Concentric Motor Housing for Hair Dryer Alignment
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Solution Overview
Problem
Existing electric motor assemblies for handheld devices, such as hair dryers, face challenges in size and weight reduction while maintaining high-speed operation and axial alignment, leading to increased lateral displacement and reduced motor output due to limitations in stator and rotor design.
Innovation Solution
The electric motor assembly features a configuration with both sides of the rotor supported by bearings, one inside the housing and the other in a bracket, with a concentric outer and inner housing design, and a stator partially housed within the inner housing, allowing for reduced size and weight while maintaining alignment and high-speed rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of the pair of frames is increased to accommodate the stator and rotor, then the motor output is improved, but the outer size and weight are significantly increased
Solution Approach 1:
The patent applies nesting by placing the stator inside the frame structure and the rotor inside the stator, creating a compact nested arrangement. The impeller is integrated with the rotor, and the housing encloses all components in a nested configuration, maximizing space utilization and reducing overall size while maintaining motor output.
Solution Approach 2:
The patent transitions from a traditional side-by-side or external mounting arrangement to a concentric, multi-dimensional nested layout where components are arranged along the axial and radial dimensions. The stator is positioned inside the frame, the rotor inside the stator, and the impeller integrated with the rotor, utilizing three-dimensional space efficiently to reduce outer dimensions.
2Volume of moving object
If the stator and rotor are made smaller to reduce size and weight, then the outer dimensions are reduced, but the motor output and coupling force are decreased
Solution Approach 1:
The patent employs dynamic balancing of the rotor and optimizes the magnetic field interaction between the stator and rotor to maintain high motor output despite reduced size. The impeller design and bearing configuration are optimized to minimize lateral displacement and maximize rotational efficiency, allowing compact dimensions without sacrificing power.
Solution Approach 2:
The patent optimizes critical parameters such as the air gap between stator and rotor, the magnetic field strength, the bearing clearance, and the impeller blade geometry to maintain high motor output in a compact design. By carefully tuning these parameters, the motor achieves high power density with reduced stator and rotor sizes.
3Device complexity
If only one bearing is used to support the rotor, then the device complexity is reduced, but the lateral displacement of the rotating shaft increases
Solution Approach 1:
The patent segments the rotor support function by using two bearings positioned at opposite ends of the rotor, with each bearing handling a portion of the support load. This segmentation of the support function reduces lateral displacement more effectively than a single bearing while adding only one additional bearing component.
Solution Approach 2:
The bearings are pre-positioned in the frame and stator assemblies, establishing precise alignment and support points before the rotor is installed. This preliminary positioning ensures that the rotor is supported at optimal locations, minimizing lateral displacement from the start of operation.
4Productivity
If the impeller rotation speed is increased to maintain air volume and wind pressure, then the productivity is improved, but the motor assembly must support higher speeds with compact dimensions
Solution Approach 1:
The patent optimizes the impeller blade geometry and rotor balance to enable high-speed rotation with minimal vibration and lateral displacement. The dynamic design of the impeller blades and the integrated rotor-impeller assembly allow the system to operate at high speeds while maintaining air volume and wind pressure, achieving high productivity in a compact form.
Solution Approach 2:
The patent optimizes parameters such as impeller blade angle, rotor inertia, bearing clearance, and magnetic field strength to enable high-speed operation. By carefully adjusting these parameters, the motor assembly achieves the necessary rotation speeds to maintain air volume and wind pressure while operating within compact dimensions.
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 configuration effectively reduces lateral displacement, maintains initial axial alignment, and enables high-speed operation without excessive size or weight increase, enhancing the motor's efficiency and lifespan.
Implementation Method 1
a stator and a rotor rotatably disposed with respect to the stator
Implementation Method 2
an electric motor is an apparatus that converts electric energy into mechanical energy
Implementation Method 3
a first bearing that is disposed at a first side of the rotor and supports the rotating shaft, a second bearing that is disposed at a second side of the rotor and supports the rotating shaft
Data Source
AI summary
An electric motor assembly for, for example, a hair dryer, includes an impeller, an outer housing in which the impeller is accommodated, an inner housing concentrically disposed in the outer housing, a stator having one side thereof accommodated in the inner housing, a rotor provided with a rotating shaft having one end coupled to the impeller and rotatably accommodated in the stator, a first bearing disposed at one side of the rotor, a second bearing disposed at another side of the rotor, and a bracket coupled to the stator and the outer housing so as to support the second bearing. Accordingly, initial alignment of the stator and the rotor may be securely maintained.