Blower Motor Flange Decoupling for Flexible Manufacturing
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Solution Overview
Problem
The existing manufacturing process for blower motors is costly and inefficient due to the need for frequent modifications when flange specifications change, leading to increased costs and reduced productivity.
Innovation Solution
A blower motor design featuring a standardized motor assembly coupled to a flange using a damper plate, allowing for easy adaptation to various flange specifications without altering the overall manufacturing process, which includes a motor assembly with a stator, rotor, printed circuit board, and motor cover, and a flange with coupling protrusions and a damper plate that supports the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the flange specifications are changed to meet different application requirements, then the adaptability of the blower motor is improved, but the manufacturing cost increases and productivity decreases due to frequent modifications of the standardized motor assembly and jigs
Solution Approach 1:
The blower motor is divided into two independent parts: a standardized motor assembly and a customizable flange. The flange is separated from the motor assembly, allowing it to be changed without affecting the motor assembly. This segmentation enables different flange specifications to be produced independently while maintaining the same motor assembly manufacturing process.
Solution Approach 2:
The motor assembly is designed as a universal component that can be coupled with various flange specifications. The coupling mechanism uses standardized features (such as coupling protrusions and corresponding recesses) that work across different flange types, allowing one motor assembly design to serve multiple applications with different flange requirements.
2Adaptability or versatility
If the flange specifications are changed to meet different application requirements, then the adaptability of the blower motor is improved, but the manufacturing cost increases due to modifications required in the standardized motor assembly and jigs
Solution Approach 1:
The flange is segmented as a separate component from the motor assembly, allowing it to be manufactured independently using different materials and processes suited to specific applications. This eliminates the need to modify the motor assembly or its manufacturing jigs when flange specifications change.
Solution Approach 2:
The flange parameters (such as coupling protrusion positions, hole patterns, and dimensions) can be changed to meet different application requirements without affecting the motor assembly. This parameter flexibility is achieved through the independent flange design, which allows customization while maintaining compatibility with the standardized motor assembly coupling interface.
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 design streamlines the production process, reduces manufacturing costs, and enhances the reliability and efficiency of the blower motor by enabling the use of standardized components and improved vibration absorption.
Implementation Method 1
enhancing vibration absorption and coupling force to increase the efficiency and reliability of the motor
Implementation Method 2
When current is applied to a coil wound around the stator core, the rotor is rotated by electromagnetic interaction with the stator
Data Source
Figure 1
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AI summary
The blower motor according to the present invention comprises a motor assembly 100; a flange 200 on which the motor assembly 100 is mounted; and a damper plate 300 coupled to the flange 200 and supporting the motor assembly 100.