Brush Roller Torque Shutdown for Upright Vacuum Overload Protection
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Solution Overview
Problem
Existing upright vacuum cleaners face challenges in implementing effective and cost-efficient overload protection for their motor, particularly when a single motor powers both the blower and brush drive, which complicates ensuring long-term stability and operational reliability.
Innovation Solution
A torque detection unit comprising a drive disk rotatably mounted on a shaft with a non-rotatable output element for the brush roller, coupled via a torsion spring to a clutch disk, uses ramps on the drive disk to adjust the clutch disk above a torque threshold, enabling a switching mechanism for safety shutdown through a circuit arrangement, including an eddy current disc and magnets for triggering the shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single motor is used for both blower and brush drive, then device complexity is reduced, but overload protection becomes more difficult to implement reliably
Solution Approach 1:
The patent introduces a torque detection unit with a drive disk, clutch disk, and torsion spring as an intermediary mechanism between the motor and the brush roller. This mediator detects torque conditions and triggers safety shutdown when overload occurs, enabling reliable protection without requiring separate motors for blower and brush drive.
2Reliability
If mechanical torque detection is implemented, then reliability of overload protection improves, but device complexity increases
Solution Approach 1:
The patent replaces complex electronic torque measurement and evaluation systems with a simple mechanical torque detection unit. The drive disk, clutch disk, and torsion spring create a mechanical system that automatically detects overload conditions and triggers shutdown through a switching element, eliminating the need for microcontrollers and electronic sensors.
3Reliability
If a torsion spring is used for torque detection, then wear is reduced and damping is improved, but response time may be delayed
Solution Approach 1:
The torsion spring in the torque detection unit acts as a cushioning element that absorbs and dampens shock loads before they can cause damage. The spring's elastic properties provide beforehand cushioning against torque peaks, allowing the system to withstand transient overloads while maintaining operational stability during normal variations.
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 creates a compact, low-wear system for mechanical torque detection and control, dampening shock loads and allowing time delays for torque peaks, thereby enhancing the operational reliability and safety of the vacuum cleaner.
Implementation Method 1
the drive disk being coupled via a torsion spring to a clutch disk
Implementation Method 2
the torsion spring dampens the belt drives of the system in particular, in order to compensate for shock loads
Implementation Method 3
a triggering element that can be coupled to the clutch disc is formed by an eddy current disc that is rotatably arranged coaxially on the shaft and that, with associated magnets, transmits a force from the rotating system to a stationary switching element
Data Source
AI summary
Disclosed is a floor care device as a brush vacuum cleaner, with a brush attachment facing the floor for receiving a driven brush roller with an overload protection device, a drive disc being rotatably mounted on a shaft and the shaft having a non-rotatable output element for the brush roller, and the drive disc having a clutch disc via a torsion spring is coupled, which can be moved axially on the shaft and is coupled to the shaft in a rotationally fixed manner via drivers, and ramps are formed on the drive disk, which axially adjust the clutch disk with corresponding ramps above a torque threshold by relative rotation, and by the actuating movement via a corresponding switching element a circuit arrangement, a safety shutdown can be controlled.