Magnet Module Locking Units for Fan Assembly
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Solution Overview
Problem
Conventional magnet module assembly in fans is costly due to waste generation in iron casing manufacturing and unreliable magnet attachment, with high-quality glue being economically unfavorable and prone to magnet loosening over time.
Innovation Solution
A magnet module comprising a sintered magnet structure, a magnetic permeable casing, and a fixing member with locking units that securely assemble the magnets and casing without glue, using insert molding or engagement for improved stability and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-quality glue is used to attach magnets to the iron casing, then the bonding reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the chemical bonding system (glue) with a mechanical bonding system (locking structure). The fixing member includes locking units that mechanically interlock with the iron casing and magnets, eliminating the need for high-quality glue while maintaining bonding reliability and reducing manufacturing costs.
Solution Approach 2:
The patent introduces a fixing member as an intermediary component between the iron casing and magnets. This fixing member includes locking units that mediate the connection, providing reliable bonding without requiring expensive glue while also simplifying the manufacturing process.
2Ease of operation
If manual assembly is used to attach magnets to the iron casing, then the manufacturing flexibility is improved, but the product yield becomes unreliable
Solution Approach 1:
The patent segments the assembly into modular components: the iron casing, magnets, and a separate fixing member with locking units. This segmentation allows for standardized, repeatable assembly operations that can be easily automated, improving both productivity and product yield while maintaining manufacturing flexibility.
Solution Approach 2:
The locking units are designed to automatically engage and secure the magnets to the iron casing without requiring complex manual operations. The self-locking mechanism ensures consistent assembly quality, improving product yield while reducing the skill level required for assembly operations.
3Manufacturing precision
If a precise machine is used to attach magnets to the iron casing, then the assembly precision is improved, but the manufacturing cost increases extremely
Solution Approach 1:
The patent divides the assembly system into separate, standardized components with built-in alignment features. The locking units and mating structures are designed to guide assembly automatically, achieving high precision without requiring expensive precise machines.
Solution Approach 2:
The patent changes the assembly approach from precision-machine-dependent to geometry-dependent. By designing locking units with specific geometric parameters that self-align and self-locate, the system achieves high assembly precision through clever design rather than expensive equipment.
Data Source
AI summary
A magnet module is disclosed. The magnet module includes a sintered magnet structure, a magnetic permeable casing and a fixing member. The sintered magnet structure is disposed in the magnetic permeable casing. The fixing member has a plurality of locking units, and the sintered magnet structure and the magnetic permeable casing are fixed by the locking units of the fixing member.