the laundry in the drum 11, thereby making it easy to reverse the rotation direction of the drum 11. When executing the first correction control, during the first predetermined time, only the drum 11 rotates in the same direction as the inertial force of the laundry, so the rotational force of the drum 11 is applied to the laundry in addition to the inertial force.

As the inertial force and the rotational force are combined in this way, centrifugal force according to the rotation of the laundry acts on the washing machine 1 for a first predetermined period of time. Also, in the case of the second correction control described above, the drum 11 is first turned off and only the pulsator 13 is rotated for a second predetermined time, so that the laundry in the drum 11 is rotated in the same manner as the pulsator 13. Since a relatively large inertial force is applied in the direction, a large centrifugal force from the laundry is applied to the washing machine 1 compared to the case where the drum 11 and the pulsator 13 are rotated in opposite directions during the second predetermined time. do. This is the same even when the pulsator 13 is turned on first in the first correction control or when the drum 11 is turned off late in the second correction control.

In this way, when centrifugal force from laundry acts on the washing machine 1, the washing machine 1 may vibrate and cause noise during the washing process. In particular, when the laundry is concentrated in one place within the drum 11, the centrifugal force increases and the vibration of the washing machine 1 tends to increase.

Therefore, the control device 15 detects the vibration of the washing machine 1 with the vibration detection means 114, and when the detected vibration is greater than a predefined predetermined vibration, the control device 15 performs vibration reduction control in the first correction control. Control is executed to shorten the length of the first predetermined time and the length of the second predetermined time in the second correction control. By shortening the first predetermined time, a water flow in a direction opposite to the rotation direction of the laundry is generated early by the pulsator 13, so that the rotation of the laundry is slowed down by the water flow, so that the water flow from the laundry to the washing machine 1 is reduced. Centrifugal force decreases.

Because of this, vibration of the washing machine 1 can be reduced. On the other hand, since the rotation time of the pulsator 13 is shortened by shortening the second predetermined time, the inertial force in the rotation direction generated by the pulsator 13 on the laundry is reduced, and the centrifugal force caused by the inertial force is also reduced. do. Because of this, vibration of the washing machine 1 can be reduced.

Additionally, by shortening the length of the first predetermined time and the second predetermined time, when the detected vibration becomes smaller than the predetermined vibration, the control device 15 returns the length of the first predetermined time and the second predetermined time to the original. It's okay to do it. For example, if the cause of the vibration is the leaning of the laundry, there is a possibility that the laundry is loosened due to the opposite rotation of the drum 11 and the pulsator 13, thereby eliminating the leaning.

Conversely, even if the first predetermined time or the second predetermined time is shortened, if the vibration of the washing machine 1 does not fall below the predetermined vibration, the first predetermined time or the second predetermined time is further shortened. However, by making the first predetermined time or the second predetermined time shorter, when the load on the motor 12 becomes larger than the target load, the control device 15 gives priority to the load reduction correction control over the vibration reduction control, so that the first predetermined time Alternatively, the second predetermined time is controlled not to be made shorter.

Through the above-described control, the load on the motor 12 can be reduced and the vibration of the washing machine 1 can be reduced.

Next, with reference to FIG. 61, processing operations when the control device 15 performs load reduction correction for the washing machine 1 will be described. In addition, FIG. 61 omits the period from the initial state when the first or second half drive mode is executed until the stop period elapses, and describes from the part where the first or second half drive mode is switched.

In step S101, the control device 15 sends an electric signal to the motor 12 to switch the mode from the first half-phase drive mode to the second half-phase drive mode, or from the second half-phase drive mode to the first half-phase drive mode. .

In the next step S102, the control device 15 determines whether the stop period is set to be shorter than the reference time. If YES, where the stop period is shorter than the reference time, the process proceeds to step S103. On the other hand, in the case of NO where the stop period is longer than the reference time, the control device 15 determines that there is a small possibility that a start-up defect of the motor 12 will occur, and skips steps after step S103 and returns thereafter.

In step S103, the load detection means 113a and 113b detect the load applied to the motor 12 when switching modes.

In step S104, the control device 15 determines whether the detection load detected in step S103 is greater than the target load. In this step S104, when the detected load is YES larger than the target load, the control device 15 determines that the motor 12 is likely to cause a starting defect and proceeds to step S105. On the other hand, when the detection load is NO, which is less than the target load, it returns thereafter.

In step S105, the first or second correction control is executed to lower the detection load to the target load or less. Which one to execute may be determined in advance by the control device 15, or may be left to the user to decide arbitrarily when operating the washing machine 1.

In the next step S106, the vibration of the washing machine 1 is detected by the vibration detection means 114. After detection, the process proceeds to step S107.

In step S107, it is determined whether or not the detected vibration is greater than a predetermined vibration. In this step S107, if the detected vibration is YES that is greater than the predetermined vibration, the process proceeds to step S108 to execute vibration reduction control. On the other hand, in this step S107, when the detected vibration is NO, which is less than or equal to the predetermined vibration, the vibration reduction control is not executed and the process returns thereafter.

In step S108, the first predetermined time or the second predetermined time is shortened as vibration reduction control. As described above, by shortening the first predetermined time or the second predetermined time, the centrifugal force of the laundry is reduced and vibration is reduced. After execution of vibration reduction control, it returns.

Therefore, this washing machine 1 includes load detection means 113a and 113b that detect the load of the motor 12, and the inverter 112 based on the detected load detected by the load detection means 113a and 113b. It is provided with a control device 15 that controls the operation of the drum 11 and the pulsator 13 by transmitting an electric signal to the motor 12 through the control device 15, which rotates the drum 11 forward and pulsates The first half-phase drive mode, which rotates the pulsator 13 in reverse, and the second half-phase drive mode, which rotates the drum 11 in reverse and the pulsator 13 in normal rotation, are alternately executed with a stop period in between. At the same time, a first correction control or a second correction that controls the timing of at least one of on and off of at least one of the drum 11 and the pulsator 13 so that the detection load is below the preset target load. Since it is configured to execute control, the direction of rotation of the drum 11 or the pulsator 13 can be reversed by using the inertial force of the laundry in the drum 11, and as a result, the first and second reciprocal drives The load applied to the motor 12 when switching modes can be reduced. As a result, it is possible to prevent the occurrence of starting defects in the motor 12.

Next, an embodiment (Embodiment 2) different from the above-described embodiment will be described. Meanwhile, the configuration of the washing machine 1 is common to the above-described embodiment, and since the control by the control device 15 is different, other configurations will be described, and common configurations will be assigned the same symbols and explanation will be omitted.

Embodiment 2 is different from Embodiment 1 in particular in the content of the load reduction correction control to reduce the load on the motor 12. Specifically, when the laundry stored in the drum 11 is rotating in the same direction as the rotation direction of the drum 11, the control device 15 slows down and stops the rotation of the drum 11 during the stop period, After the stop, the next first half drive mode or second half drive mode is executed.

That is, in Embodiment 1, the load applied to the motor 12 when switching modes is corrected by correcting the timing of turning on or off the drum 11 or the pulsator 13 by the first or second correction control. However, in Embodiment 2, the rotation of the drum 11 is slowed down and stopped during the stop period by the third correction control as the load reduction correction control, and after the stop, the next first half drive mode or the second 2 By turning on the reverse drive mode, the load applied to the motor 12 is reduced.

Below, the third correction control will be described in detail with reference to FIG. 62.

Figure 62 shows an electrical signal transmitted to the motor 12 when the third correction control is executed. As described above, the third correction control slows down and stops the rotation of the drum 11 in the stop period between the first half drive mode and the second half drive mode, and after the stop, performs the next first or second half drive mode. This is the control that turns the mode on.

The third correction control is executed when the laundry in the drum 11 rotates in the rotation direction of the drum 11 instead of the pulsator 13, for example, because the laundry sticks to the drum. Additionally, whether or not the laundry is rotating along the rotation direction of the drum 11 can be detected by the load detection means 113a and 113b, as in Embodiment 1.

Referring to FIG. 62, first, the control device 15 turns on the first half drive mode to rotate the drum 11 forward and the pulsator 13 in reverse.

Next, the control device 15 turns off the first upper half drive mode and makes the motor 12 idle during the stop period. In the stop period, the load detection means 113a, 113b (in particular, the position sensor) detects the direction in which the laundry in the drum 11 is rotating.

In addition, when the rotation direction of the laundry is the same as the rotation direction of the drum 11, the control device 15 determines that an excessive load is applied to the motor 12 when reversing the rotation direction of the drum 11, and 3 Compensation control is executed to slow down the rotation of the drum 11 and stop it during the stop period.

Specifically, so-called electromagnetic brake control is performed to apply a pulse signal of anti-phase to the motor 12 and generate a brake on the rotation of the drum 11. The size of the pulse signal is sufficient to stop the rotation of the drum 11 during the stop period. Additionally, the brake can also be generated by applying short pulses of opposite phase multiple times.

After the stop period has elapsed, the control device 15 turns on the second half-phase drive mode to rotate the drum 11 in reverse and rotate the pulsator 13 forward. By stopping the rotation of the drum 11 by the third correction control, no inertial force in the forward rotation direction is generated in the drum 11, so the starting force applied to the motor 12 when rotating the drum 11 in reverse The load becomes smaller.

Moreover, even if the drum 11 is stopped, as shown in FIG. 62, an inertial force in the forward rotation direction remains on the laundry in the drum 11, so if the rotation direction of the pulsator 13 is reversed to the forward rotation direction, The laundry becomes easier to spin along the rotation direction of the pulsator 13. When the laundry rotates in the rotation direction of the pulsator 13, as shown in FIG. 62, the inertial force of the laundry acts in the rotation direction of the pulsator 13, so the stop period after turning off the second upper half drive mode The inertial force of the drum 11 in is reduced by the inertial force of the laundry.

For this reason, when the next first half drive mode is turned on to reverse the rotation direction of the drum 11, the starting load applied to the motor 12 can be reduced. In addition, if only the rotation of the drum 11 is slowed down, only a smaller load is applied to the motor 12 than if the rotation direction of the drum 11 is reversed, so the third correction control provides a load to the motor 12. There is no excessive load applied.

Also, in Embodiment 2, when the stop period is set to a time longer than the above reference time, the control device 15 determines that the inertial force of the drum 11 is sufficiently reduced during the stop period and performs the third correction control. Do not run .

(variation examples, etc.)

For example, one motor 12 is provided with an inner rotor 30 and an outer rotor 20, and drives the drum 11 with the inner rotor 30 and drives the pulsator 13 with the outer rotor 20. Although it is configured to drive, it is not limited to this, and two motors may be provided and connected to the drum 11 and the pulsator 13, respectively.

At this time, one inverter may be provided for two motors, or one inverter may be provided for two motors. Additionally, when using one inverter, it is desirable to use a variable magnetic pole motor as the motor.

In addition, when the detection load detected by the load detection means 113a and 113b becomes larger than the target load, the first or second correction control is executed, but the present invention is not limited to this. For example, it is possible to always have the first or second correction control running during the washing process.

Additionally, when the stop period is longer than the reference time, the first to third correction controls are not executed. However, this is not limited to this, and the first to third correction controls may be executed regardless of the length of the stop period.

Additionally, the first to third correction controls may be combined respectively. For example, by combining the first correction control and the second correction control, the timing of turning on the drum 11 is accelerated while the timing of turning off the pulsator 13 is delayed. In this way, by combining the first to third correction controls, the inertial force of the laundry in the drum 11 can be more easily utilized, and the load on the motor 12 is expected to be further reduced.

<Embodiment 7>

The seventh embodiment relates to a washing machine capable of independently driving a washing machine and a pulsator.

As shown in FIG. 63, the motor 12 includes an unbalance detection means 121a that detects the amount of unbalance of the pulsator 13 driven and connected to the outer rotor 20 and the drum 11 driven and connected to the inner rotor 30. , 121b) is connected. The detection means 121a detects the amount of unbalance of the pulsator 13, and the detection means 121b detects the amount of unbalance of the drum 11.

The unbalance detection means 121a and 121b are not particularly limited as long as they can detect the amount of unbalance of the pulsator 13 and the drum 11. For example, a current sensor, vibration sensor, speed sensor, etc. can be used. The amount of imbalance detected by the imbalance detection means 121a and 121b is transmitted to the control device 15 as detection signals D121a and 121b. D121a is a detection signal of the unbalance detection means 121a, and D121b is a detection signal of the unbalance detection means 121b.

(Control of the rotational motion of the motor)

Since this washing machine 1 can drive each of the rotors 20 and 30 independently, different types of operation can be realized.

＝Motor control during washing operation＝

During washing operation, normal washing in which only the outer rotor (20) (pulsator (13)) is driven, reverse water flow in which the inner rotor (30) (drum (11)) and outer rotor (20) are driven in reverse, inner A weak water flow that drives only the rotor 30 is provided.

＝Motor control during dehydration operation＝

During dehydration operation, both rotors 20 and 30 can be driven simultaneously in the same direction. For this reason, it is easy to obtain a large torque, especially at low speeds, and the effect of faster starting can be obtained. Additionally, in this form, the control device 15 performs motor control during dehydration operation to eliminate imbalance.

Below, motor control according to the resolution of imbalance during dehydration operation will be described in detail with reference to FIGS. 64 to 70.

―Control Example 1―

As shown in FIG. 64, first, in step S110, both rotors 20 and 30 are driven to rotate in the same direction, and the rotation speed (rotation speed) ωIL of the inner rotor 30 and that of the outer rotor 20 The rotation speed ωOL is increased until it reaches the predetermined rotation speed ω1 (ω1 < ωC). That is, the drum 11 and the pulsator 13 rotate at the same rotation speed ω1. In addition, in the present disclosure, the same is a concept that includes substantially the same range. Additionally, ωC is the resonance rotation speed of the washing machine 1 (drum 11).

After the rotational speeds ωOL and ωIL of the outer rotor 20 and the inner rotor 30 become ω1, in step S111, the unbalance detection means 121a and 121b detect the amount of unbalance between the drum 11 and the pulsator 13. and proceeds to step S112.

In step S112, if the detected value M _USB of the unbalance amount of the drum 11 is less than or equal to the predetermined value α and the detected value M _UPL of the unbalance amount of the pulsator 13 is less than or equal to the predetermined value β (YES in S112), step S113 It proceeds as follows.

In step S113, while maintaining the rotation speeds ωIL and ωOL of the outer and inner rotors 20 and 30 the same, the rotation speed is increased to a predetermined rotation speed greater than the resonance rotation speed ωC at the same speed gradient, and after a predetermined time has elapsed, a dehydration operation is performed. Terminate.

FIG. 65 is a graph showing time changes in the rotational speed of the rotors 20 and 30 (in FIG. 65, they are described as drum speed and pulsator speed, and are the same in FIGS. 66 and 70) according to Control Example 1. As shown in FIG. 65, when the detected values of the amount of unbalance between the drum 11 and the pulsator 13 M _USB and M _UPL are below the predetermined value, that is, when the amount of vibration is predicted to be below the predetermined value even if accelerated as is. , the rotation speed of the two rotors 20 and 30 is increased to the rotation speed above the resonance rotation speed ωC at the same speed slope (see after time T130 in FIG. 65). Because of this, the dehydration operation can be completed in a shorter time.

―Control Example 2―

On the other hand, in step S112, if the detected value M _USB of the unbalance amount of the drum 11 is greater than the predetermined value α, or if the detected value M _UPL of the unbalance amount of the pulsator 13 is greater than the predetermined value β (S112 NO), proceeds to step S114.

In step S114, if the condition of equation (1) below is satisfied (YES in step S114), the process proceeds to rotation control. Specifically, the process proceeds to steps S115 and S116.

│(M _USB ×L1)—(M _UPL ×L2)│≤γ·····(1)

Here, as shown in FIGS. 68 and 69, L1 is the rotation radius of the unbalanced USB on the drum 11 side, and L2 is the rotation radius of the unbalanced UPL on the pulsator 13 side.

_{In other} words _, 'M _USB . Additionally, γ is a predetermined amount of moment that can be set arbitrarily. Additionally, the radius of the drum 11 and the radius of the pulsator 13 may be used as L1 and L2 in the above equation (1), respectively. The same applies to equation (2) below.

In step S115, while maintaining the rotation speed ωIL of the inner rotor 30 at ω1, the rotation speed ωOL of the outer rotor 20 is changed from ω1 to ω2 (ω2 < ω1). Figure 66 is a graph showing the time change in the rotation speed of the two rotors 20 and 30 according to Control Example 2, and shows the speed change in step S115 from time T120 to time T121.

In this way, by providing a predetermined speed difference (rotation speed difference: ω1 - ω2) between the outer rotor 20 and the inner rotor 30 and rotating it, the position of the unbalanced USB on the drum 11 side and the pulsator ( 13) The positional relationship of the unbalanced UPL position on the side can be changed periodically. Because of this, the unbalance amount (UT) of the drum 11 and the pulsator 13 changes periodically.

Figure 67 shows the results of detecting the periodic change in the amount of unbalance using a current sensor as the unbalance detection means 121a and 121b. In Figure 67, the solid line represents the q-axis current waveform, which is the detection signal (D121a, D121b) of the unbalance detection means (121a, 121b). FIG. 68 is a diagram showing the position of the imbalance at point A in FIG. 67 (when the amplitude of the detection signals D121a and D121b is maximum). FIG. 69 is a diagram showing the position of the imbalance at point B in FIG. 67 (when the amplitude of the detection signals D121a and D121b is minimum).

As shown in FIG. 67, the period of the detection signal of the unbalance detection means 121a and 121b on the pulsator side and the drum side is different, while the amplitude indicating the amount of unbalance (dashed line in FIG. 67) changes at the same period. Therefore, the control device 15 detects periodic changes in the unbalance amount (UT) by checking the detection signals (D121a, D121b) from the unbalance detection means (121a, 121b) on either the pulsator side or the drum side. can do.

Therefore, in step S116, based on one of the detection signals D121a and D121b, the rotation speed ωOL of the outer rotor 20 is changed from ω2 to ω1 according to the timing at which the detected value M _USB or M _UPL of the unbalance amount becomes minimum. It changes linearly and proceeds to step S113. The rotation speed change corresponding to step S116 is shown from time T122 to time T130 in FIG. 66. Additionally, the control device 15 may determine the timing at which the amount of unbalance becomes minimum based on both detection signals D121a and D121b.

For this reason, the drum 11 and the pulsator 13 rotate at the same number of rotations with each of the unbalanced USB and UPL in opposing positions in a plan view, as shown in FIG. 69. Due to rotation at such opposing positions, the respective unbalance moments cancel each other out, thereby minimizing the total unbalance amount (total unbalance amount) of the drum 11 and the pulsator 13.

Thereafter, in step S113, the rotation speeds ωIL and ωOL of both rotors 20 and 30 are increased at the same speed gradient from ω1 to a predetermined rotation speed equal to or higher than the resonance rotation speed ωC, and the dehydration operation is terminated after a predetermined time has elapsed. (See after time T130 in Figure 66). Because of this, acceleration can be achieved while maintaining the amount of unbalance minimized in step S116, and vibration of the drum 11 can be prevented. In addition, since the amount of unbalance is actively controlled, when the washing machine 10 is continuously used, the variation in the vibration of the drum 11 during the spin-drying operation can be reduced.

Additionally, in this specification, the same speed slope is a concept that includes substantially the same range. For example, it is a concept that includes the speed slope difference (time difference) in the range where the relative positions of unbalanced USB and unbalanced UPL do not substantially change.

―Control Example 3―

On the other hand, in step S114, if the condition of the following equation (2) is satisfied (NO in step S114), the process moves to speed change control. Specifically, the process proceeds to step S117.

│(M _USB ×L1)—(M _UPL ×L2)│＞γ·····(2)

In step S117, a comparison is performed between the moment amount P _USB due to unbalance on the drum 11 side and the moment amount P _UPL due to unbalance on the pulsator 13 side, and a predetermined speed change is given to the side with the larger moment amount.

Specifically, for example, when the moment amount P _UPL on the pulsator 13 side is large, the rotational speed ωOL of the outer rotor 20 is slowed down to a rectangular waveform (predetermined period). That is, the speed is varied in a rectangular waveform between ω1 and ω3 (ω3 < ω1). At this time, the rotation speed ωIL of the inner rotor 30 is maintained at ω1. FIG. 70 is a diagram showing the time change in the rotation speed of the rotors 20 and 30 according to Control Example 3, and shows an example of the speed change in step S117 from time T111 to time T112.

In this way, the state of unbalance can be changed by providing a predetermined speed change to the side with the larger moment amount. Additionally, the speed fluctuation is not limited to decelerating to a rectangular waveform and can be set arbitrarily. For example, the speed may be accelerated using a rectangular waveform, or the speed may be accelerated or decelerated using a triangular waveform or trapezoidal waveform, or a combination of these may be used. However, from the viewpoint of burden caused by motor torque and heat generation, it is desirable to reduce the speed.

After the predetermined speed change control is performed, the flow returns to S112, and determination of the detected values M _USB and M _UPL of the amount of unbalance of the drum 11 and the pulsator 13 is performed. In the subsequent flow, one of 'Control Example 1', 'Control Example 2', or the above speed change control is implemented depending on the amount of unbalance or the amount of moment.

Figure 70 shows an example in which the rotation control described in 'Control Example 2' was implemented after time T112. Additionally, in the case where speed variation control is repeatedly implemented, the variation speed of the speed variation control may be increased or decreased or the mode (shape, etc.) of the variation waveform may be changed for each implementation. Additionally, an upper limit may be set to the number of repetitions of speed change control.

As described above, according to the washing machine 1 according to the present embodiment, the drum and the pulsator are rotated at a predetermined speed difference, and the drum and the pulsator are accelerated at the same speed at the timing when the unbalance is minimized, so that the unbalance is maintained. occurrence can be prevented.

More specifically, the total unbalance (total value of unbalance) of the drum 11 and the pulsator 13 is minimized because the unbalance moments cancel each other when each unbalance is in an opposing position.

Therefore, in this form, the position of the unbalance is periodically changed by providing a predetermined speed difference between the drum 11 and the pulsator 13, and the unbalance is adjusted to the timing at which the unbalance is at a minimum, that is, the position where the unbalance is opposed. When this happens, the rotation of the drum 11 and the pulsator 13 is controlled so that they reach the same speed, and then they are accelerated together at the same speed inclination while maintaining the same speed. The timing at which this imbalance becomes minimum can be determined by checking the detection signals D121a and D121b from any one of the imbalance detection means 121a and 121b.

Because of this, since the drum 11 and the pulsator 13 can be accelerated while the unbalance is in an opposing position, the occurrence of unbalance can be prevented more effectively and stably. In this way, since the occurrence of imbalance can be prevented, vibration of the drum can be prevented and dehydration time can be shortened. In addition, since the position of the imbalance is actively controlled to be at the opposite position, the vibration deviation of the drum during dehydration operation can be reduced when used continuously.

Additionally, in step S112 of FIG. 64, when the amount of unbalance is below a predetermined reference value, the drum 11 and the pulsator 13 are rotated without performing rotation control based on the judgment that dehydration operation can be performed below the predetermined vibration even if accelerated. are accelerated at the same time with the same speed gradient. Because of this, the dehydration time can be completed in a shorter time. In addition, since the drum 11 and the pulsator 13 are accelerated simultaneously, it is easy to obtain a large torque especially at low speeds, the effect of faster starting can be obtained, and the dehydration time can be shortened.

Additionally, in step S114 of FIG. 64, when the difference in unbalance moment between the drum 11 and the pulsator 13 is greater than a predetermined value, a predetermined speed change control is performed in step S117. When the difference in unbalance moment between the drum 11 and the pulsator 13 is large, rotation control may not be able to sufficiently prevent the occurrence of unbalance, so rotation control or acceleration control can be effectively performed by speed fluctuation control. Change the state of unbalance so that it can be performed. By performing such speed change control, unbalance can be resolved without stopping the drum 11 and the pulsator 13, making it possible to significantly shorten the dehydration time.

(variation examples, etc.)

In step S115 of FIG. 64, the rotational speed ωOL of the outer rotor 20 is reduced from ω1 to ω2 (ω2<ω1), but the rotational speed ωOL can also be increased from ω1 to ω4 (ωc>ω4>ω1). . Additionally, in step S115 of FIG. 64, the rotation speed ωIL of the inner rotor 30 can be changed from ω1 to ω2 or ω4 while maintaining the rotation speed ωOL of the outer rotor 20 at ω1.

In any of the above cases, in step S116, the rotation speeds ωOL and ωIL of the two rotors 20 and 30 are made the same according to the timing when the detected value of the unbalance amount M _USB or M _UPL becomes minimum, and the process proceeds to step S113. do. Additionally, the same rotation speed described above is not limited to ω1 and may be a different rotation speed. For example, the same rotation number may be ω2 or ω4.

Additionally, in Figures 66 and 70, rotation control is performed at a rotation speed equal to or less than the resonance rotation speed ωC, but this is not limited. For example, after increasing the resonance rotation speed to a predetermined rotation speed ωC or more in step S113, rotation control may be performed to correct the imbalance. In this case, as in steps S115 and S116 of FIG. 64, the drum and pulsator are rotated at a predetermined speed difference, and the drum and pulsator are returned to the same speed at the timing when the unbalance is minimized.

<Eighth Embodiment>

The eighth embodiment relates to spin-drying operation of a washing machine.

(Control of the rotational motion of the motor)

As shown in FIG. 71, a speed sensor 18 serving as a speed detection unit that detects the rotational speeds of the outer rotor 20 and the inner rotor 30 is connected to the motor 12. Signals representing the rotational speeds of the outer rotor 20 and the inner rotor 30 detected by the speed sensor 18 are transmitted to the control device 15.

During the dewatering operation of the drum 11, the control device 15 sets the rotational speed of the inner rotor 30 detected by the speed sensor 18 to the target speed, and sets the rotational speed of the outer rotor 20 to the target speed. The rotational motion of the outer rotor 20 is controlled to be almost identical. That is, in this embodiment, control is performed to follow the outer rotor 20, which rotates the pulsator 13, based on the inner rotor 30, which rotates the drum 11. In this way, by synchronizing the outer rotor 20 and the inner rotor 30 during the spin-drying operation to suppress speed fluctuations, damage to the fabric of laundry can be reduced.

However, when a speed difference occurs between the rotation speed of the outer rotor 20 and the rotation speed of the inner rotor 30, this speed difference accumulates to create a phase difference between the outer rotor 20 and the inner rotor 30. It comes into existence.

For example, if the speed difference between the rotation speed of the outer rotor 20 and the rotation speed of the inner rotor 30 is 5 rpm, and the rotation continues with this speed difference constant, a phase difference of 30 deg will occur after 1 second. . Also, if such a phase difference occurs, laundry is pulled between the drum 11 and the pulsator 13 during the spin-drying operation of the drum 11, which is not desirable because damage to the fabric occurs.

Therefore, in this embodiment, such phase difference can be resolved during the dewatering operation of the drum 11.

Specifically, as shown in FIG. 71, the control device 15 has a phase calculation unit 15b. The phase calculation unit 15b calculates the phases of the outer rotor 20 and the inner rotor 30 by integrating the rotational speeds of the outer rotor 20 and the inner rotor 30 transmitted from the speed sensor 18. Additionally, the phase calculation unit 15b calculates the phase difference of the outer rotor 20 with respect to the inner rotor 30 based on the phases of the outer rotor 20 and the inner rotor 30. The control device 15 controls the rotational operation of the outer rotor 20 to resolve the phase difference calculated by the phase calculation unit 15b.

(Motor operation during dehydration operation)

Hereinafter, the operation of the motor during dehydration operation will be explained using Figure 72. As shown in FIG. 72, first, in step 101, the rotational operation of the inner rotor 30 is controlled so that the rotational speed of the inner rotor 30 becomes the target rotational speed, and the process proceeds to step S102. In the example shown in FIG. 73, the target speed of the inner rotor 30 is 1000 rpm.

In step S102, the phase of the inner rotor 30 is calculated by the phase calculation unit 15b based on the rotational speed of the inner rotor 30, and the process proceeds to step S103.

In step S103, the rotation speed of the inner rotor 30 is set to the target speed, the rotation operation of the outer rotor 20 is controlled so that the rotation speed of the outer rotor 20 is approximately equal to the target speed, and the process proceeds to step S104. .

In step S104, the phase of the outer rotor 20 is calculated by the phase calculation unit 15b based on the rotational speed of the outer rotor 20, and the process proceeds to step S105.

In step S105, the phase calculation unit 15b calculates the phase difference of the outer rotor 20 with respect to the inner rotor 30, and proceeds to step S106. Here, in the example shown in Figure 73, a phase difference of about 10 deg occurs in up to 0.5 seconds.

In step S106, the control device 15 determines whether the phase difference between the outer rotor 20 and the inner rotor 30 is less than a predetermined value. If the determination in step S106 is 'YES', the process returns to step S101 and repeats the process. If the determination in step S106 is 'NO', the process branches to step S107. In the example shown in Figure 73, a predetermined value is set so that the phase difference is 0deg.

In step S107, the target speed of the outer rotor 20 is corrected so that the phase difference is smaller than the predetermined value, and the process proceeds to step S104.

Here, in the example shown in FIG. 73, the rotation speed of the outer rotor 20 is lower than the rotation speed of the inner rotor 30 for about 0 to 0.4 seconds, so the target speed is set to accelerate the outer rotor 20. is being corrected. Meanwhile, since the rotation speed of the outer rotor 20 exceeds the rotation speed of the inner rotor 30 for about 0.4 to 0.9 seconds, the target speed is corrected to decelerate the outer rotor 20.

As described above, according to the washing machine 1 according to the present embodiment, the inner rotor 30 is accelerated to the target rotation speed, while the outer rotor 20 adjusts the rotation speed of the inner rotor 30 as a reference. Since control is performed to follow the target speed, the speed difference between the outer rotor 20 and the inner rotor 30 can be reduced.

Additionally, when the phase difference between the outer rotor 20 and the inner rotor 30 becomes greater than a predetermined value, the rotational operation of the outer rotor 20 is controlled to eliminate the phase difference. As a result, before the laundry placed across the drum 11 and the pulsator 13 is pulled due to the misalignment of the drum 11 and the pulsator 13, damage to the fabric of the laundry is prevented by resolving this misalignment. It can be reduced.

<Embodiment 9>

The ninth embodiment also relates to the spin-drying operation of a washing machine in the same way as the eighth embodiment.

(Control of the rotational motion of the motor)

As shown in Fig. 74, similarly to the eighth embodiment, a speed sensor 18 is connected to the motor 12. In addition, in the embodiment of FIG. 9, a current sensor 19 is further provided to detect the current flowing through the coil 63 provided in the stator 60 of the motor 12.

The rotation speed of each of the outer rotor 20 and the inner rotor 30 detected by the speed sensor 18 and the current value of the motor 12 detected by the current sensor 19 are fed back to the control device 15 and controlled. The device 15 rotates the outer rotor 20 and the inner rotor 30 at a target rotation speed.

In particular, the control device 15 sets the rotation speed of the inner rotor 30 detected by the speed sensor 18 to the target speed during the dehydration operation of the drum 11, and sets the rotation speed of the outer rotor 20 to the target speed. The rotational speed of the outer rotor 20 is controlled to almost coincide with . That is, in this embodiment, control is performed to follow the outer rotor 20, which rotates the pulsator 13, based on the inner rotor 30, which rotates the drum 11. In this way, by synchronizing the outer rotor 20 and the inner rotor 30 during the spin-drying operation to suppress speed changes, damage to the fabric of laundry can be reduced.

Additionally, during the spin-drying operation of the drum 11, the control device 15 synchronizes the outer rotor 20 and the inner rotor 30 to accelerate the rotational speed, while the pulsator 13 due to laundry is moved to the drum. When it is determined that the spinning phenomenon along (11) has disappeared, the supply of electricity to the motor 12 that rotates the outer rotor 20 is stopped to allow the pulsator 13 to rotate free. That is, in this embodiment, at the timing when the pulse of the pulsator 13 disappears, only the outer rotor 20 is set to a rotation-free state, and acceleration control of the rotation speed of the inner rotor 30 is continued. As a result, the pulsator 13 can be rotated free at an appropriate timing according to the weight, condition, type, etc. of the laundry, thereby reducing damage to the fabric of the laundry and saving power by stopping the energization to the motor 12. You can.

Whether or not the phenomenon of the pulsator 13 rotating along the drum 11 caused by the laundry has disappeared can be determined by the instability of the rotation speed of the outer rotor 20. Figure 75 is a graph showing the rotational speed variation of the outer rotor 20 during heavy load and light load. In addition, in the graph of FIG. 75, the rotational speed change period of the outer rotor 20 at the time of heavy load and at the time of light load is the same for convenience, but in reality, it is not limited to this. The rotational operation of the outer rotor 20 is controlled by the control device 15 to rotate at a set rotation speed.

Here, during heavy load, that is, when laundry rubs against the pulsator 13 and moves along the outer rotor 20, the actual rotation speed (speed sensor 18) relative to the set rotation speed of the outer rotor 20 While the variation in the rotation speed detected in ) is small, at light load, that is, when there is no friction of the outer rotor 20 due to laundry, the actual rotation speed relative to the set rotation speed of the outer rotor 20 The fluctuation of is large.

When dehydration starts, laundry is evenly distributed within the drum 11 and piles up on the bottom of the drum 11 due to gravity. When synchronous operation of the outer rotor 20 and the inner rotor 30 is started from this initial state, the outer rotor 20 operates at a heavy load, so the actual rotation speed relative to the set rotation speed of the outer rotor 20 The fluctuations are small. As the rotational speed of the outer rotor 20 and the inner rotor 30 accelerates, the laundry adheres to the inner wall of the drum 11 by centrifugal force, so the laundry rubbing against the outer rotor 20 decreases and the outer rotor ( 20) The load gradually becomes lighter.

That is, the variation of the actual rotation speed of the outer rotor 20 with respect to the set rotation speed gradually increases. Therefore, when the change in the rotation speed of the outer rotor 20 detected by the speed sensor 18 with respect to the set rotation speed of the outer rotor 20 becomes greater than a predetermined amount, the control device 15 detects the pulsator (pulsator) due to the laundry. It can be determined that the phenomenon of rotation along the drum 11 of 13) has disappeared.

Additionally, it can be determined from the current detected by the current sensor 19 whether or not the phenomenon of laundry rotating along the drum 11 of the pulsator 13 has disappeared. Figure 76 is a graph showing time changes in the rotation speed of the outer rotor 20 and the motor current. When the dehydration operation is started, the q-axis current of the motor 12 increases, and the outer rotor 20 gradually increases the rotation speed and reaches the set rotation speed.

When the voltage is saturated during rotational acceleration of the outer rotor 20, the d-axis current of the motor 12 is increased to advance the phase. When the laundry rubs against the pulsator 13 and the outer rotor 20 is stretched, both the d-axis current and the q-axis current are large because the load on the motor 12 is heavy, but the outer rotor 20 is stretched. When this disappears, the load on the motor 12 becomes lighter and both the d-axis current and the q-axis current become smaller.

Accordingly, the control device 15 converts the current detected by the current sensor 19 into a rotational coordinate system and converts the rotational coordinate system current, specifically, the d-axis current, the q-axis current, and at least one of the vector quantities combining these into a predetermined amount. When it becomes smaller than this, it can be determined that the phenomenon of laundry rotating along the drum 11 of the pulsator 13 has disappeared. Alternatively, the direction of the pulsator 13 can be determined from the advance angle of the combined current of the d-axis current and the q-axis current.

(Motor operation during dehydration operation)

Hereinafter, the operation of the motor during dehydration operation will be explained using Figure 77. As shown in FIG. 77, first, in step S1, the control device 15 starts synchronous operation of the outer rotor 20 and the inner rotor 30 to accelerate the rotation speed, and proceeds to step S2.

In step S2, the control device 15 determines whether or not the pulsator 13 is irritated by the laundry. The presence or absence of a pulse along the pulsator 13 can be determined from the rotational speed variation of the outer rotor 20 or the current amount of the motor 12, as described above. If it is determined that there is a pulse on the pulsator 13, the process returns to step S1. On the other hand, if it is determined that there is no pulse of the pulsator 13, the process proceeds to step S3.

In step S3, the control device 15 stops energizing the motor 12 that rotates the outer rotor 20 to make the pulsator 13 rotate free, and proceeds to step S4.

In step S4, the control device 15 sets the pulsator 13 to rotation-free, that is, determines that the phenomenon of the pulsator 13 rotating along the drum 11 caused by laundry has disappeared. Memorize the rotation speed of 20, and proceed to step S5.

In step S5, the control device 15 maximizes the rotation speed of the inner rotor 30 to rotate the drum 11 at the maximum rotation speed, and proceeds to step S6.

In step S6, the control device 15 lowers the rotation speed of the inner rotor 30 to slow down the drum 11, and proceeds to step S7.

In step S7, the control device 15 determines whether the rotation speed of the inner rotor 30 is smaller than the rotation speed of the outer rotor 20 memorized when the pulsator 13 was set to rotation-free. If the rotation speed of the inner rotor 30 is greater than the memorized rotation speed, the process returns to step S6. On the other hand, if the rotation speed of the inner rotor 30 is lower than the stored rotation speed, the process proceeds to step S8.

In step S8, the control device 15 resumes energizing the motor 12 that rotates the outer rotor 20, restarts synchronous operation of the outer rotor 20 and the inner rotor 30, and gradually lowers the rotation speed. , proceeds to step S9.

In step S9, the control device 15 stops energizing the motor 12 and sets the rotation speeds of the outer rotor 20 and the inner rotor 30 to zero.

As described above, by starting to rotate the pulsator 13 again at the rotation speed when the pulsator 13 was set to rotation free, the pulsator 13 rotates at an appropriate timing according to the weight, condition, type, etc. of the laundry. can be resumed, reducing damage to laundry fabric.

Additionally, when the rotation speed of the outer rotor 20 reaches a predetermined rotation speed, the pulsator 13 may be started to rotate again. In this case, step S4 can be omitted. However, it is desirable to prepare several values as the predetermined rotation speed and allow the user to arbitrarily change the set value depending on the weight, condition, type, etc. of the laundry.

As described above, according to the washing machine 1 according to the present embodiment, when it is determined that the pulsator 13 caused by the laundry has disappeared during the spin-drying operation of the drum 11, the pulsator 13 is rotated. Since it is set to free, the laundry rotating along the drum 11 does not damage the laundry by rubbing against the pulsator 13 that is free to rotate and rotating along the pulsator 13, and the outer rotor 20 Power consumption can be reduced by stopping the supply of electricity to the motor 12 that rotates.

In addition, the presence or absence of a pulse in the pulsator 13 can be easily determined from changes in the rotational speed of the outer rotor 20 or the current supplied to the motor 12.

In addition, at the end of the dehydration process, the laundry rotating along the drum 11 rubs against the non-rotating pulsator 13 and rotates along the pulsator 13, thereby preventing damage to the laundry.

In addition, since the rotation of the pulsator 13 can be resumed at an appropriate timing according to the weight, condition, type, etc. of the laundry, damage to the fabric of the laundry can be reduced.

<Example 10>

The tenth embodiment also relates to the spin-drying operation of a washing machine in the same way as the eighth and ninth embodiments.

＝Motor control during dehydration operation＝

During dehydration operation, the two rotors 20 and 30 can be driven simultaneously in the same direction. As a result, it becomes easy to obtain large torque, especially at low speeds, and the effect of faster starting can be obtained.

In addition, for the purpose of increasing energy efficiency during dehydration operation, that is, reducing the total energy consumption of the washing machine, it is possible to control the rotation of the drum 12 with the pulsator 13 in the rotation-free state.

Figures 78 and 79 are block diagrams showing the configuration of the motor 12 and the control device 15 (partial excerpt).

―Motor control according to normal conditions―

Figure 78 is a block diagram focusing on the block that operates when the pulsator 13 is in a rotation-free state among the components of the motor 12 and the control device 15. In this form, both the motor 12 side and the pulsator 13 side are controlled by the control device 15 shown in FIG. 78.

As shown in FIG. 78, an inverter 131 that drives the motor 12 is connected to the motor 12. In addition, the motor 12 is equipped with speed detection means 130 that detects the rotational speed of each of the pulsator 13 driven and connected to the outer rotor 20 and the drum 11 driven and connected to the inner rotor 30. .

The speed detection means 130 is not particularly limited as long as it can detect the rotational speed of the pulsator 13, and for example, a speed sensor such as a Hall sensor can be used. The speed ωmm detected by the speed detection means 130 is transmitted to the phase calculator 133 and the control device 15.

A current sensor 132 is connected to the inverter 131 and detects the phase current Iuvw flowing in each phase of the inverter 131.

The phase calculator 133 has a function of converting the detection speed ωmm into an angle θ, and can be realized by, for example, an integrator. The voltage converter 134 receives the voltage command value Vdqs from the current controller 152, which will be described later, converts it into a three-phase voltage, and outputs it to the inverter 131.

The current converter 135 receives the phase current Iuvw detected by the current sensor 132, converts it into Idqm, which is a composite current of the q-axis current Iq and the d-axis current Id, and feeds it back to the control device 15. The angle θ output from the phase calculator 133 is used for rotation conversion performed by the voltage converter 134 and the current converter 135 in the process of converting voltage and current.

In Figure 78, the control device 15 further includes a speed controller 151, a current controller 152, a field weakening controller 153, and a torque command unit 154.

The speed controller 151 receives the difference between the speed command value ωms according to the speed profile during dehydration and the detection speed ωmm received from the speed detection means 130, and the rotation speed of the drum 11 and the pulsator 13 is set to the speed command. Outputs the torque command value Iqs that becomes the value ωms.

The current controller 152 generates a current command value Idqs that is a combination of the torque command value Iqs output from the speed controller 151 and the d-axis current command value Ids output from the field weakening controller, and the q-axis current received from the current converter 135. and the difference between the composite current Idqm of the d-axis current, and output the voltage command value Vdqs at which the q-axis current and the d-axis current of the motor 12 become the current command value Idqs.

Figure 80 is a graph showing changes in the rotation speed, Iq, and Id time of the drum and pulsator in a rotation-free state.

In addition, in FIG. 80, the upper drawing shows time changes in the rotational speed No1 of the pulsator 13 (outer rotor 20) and the rotational speed Ni of the drum 11 (inner rotor 30). In addition, the middle figure shows the time changes of the q-axis current Iqi and the d-axis current Idi according to the motor drive on the drum 11 side, and the bottom figure shows the q-axis current Iqo according to the motor drive on the pulsator 13 side. and d-axis current Ido (hereinafter, simply referred to as q-axis current Iqo and d-axis current Ido). Hereinafter, the same applies to Figure 81.

In the form of Fig. 80, as shown in the upper figure, the rotation speed No1 of the pulsator 13 follows the rotation speed Ni of the drum 11 in the entire time range at the same speed, and the pulsator 13 in Fig. 81 The same applies to the rotation speed No1 of the data 13. For example, if a spin-drying operation is performed while a large amount of laundry is pressed in, such a state may occur.

First, as shown in the middle diagram of FIG. 80, the control unit 15 sets the speed command value ωms of the drum 11 to 1000 [rpm], and the q-axis current Iqi on the drum 11 side increases accordingly. do. Thereafter, the resistance due to the induced back electromotive force increases as the rotation speed of the drum 11 increases.

For this reason, field weakening control is performed in the control device 15 to reduce this resistance. The field weakening controller 153 outputs a reverse d-axis current Idi whose absolute value increases with time to the current controller 152 on the drum 11 side. Additionally, known techniques can be applied to field weakening control.

In addition, since a state occurs in which the pulsator 13 follows the rotation of the drum 11, a reverse q-axis current Iqo whose absolute value increases with time is generated on the pulsator 13 side. I'm doing it. Additionally, as the rotation speed of the pulsator 13 increases, the resistance due to the induced back electromotive force increases. Therefore, field weakening control is performed in the control device 15 to reduce this resistance. The field weakening controller 153 outputs a reverse d-axis current Idi whose absolute value increases over time to the current controller 152 on the pulsator 13 side.

Since the q-axis current Iqo and induced back electromotive force on the pulsator 13 side also increase the resistance on the drum 11 side rotating around the same axis as the pulsator 13, the d-axis on the drum 11 side Since the current Idi diverges and reaches the saturation current, loss of synchronism or loss of control occurs (see E in the middle diagram of FIG. 80).

As a result, as shown in the top drawing of FIG. 80, the rotational speed of the drum 11 does not reach 1000 [rpm], which is the speed command value ωms, even after a predetermined time has elapsed, and there are cases where the speed increase reaches a limit. In other words, there are cases where stable operation (control) is not possible up to high-speed ranges. In addition, in the upper drawing of Figure 80, an example of a case in which speed increase is ideally performed is shown by a dashed-dotted line.

―Motor control according to torque control mode―

Figure 79 is a block diagram focusing on blocks that operate in torque control mode among the components of the motor 12 and the control device 15. In addition, in this embodiment, the drum 11 side is operated according to the block diagram in FIG. 78, and the pulsator 13 side is operated according to the block diagram in FIG. 79.

In the form of Figure 79, a torque command unit 154 that outputs a predetermined torque command value Iqs to the current controller 152 is provided instead of the speed controller 151 in Figure 78. In addition, when operating the pulsator 13 side in the block diagram of FIG. 79, a torque command unit 154 is provided in parallel with the speed controller 151 for the control device 15 in FIG. 78, for example For example, the control program may use a switch to select which of the speed controller 151 and the torque command unit 154 is used.

The predetermined torque command value Iqs can be set to an arbitrary value so that stable operation up to the desired high speed range is realized even when rotation occurs along the drum 11 of the pulsator 13. In addition, the predetermined torque command value Iqs reduces the energy consumption of the entire washing machine compared to the case where a dent occurs along the drum 11 of the pulsator 13 with the pulsator 13 in the rotation-free state. Any value can be set.

For example, the predetermined torque command value Iqs can be set to Iqs=0. Here, when the phenomenon of rotation of the pulsator 13 along the drum 11 occurs, the torque for turning the pulsator 13 is unnecessary, so the torque command value is set to Iqs = 0 as above. It is possible.

Figure 81 shows an example in which the control device 15 performs a dehydration operation in torque control mode from the start stage of the dehydration operation in a state where the rotation speed of the drum 11 and the pulsator 13 is 0 [rpm]. It is showing. For example, when the control unit 15 can drive the drum 11 immediately before the start of the dewatering operation and detect whether or not a dewatering operation is occurring, the control unit 15 enters the torque control mode from the start stage of the dehydrating operation according to the result. There are cases where it operates as .

As in the case of FIG. 80, first, as shown in the middle part of FIG. 81, the control unit 15 sets the speed command value ωms of the drum 11 to 1000 [rpm], and accordingly, the speed command value ωms on the drum 11 side is set. The q-axis current Iqi increases. Thereafter, in order to reduce the resistance due to the back electromotive force induced by the increase in the rotation speed of the drum 11, field weakening control is performed, and the d-axis in the reverse direction whose absolute value increases with time relative to the drum 11 side. Current Idi is given.

As shown in the upper drawing of FIG. 81, a state occurs in which the pulsator 13 follows the rotation of the drum 11. However, since the control device 15 controls the torque of the pulsator by outputting a torque command value Iqs = 0 from the torque command unit 154, as shown in the bottom drawing of FIG. 81, the pulsator 13 side The q-axis current Iqo becomes approximately “0”.

On the other hand, since the resistance increases due to the induced back electromotive force as the rotation speed of the pulsator 13 increases, the field weakening controller 153 of the control device 15 is the current controller 152 on the pulsator 13 side. The reverse d-axis current Ido, whose absolute value increases over time, is output.

Here, in FIG. 81, the q-axis current Iqo and the induced back electromotive force on the pulsator 13 side are reduced due to the torque control on the pulsator side, which will be described later, so, as shown in the middle part of FIG. 81, the drum 11 It is possible that an increase in the q-axis current Iqi on the side at the beginning of the dewatering process can at least increase the rotation speed of the drum 11. Additionally, as shown in the top drawing of Figure 81, the motor 12 can be rotated at a higher speed, and it is possible to realize stable operation up to the high-speed range during dehydration operation.

Figures 82 and 83 show time changes in the phase current of the inverter in the rotation free state and torque control mode. Figure 82 is a graph in a rotation-free state, and Figure 83 is a graph in torque control mode.

As shown in Figures 82, 83, and Table 1 below, by performing torque control on the pulsator side, the q-axis current Iqi and d-axis current Idi on the drum 11 side and the pulsator 13 side It is possible to significantly reduce the q-axis current Iqo and d-axis current Ido.

When reaching 1000rpm I _di I _do I _qi I _qo No torque control -3A -3.26A 0.85A -0.83A With torque control -1.8A -2.8A 0.13A -0.07A

As described above, according to the present embodiment, by setting the torque command value Iqs to "0", the resistance generated by the counter electromotive force on the pulsator side and the control current on the drum side influencing each other is eliminated, thereby reducing the load on the drum side motor. reduced, and energy consumption can be significantly reduced.

(variation examples, etc.)

An example in which the control device 15 performs the dehydration operation in torque control mode from the start of the dehydration operation is shown, but the present invention is not limited to this. For example, when the speed of the pulsator 13 detected by the speed detection means 130 reaches a predetermined threshold C, it is determined that the phenomenon of the pulsator 13 rotating along the drum 11 has occurred. You can do it. The upper drawing of Figure 81 shows an example in which the threshold C is set to 10 [rpm].

In this case, the pulsator 13 side is controlled as shown in the block diagram of Figure 78 when the speed of the pulsator 13 is less than 10 [rpm], and when the speed of the pulsator 13 reaches a predetermined 10 [rpm], the side is controlled as shown in Figure 79 It is controlled by a block diagram. Since the specific control by the control device 15 is the same as the above embodiment, detailed description thereof is omitted here.

The predetermined threshold C can be set arbitrarily, but is preferably set based on the criteria shown below, for example. Speed sensors used in washing machines generally use Hall sensors, but in the case of Hall sensors, it is not desirable to control them at less than 10 [rpm] due to resolution issues.

That is, for systems where it is difficult to sense the exact speed (magnetic pole position) due to problems with resolution, such as when using a Hall sensor, it is desirable to set the threshold C to a rotation speed higher than the resolution. Therefore, in this specification, an example in which 10 [rpm] is set as the threshold C is shown.

In addition, the case where the rotation speed No1 of the pulsator 13 follows the rotation speed Ni of the drum 11 at the same speed in the entire time range has been described, but the case is not limited to the case where the rotation speed No1 of the pulsator 13 follows the rotation speed Ni at the same speed.

For example, when the amount of laundry decreases, the state in which the pulsator 13 rotates along the drum 11 changes, so that, for example, the rotation speed of the pulsator 13 changes to rotation speed No2 at the top of Figure 81, There are cases where the situation is the same as No3. Rotational speed No2 represents an example in which the rotation of the pulsator 13 was stabilized at about 400 [rpm], and rotational speed No3 represents an example in which the pulsator 13 was released during the dehydration operation. Even in such a case, the control device 15 may perform torque control based on a predetermined standard, and the same effect can be obtained.

In addition, as shown by the rotation speed No3, the control device 15 reduces the rotation speed of the pulsator 13 during the dehydration operation so that the rotation speed of the pulsator 13 is lower than a predetermined speed (for example, (below the threshold D), the pulsator 13 can be controlled to return to the rotation-free state.

Because of this, energy consumption due to driving of the pulsator 13 can be optimized depending on the state of the pulsator 13. In addition, it is desirable to set the threshold D to a value smaller than the threshold C in consideration of hysteresis, and the upper drawing of Figure 81 shows an example in which the threshold D is set to 5 [rpm].

1 washing machine
10 water tank
11 drum
12 motor
13 Pulsator
15 Control device (control unit)
15a dual rotation control
15b phase calculation unit
18 Speed sensor (speed detection unit)
19 Current sensor (current detection unit)
20 Outer rotor (first rotor)
30 Inner rotor (2nd rotor)
40 inner shaft
50 outer shaft
60 stater
60a body part
60b flange part
61 I-shaped core (core element)
61a medial tooth
61b outer teeth
62 insulator
63 coil
75 Resin molded body
80a∼80c upper arm switching element
80d∼80f lower arm switching element
81 main nexus
Part 82 Connector
84 core insertion part
90a∼90c upper arm switching element
90d∼90f lower arm switching element
101 Drum side inverter circuit
102 Pulsator side inverter circuit
103 Drum side current sensor (rotation speed detection means)
104 Pulsator side current sensor (rotation speed detection means)
105 Drum side position sensor (rotation speed detection means)
106 Pulsator side position sensor (rotation speed detection means)
108 voltage sensor (voltage detection means)
112 inverter
113a load detection means
113b load detection means
114 Vibration detection means
121a unbalance detection means
121b unbalance detection means
130 Speed detection means
M winding machine
D mold
C1 core holding structure
C2 winding body
J vertical axis
Wa jumper wire
Va∼Vc command signal
Va'∼Vc' command signal
C carrier

Claims (15)

inner rotor;
An outer rotor installed on the outer circumference of the inner rotor; and
A stator installed between the inner rotor and the outer rotor, formed in a ring shape, and including a plurality of coils and a plurality of core elements,
The constant of the current driving the inner rotor and the constant of the current driving the outer rotor are different from each other,
The plurality of coils and the plurality of core elements of the stator independently rotate the inner rotor and the outer rotor when a composite current in which a current driving the inner rotor and a current driving the outer rotor of different constants overlap each other are supplied. It is formed to generate a rotating magnetic field that can be driven,
Each tooth of the plurality of core elements includes an inner tooth facing the inner rotor and an outer tooth facing the outer rotor,
The inner rotor includes a plurality of inner magnets arranged circumferentially to correspond to the inner circumferential surface of the stator, and the outer rotor includes a plurality of outer magnets arranged circumferentially to face the outer circumferential surface of the stator,
The width of the teeth of the plurality of core elements of the stator is greater than 1/2 of the width of the outer magnet or the inner magnet facing the plurality of core elements,
When the number of slots (S) of the stator, the number of magnetic poles (P1) of one of the inner rotor and the outer rotor, and the number of magnetic poles (P2) of the other rotor are an integer of 1 or more,
S=12n
P1=(6±1)·2n
P2=(6±2)·2n
A motor for a washing machine that is set to satisfy the conditions. According to claim 1,
A motor for a washing machine, wherein the width of the teeth of the core element of the stator is larger than the width of the facing outer magnet or the inner magnet. delete According to claim 1,
A motor for a washing machine, characterized in that the winding coefficient of the coil with respect to the fundamental wave of the magnetic flux distribution of the inner rotor and the outer rotor is greater than 0.5 for both the inner rotor and the outer rotor. According to claim 1,
A motor for a washing machine, wherein the number of rotating magnetic fields generated by the stator is different from the number of magnetic poles of the inner rotor and the number of magnetic poles of the outer rotor. According to clause 1,
A motor for a washing machine, wherein the disconnection coefficient of the coil with respect to harmonics of the magnetic flux distribution of the inner rotor and the outer rotor is less than 1 for either the inner rotor or the outer rotor. According to claim 1,
The stator is,
A plurality of core elements arranged independently at regular intervals in the circumferential direction; and
A plurality of coils formed by winding a wire around each of the plurality of core elements,
Teeth of each of the plurality of core elements,
inner teeth facing the inner rotor;
Provided with an outer tooth facing the outer rotor,
The number of magnetic poles of the inner rotor and the number of magnetic poles of the outer rotor are different,
The plurality of core elements include a number smaller than either the number of magnetic poles of the inner rotor or the number of magnetic poles of the outer rotor,
Any one of the inner teeth and the outer teeth, which faces the rotor with the largest number of magnetic poles among the inner rotor and the outer rotor, is in the range of 180°/Nc to 257°/Nc (Nc is the number of core elements). A motor for a washing machine having a set tooth opening. According to claim 7,
The other of the inner and outer teeth, which faces the inner rotor and the outer rotor with a smaller number of magnetic poles, is in the range of 96°/Nc to 342°/Nc (Nc is the number of core elements). Motor for a washing machine, having set tooth openings. According to claim 7,
A motor for a washing machine that satisfies the following conditions when the number of magnetic poles of the rotor with a small number of magnetic poles among the inner rotor and the outer rotor is set to P1, and the number of magnetic poles of the rotor with a large number of magnetic poles is set to P2.
Nc＝12n
P1=(6±1)·2n
P2=(6±2)·2n
(n is an integer greater than or equal to 1) According to claim 1,
The stator is,
A plurality of core elements each separately and independently disposed;
an insulator accommodating the plurality of core elements;
a plurality of coils formed by winding a wire around each of the plurality of core elements with the insulator interposed therebetween; and
It includes a resin molded body embedding the plurality of core elements, the plurality of coils, and the insulator,
The insulator is formed of a pair of ring-shaped connectors connected to each other in the axial direction, with the plurality of core elements sandwiched between them,
The pair of ring-shaped connectors is a motor for a washing machine, wherein a plurality of core insertion portions into which each of the plurality of core elements is inserted are provided at equal intervals in the circumferential direction. According to claim 10,
The pair of ring-shaped connectors,
A ring-shaped main connector formed as an integral body; and
A motor for a washing machine, including a secondary connection body formed by connecting a plurality of arc-shaped connection elements. According to claim 10,
An inner core surface portion and an outer core surface portion where each of the plurality of core elements is exposed are provided on the inner peripheral surface and outer peripheral surface of the core holding structure formed by connecting the pair of ring-shaped connectors,
The motor for a washing machine, wherein the inner core surface portion is located inside the inner peripheral surface of the insulator, and the outer core surface portion is located outside the outer peripheral surface of the insulator. A motor for a washing machine according to any one of claims 1, 2, 4 to 12;
A drum connected to the inner rotor of the washing machine motor and accommodating laundry; and
A pulsator connected to the outer rotor of the washing machine motor and agitating the laundry in the drum.

delete delete

Images