Brush Roller Overload Cutoff Using an Eddy Current Disk
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Solution Overview
Problem
Existing brush vacuum cleaners face complexity and high costs in implementing effective overload protection mechanisms, particularly in devices with a single motor for both fan and brush drive, requiring additional switches and extensive electronic controls to ensure stability and safety.
Innovation Solution
A mechanical overload protection system using an eddy current disk and pivotable support with a magnet, which generates a magnetic field to control a switching element and trigger a safety cutoff when torque exceeds a threshold, allowing for simple and cost-effective detection and response to overload conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical or electronic decoupling devices are used for overload protection, then safety and stability are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces complex electronic control systems with a purely mechanical torque detection and response system. A torque-sensitive element directly mechanically linked to the brush roll detects overload conditions and triggers a mechanical disengagement mechanism, eliminating the need for microcontrollers, sensors, and electronic circuitry while maintaining reliable overload protection.
Solution Approach 2:
The overload protection system is designed to automatically detect and respond to torque overload conditions without external intervention. The mechanical system self-regulates by detecting torque through the torque-sensitive element and automatically disengaging the drive train when threshold values are exceeded, providing autonomous safety functionality.
2Measurement precision
If electronic torque measurement and microcontroller-based shutdown systems are implemented, then torque detection precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent employs a simple, inexpensive mechanical torque-sensitive element that can be manufactured at low cost using conventional machining processes. This element provides sufficient torque detection capability without requiring expensive electronic sensors, microcontrollers, or complex circuit boards, making the system economically viable for mass production.
Solution Approach 2:
The invention substitutes electronic measurement systems with a purely mechanical torque detection mechanism. The torque-sensitive element translates torque directly into mechanical displacement or force that actuates the disengagement mechanism, providing accurate torque measurement without electronic components and thereby reducing manufacturing costs.
3Reliability
If additional main switches and electronic control components are added, then safety functionality is improved, but ease of operation and device simplicity deteriorate
Solution Approach 1:
The patent combines the torque detection function, threshold evaluation, and shutdown actuation into a single integrated mechanical assembly. The torque-sensitive element, threshold-setting mechanism, and disengagement actuator work together as one unified system, eliminating the need for separate switches and electronic control units, thereby maintaining operational simplicity.
Solution Approach 2:
The mechanical torque-sensitive element serves multiple functions simultaneously: it detects torque magnitude, compares it against threshold values, and directly actuates the disengagement mechanism. This multi-functionality within a single mechanical component simplifies the overall system and maintains ease of operation while ensuring reliable safety shutdown.
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 provides a straightforward and cost-effective means to detect torque overload and initiate a safe shutdown in brush vacuum cleaners, compensating for torque peaks and preventing unintended shutdowns due to impact stresses.
Implementation Method 1
an eddy current disk (11) which can be coupled to the driven element (8) and which is assigned at least one magnet (14), wherein a support (13) for the magnet (14) can be moved by a magnetic field formed by generated eddy current
Implementation Method 2
a magnetic field of the coupled eddy current disk formed by the generated eddy current
Data Source
AI summary
A brush vacuum cleaner having a floor brush set with a driven brush roller having an overload protection. The brush set has at least one electric motor for a suction fan and for the drive of the brush roller, which includes a torque detecting unit. A safety shutdown is accomplished via a switch arrangement above an overload torque threshold. A driven element of the torque detection unit is disposed in the drive train which, above the torque threshold, is coupled via a switchable coupling element to an eddy current disk made of electrically conductive material. The eddy current disk has at least one magnet pivotably positioned on a fixedly mounted movable support. An adjustment of the support is made by a magnetic field of the coupled eddy current disk formed by the generated eddy current. The support controls a corresponding circuit arrangement such as a switching element as safety cut-off.