Integrated Stator Rotor for DC Brushless Ceiling Fan Motor
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Solution Overview
Problem
Conventional AC monophase ceiling fan motors suffer from inefficiency, high working temperatures leading to insulation degradation and bearing noise, and unstable production quality due to the stacking and riveting of silicon steel laminations.
Innovation Solution
A DC brushless ceiling fan motor design featuring a stator and rotor made of permeable materials, integrated using a secondary production process, along with an electrical controlling circuit comprising a computer microprocessor, power filter, frequency converter, phase detector, and remote or manual control devices to enhance efficiency and power savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional AC monophase motor design with stacked silicon steel laminations is used, then manufacturing experience and availability are maintained, but production efficiency is low and quality is unstable
Solution Approach 1:
The patent merges multiple separate manufacturing processes (stacking silicon steel laminations, riveting, winding) into a single integrated injection molding process that produces the stator body, rotor body, and windings in one operation. This eliminates assembly inaccuracies and improves both productivity and manufacturing precision simultaneously.
2Use of energy by moving object
If stacked silicon steel laminations secured by rivets are used, then conventional manufacturing methods are maintained, but power factor is low resulting in high power consumption
Solution Approach 1:
The patent replaces the conventional AC monophase motor structure with a DC brushless motor structure, substituting mechanical commutators and brushes with electronic control systems. This improves power factor and reduces power consumption while maintaining manageable device complexity through integrated circuitry.
3Reliability
If conventional AC motor design is used, then existing motor structure is maintained, but working temperature is high causing insulation degradation and bearing wear
Solution Approach 1:
The patent replaces the AC motor design with a DC brushless motor design that eliminates the need for insulation materials and traditional bearings through magnetic levitation or contactless support systems. This substitution reduces working temperature and eliminates the degradation mechanisms present in conventional motors.
4Manufacturing precision
If manual stacking and riveting processes are used, then conventional production methods are maintained, but assembly inaccuracies occur influencing product measurement stability
Solution Approach 1:
The patent combines multiple discrete manufacturing steps into a single integrated injection molding process that forms the stator body, rotor body, and windings as one unified component. This merger eliminates all assembly operations, ensuring consistent product measurements while simplifying the overall production process.
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 new design improves efficiency, reduces temperature-related issues, and stabilizes production, enabling mass production by integrating the stator and rotor with a controlling circuit that optimizes motor speed and orientation control.
Implementation Method 1
a DC brushless ceiling fan motor containing a stator and motor therein made of permeable material
Data Source
AI summary
A stator and rotor for a DC brushless ceiling fan motor includes an integrated design of the stator and rotor to form an integrated stator, the integrated stator is made of a permeable material and is formed by means of a secondary production process. The DC brushless ceiling fan motor further includes an electrical controlling circuit that comprises a computer microprocessor, a power supply, a frequency converter, a phase detector and a remote control device or a manual control switch with the purpose of controlling the speed and the orientation of the motor, and thus achieving the result of low working temperature and high electrical efficiency.