Vibratory Linear Actuator Integral Stator Support Unit
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Solution Overview
Problem
Existing vibratory linear actuators for electric razors are costly due to the need for screw coupling to stabilize the gap size between magnets and electromagnets, and additional screws are required for fixing the actuator to the housing, increasing complexity and cost.
Innovation Solution
The support unit and stator are fixed together without screws, using jut portions and engaged portions for magnetic attraction to maintain a constant gap size, eliminating the need for additional fixing means and reducing component parts and assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screw coupling is used to fix the stator and support unit together, then the gap size between magnets and electromagnets is stabilized, but the manufacturing cost increases and device complexity increases
Solution Approach 1:
The stator and support unit are merged into a single integral body through mold molding, eliminating the need for separate screw coupling. This combining of previously separate components resolves the contradiction by maintaining gap stability through the integrated structure while reducing the number of parts and assembly complexity.
Solution Approach 2:
The mechanical screw coupling system is replaced with a mold-formed integral structure. The gap stability previously achieved through mechanical fastening is now inherent in the molded design, substituting a complex mechanical assembly with a simpler monolithic structure that maintains precision without additional components.
2Manufacturing precision
If screw coupling is used to fix the stator and support unit together, then the gap size between magnets and electromagnets is stabilized, but the manufacturing cost increases
Solution Approach 1:
The stator and support unit are combined into one molded piece, eliminating the need for separate manufacturing of multiple components and the subsequent screw assembly process. This integration reduces manufacturing steps, material requirements, and assembly operations, thereby lowering production costs while maintaining gap precision.
Solution Approach 2:
The screw fastening system is replaced with a mold-formed integral structure, eliminating the need for separate fasteners and assembly operations. This substitution reduces manufacturing complexity and cost while preserving the critical gap dimension stability through the inherent precision of the molded design.
3Reliability
If additional screws are used to fix the actuator to the housing, then the actuator is securely fixed, but the device complexity and number of component parts increases
Solution Approach 1:
The stator-support unit assembly is merged into a single integral component that can be directly fixed to the housing as one unit. This eliminates the need for separate screw coupling between the stator and support unit, reducing the total number of screws and parts while maintaining secure fixation through the simplified assembly structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces costs and stabilizes the actuator's characteristics by eliminating the need for screws, simplifying assembly, and maintaining a consistent gap size, while allowing for a smaller and more affordable actuator design.
Implementation Method 1
an electromagnet arranged in the stator, a plurality of permanent magnets arranged in the movable members, the movable members being caused to vibrate by supplying an electric current to the electromagnet
Implementation Method 2
the magnetic pole surface of the electromagnet can oppose the magnetic pole surfaces of the permanent magnets with a gap left therebetween
Implementation Method 3
The support unit and the plurality of movable members are connected to each other by thin elastic pieces
Data Source
Figure 1
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AI summary
A vibratory linear actuator includes a stator with a magnetic pole surface, a movable member with a magnetic pole surface, an electromagnet arranged in one of the stator and the movable member, a permanent magnet arranged in the other of the stator and the movable member and a support unit for movably supporting the movable member so that the magnetic pole surface of the electromagnet can oppose the magnetic pole surface with a gap left therebetween. The actuator is designed to vibrate the movable member by supplying an electric current to the electromagnet. The support unit includes a fixed portion to be fixed to a housing for accommodating the actuator, and the stator is configured to be fixed to the support unit as the support unit is fixed to the housing.