Integral Swing Unit Structure for Compact High-Force Vibrators
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Solution Overview
Problem
Existing vibration generators face challenges in increasing vibration force relative to size due to the need for large space for deformation of plate springs, complex assembly processes, and high variability in performance.
Innovation Solution
A vibration generator with a frame, swing unit, and elastic member integrally molded together, where the swing unit is movable within the frame, and a coil is used to excite the swing unit for reciprocatory motion, allowing for efficient vibration generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a plate spring is used to hold the magnet in a linear motor, then the magnet can be moved by elastic deformation, but a relatively large space is required for the plate spring to deform
Solution Approach 1:
The plate spring is divided into multiple segments (first plate spring segment and second plate spring segment) connected at a joint. This segmentation allows the spring to achieve the necessary elastic deformation within a smaller overall space, as each segment can deform independently rather than requiring a single large deformation zone.
Solution Approach 2:
The plate spring structure transitions from a single-plane deformation to a multi-dimensional deformation by introducing a joint that allows bending in different directions. The first and second plate spring segments can deform in different planes, effectively utilizing three-dimensional space for elastic deformation and reducing the required footprint area.
2Ease of manufacture
If the magnet, plate spring, and frame unit are assembled as separate members, then the vibration generator can be manufactured, but the number of assembly steps increases and manufacturing becomes relatively complicated
Solution Approach 1:
The first plate spring segment is integrally formed with the frame unit, and the second plate spring segment is integrally formed with the magnet. This merging of components reduces the number of separate parts that need to be assembled, simplifying the manufacturing process and reducing assembly steps while maintaining the functional benefits of the plate spring structure.
3Manufacturing precision
If separate members are assembled to form the vibration generator, then manufacturing is possible, but assembly accuracy is difficult to ensure and performance variation increases
Solution Approach 1:
By integrally forming the plate spring segments with the frame unit and magnet respectively, the patent eliminates the need for precise assembly between separate components. The integral formation ensures consistent geometric relationships and eliminates assembly tolerances, thereby improving manufacturing precision and reducing performance variation between individual vibration generators.
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 enables easy and accurate assembly, reduces manufacturing complexity, and achieves a large vibration force while maintaining a compact size, with improved reliability and durability.
Implementation Method 1
a coil unit disposed so as to sandwich the magnet from above and underneath being excited
Implementation Method 2
the swing unit moves with respect to the frame according to excitation of the coil
Implementation Method 3
the swing unit is movable with respect to the frame while deforming the elastic member
Data Source
AI summary
A vibrator includes a frame, a swing unit, and an elastic member. The swing unit is disposed within the frame and holds a magnet. The elastic member connects the swing unit and the frame. The swing unit is movable with respect to the frame while deforming the elastic member. The frame, the swing unit, and the elastic member are integrally molded with each other.