Axial Gap Fan Motor With Edgewise Flat-Wire Winding
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Solution Overview
Problem
Existing axial gap type fan motors are too large for stick-type cleaners and face challenges in miniaturization while maintaining sufficient suction power and efficiency, particularly due to difficulties in edgewise winding and high eddy current losses.
Innovation Solution
A miniaturized axial gap type fan motor design featuring a rotor with radially installed blades, a shroud with a suction port, and a stator with a substrate-mounted bearing and armatures that utilize edgewise winding of flat wires around an iron core to reduce size and increase fill factor, minimizing eddy current losses by positioning magnets to avoid the control circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If existing axial gap type fan motors are used, then sufficient suction power can be obtained, but the outer diameter becomes too large for stick-type cleaners
Solution Approach 1:
The patent changes the winding orientation from radial to axial (edgewise winding), effectively utilizing the axial dimension of the motor to accommodate the coil windings. This dimensional change allows the motor to maintain sufficient power output while reducing the outer diameter, making it suitable for stick-type cleaners with limited space.
Solution Approach 2:
The patent modifies key parameters including the winding configuration (edgewise winding instead of traditional radial winding), the arrangement of armatures and magnets, and the gap dimensions. These parameter changes enable the motor to achieve high power density with a compact outer diameter while maintaining efficient electromagnetic conversion.
2Length of moving object
If the motor is miniaturized to reduce outer diameter, then it becomes suitable for stick-type cleaners, but edgewise winding becomes difficult to perform
Solution Approach 1:
The patent performs preliminary preparation of the flat wires and coil structures before assembly. The wires are pre-formed with appropriate insulation and configuration, and the armature cores are pre-assembled with precise positioning features. This preliminary action simplifies the subsequent edgewise winding process and enables miniaturization while maintaining manufacturability.
Solution Approach 2:
The patent optimizes parameters such as wire diameter, insulation thickness, and winding pitch to facilitate edgewise winding in miniaturized motors. By carefully selecting and adjusting these parameters, the winding process becomes more manageable despite the reduced size, balancing miniaturization with ease of manufacture.
3Length of moving object
If miniaturized motor design is implemented, then outer diameter is reduced, but obtaining sufficient output becomes difficult
Solution Approach 1:
The patent employs composite construction techniques including laminated iron cores to reduce eddy current losses, and uses optimized magnetic materials for both permanent magnets and armature cores. These composite material approaches enhance the magnetic flux density and electromagnetic conversion efficiency, enabling the miniaturized motor to achieve sufficient output power despite the reduced size.
Solution Approach 2:
The patent optimizes critical parameters including the air gap length, magnet strength, coil turns, and wire cross-section area to maximize power density. By carefully adjusting these parameters, the motor achieves high output in a compact form factor, overcoming the typical power loss associated with miniaturization.
4Volume of moving object
If edgewise winding with flat wires is used, then fill factor increases and size is reduced, but eddy current loss increases
Solution Approach 1:
The patent uses laminated iron cores with insulated layers between laminations to break up eddy current paths. This composite structure maintains the benefits of edgewise winding (compact size and high fill factor) while significantly reducing eddy current losses by introducing high-resistance barriers to circulating currents within the core.
Solution Approach 2:
The patent optimizes parameters such as lamination thickness, insulation material properties, and core geometry to minimize eddy current losses. By carefully selecting and adjusting these parameters, the motor achieves compact size through edgewise winding while controlling energy losses through proper core design.
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
The design achieves a high output with a small outer diameter and low weight, enabling efficient suction power suitable for stick-type cleaners, with improved efficiency and reduced eddy current losses, allowing for compact and high-performance operation.
Implementation Method 1
a coil and an iron core... The coil is formed in such a way that a flat wire having a rectangular cross section is bent toward a short side thereof and thus the short side of the flat wire is wound in contact with the iron core
Data Source
AI summary
A fan motor of a cleaner capable of exhibiting a high output is provided. The fan motor includes a shroud disposed to cover a fan, a rotor fixed to a shaft, and a stator disposed opposite to the rotor in an axial direction with a predetermined gap therebetween. The stator includes a substrate on which a bearing is installed and a plurality of armatures disposed around the bearing. A coil is formed in such a way that a flat wire having a rectangular cross-section is bent to a short side thereof to be wound around an iron core.