State-of-the-art manufacturing

Quality control is integral to Fisher & Paykel Technologies and nowhere this is more evident than in our manufacturing processes. Fisher & Paykel’s Quality Management System is certified to ISO 9001:2015 by an Accredited Certification Body.

Our factory in Huangdao, China is 28,500sqm and has a capacity of six million motors per year. We continually invest in cutting-edge automated manufacturing technologies that deliver 100% real-time measuring and monitoring, allowing us to produce robust and reliable products of premium quality.

We maintain and improve the integrity of our machines using Total Preventive Maintenance (TPM), constantly calibrating and recalibrating them to the highest standards.

Sophisticated motor controller

We use Field Oriented Control (FOC) for our 3-phase motors. This is a variable frequency drive (vfd) control method used to precisely control motor speed and torque by varying motor input frequency and voltage.

 

FOC offers many benefits:

  • High efficiency
  • Elimination of position sensor
  • Improved response
  • Reduced torque ripple
  • Low audible noise
  • Extended speed range operation

FOC allows us to run our motors in sinusoidal mode. The sinusoidal commutation method, in which all three phases are permanently energized with a sinusoidal current, replaces the position sensor with a sophisticated algorithm that estimates the rotor position while maintaining precise control of the motor speed and torque delivery.

By optimizing the use of FOC for our motors, we can monitor motor run parameters and adjust how the product behaves in real time. For washing machines, this means sophisticated load-sensing, with the controller enabling detection of load size, position and content. The motor controller uses this information to manage the real-time behaviour of the machine for the best wash performance.

We apply smart technology to other systems, for example, air-moving products and pumps, improving their performance and creating a better consumer experience. We can customise control solutions, hardware and software, to client-specific requirements, providing better system-level performance.

Permanent magnet synchronous motor

Permanent magnet synchronous motors (PMSM) have a permanent magnet rotor and copper or aluminium windings on the stator. The 3-phase stator structure has sinusoidal distributed windings that create a sinusoidal back EMF waveform.

The benefits of this motor technology are:

  • Ability to generate torque at zero speed
  • High torque density, smaller frame size for same power
  • High efficiency

This motor technology is a Fisher & Paykel innovation and it has become our specialty. We developed an accurate way to manufacture our magnets, a unique lamination construction, a smart engineering plastic molding method and our proprietary design tools. Read more about our developments below.

Magnet manufacturing method

Our magnet technology focusses magnetic flux to where it is most useful, producing a greater degree of torque between the stator and the rotor.

 

By utilising the magnetic material, reducing flux loss and heat rise, we can build highly efficient, quiet, low vibrating and dynamic motors into a smaller envelope.

Although we have extensive magnetic design experience, we are continually evolving and improving the original design to produce the best quality motors possible.

Lamination construction

Our lamination construction method lets us bend thicker laminate material, producing motors that are thinner, quieter and more powerful.

The lamination process also creates less material waste than most lamination manufacturing processes, which is better for the environment.

It’s a complicated method that we have continuously improved over the years. As our tools improve and we continue to learn more, we are applying these insights across our product range.

Engineering plastic rotor

Our expertise in plastics is part of our heritage. We were the first manufacturer to develop a plastic motor for laundry applications.

It was a novel idea at the time, but that move represented a leap for electric motors used in laundry applications. All the components are placed inside the mold tool then overmolded with a plastic shell. This produces a more accurate component with greater stiffness and strength, making the component less resonant, quieter and longer lasting.

Proprietary design tools

Our customization tools consider material usage, manufacturing and specific customer requirements and needs.

Using your specifications and our proprietary tools, we run thousands of highly-detailed virtual iterations to come up with the best motor design possible – resulting in a motor that is more efficient, quieter and precisely controllable.