Motor assembly and method of manufacturing the same
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Solution Overview
Problem
Eccentricity in motor assemblies of vacuum cleaners, caused by manufacturing and assembly tolerances, leads to increased vibration and noise, which are transferred outside the device.
Innovation Solution
A method of manufacturing a motor assembly that includes disposing balls in a ring-shaped groove of the impeller, rotating the impeller beyond its resonant speed to move the balls to a compensation position, and fixing them using an adhesive or a fixing member to compensate for eccentricity, thereby reducing vibration and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise processing of rotating bodies is performed, then manufacturing precision is improved, but assembly time increases and eccentricity may still occur due to assembly tolerances
Solution Approach 1:
The ball compensator enables the impeller to self-adjust and compensate for eccentricity automatically during operation. The system uses its own operational dynamics (rotation) to move the balls to compensation positions, eliminating the need for complex external adjustment mechanisms or prolonged assembly procedures.
Solution Approach 2:
The invention changes the physical state and position of the balls within the groove during rotation. By utilizing centrifugal force and gravity during high-speed rotation, the balls move to specific positions that compensate for eccentricity, transforming a static assembly problem into a dynamic solution.
2Manufacturing precision
If assembly tolerances are reduced, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the eccentricity compensation function from the main motor assembly structure by adding a separate, simple ball compensator system. This isolated component handles the tolerance compensation independently, keeping the core motor assembly simple while addressing precision issues.
Solution Approach 2:
The ball compensator introduces a dynamic element to an otherwise static assembly problem. The balls can move freely within the groove during operation, allowing the system to dynamically adapt to and compensate for assembly tolerances without requiring complex precision control mechanisms.
3Manufacturing precision
If eccentricity compensation is performed using traditional methods, then manufacturing precision is improved, but processing time increases significantly
Solution Approach 1:
The balls are pre-positioned in the groove during assembly, and the compensation action is automatically triggered during the first high-speed rotation of the impeller. This preliminary positioning combined with automatic activation during normal operation eliminates the need for separate, time-consuming compensation procedures.
Solution Approach 2:
The eccentricity compensation is integrated into the normal operational rotation of the impeller. Instead of requiring a separate, prolonged adjustment phase, the compensation occurs rapidly during the first operational rotation, allowing the system to quickly transition from assembly to productive operation.
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 method effectively compensates for eccentricity within a short processing time, stabilizing the motor assembly and reducing vibration and noise in vacuum cleaners.
Implementation Method 1
rotating the impeller at a speed greater than the resonant rotation speed to move the balls to a compensation position
Implementation Method 2
Fixing the balls fixed at the compensation position may be performed using an adhesive to fix the balls at the compensation position
Data Source
AI summary
A method of manufacturing a motor assembly comprising a motor and an impeller coupled to a rotation shaft of the motor, the method includes disposing a plurality of balls in a ring-shaped groove formed in a surface of the impeller; rotating the impeller at a speed greater than a resonant rotation speed to move the balls to a compensation position for compensating for an eccentricity in the motor assembly; and fixing the balls at the compensation position in the groove.