Environmental Sensor Blower Using Non-Contact Bearings

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Solution Overview

Problem

Existing particle counters face inefficiencies in air moving systems due to conventional blowers with lubricated ball bearings, leading to energy waste, reduced blower lifetime, and contamination risks in cleanroom environments.

Innovation Solution

A gaseous-fluid environmental sensor with a blower utilizing non-contact fluid dynamic bearings, which eliminates physical contact and lubricant-related issues, allowing for high RPM operation and efficient air movement without contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional blowers with lubricated ball bearings are used, then the blower can move air effectively, but energy is wasted and the blower lifetime is reduced

Engineering Contradiction:

Improveenergy efficiencyVSAvoidblower lifetime

Core Design Contradiction:

Loss of energyVSDuration of action of moving object

Solution Approach 1:

The patent replaces conventional mechanical ball bearing systems with magnetic bearing technology. The magnetic bearings use magnetic fields to support and rotate the impeller without physical contact, eliminating mechanical friction and lubrication requirements. This substitution of mechanical contact with magnetic field interaction directly addresses the energy loss and lifetime issues associated with conventional lubricated bearings.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs magnetic fields (analogous to pneumatic/hydraulic principles of using a fluid medium) to create a non-contact support system. The magnetic bearing system uses magnetic flux to provide radial and axial support forces, replacing solid mechanical contact with a field-based interaction that eliminates friction and wear.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If conventional blowers with lubricated ball bearings are used, then the blower can operate, but contamination risks arise in cleanroom environments

Engineering Contradiction:

Improvecontamination preventionVSAvoidblower design complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The replacement of mechanical ball bearings with magnetic bearings eliminates the need for lubricants and sealed enclosures, thereby removing the contamination source. The magnetic bearing system inherently prevents lubricant leakage and particulate generation, making it suitable for cleanroom and sterile environments without requiring additional containment measures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the lubrication system entirely from the blower design. By eliminating the lubricant reservoir, delivery mechanisms, and associated sealing requirements, the design removes the primary source of contamination while maintaining operational reliability in sensitive environments.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If higher flow rates are achieved using conventional blowers, then more air can be moved, but energy consumption increases

Engineering Contradiction:

Improveflow rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The magnetic bearing system reduces rotational friction and mechanical losses, allowing the impeller to rotate more efficiently at higher speeds. This enables the blower to achieve higher flow rates with lower energy input compared to conventional mechanically-bearing blowers, as more of the input energy is converted to useful airflow rather than being lost to friction and heat.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enhances energy efficiency, extends blower lifetime, and prevents contamination in clean environments by using non-contact fluid dynamic bearings in the blower, enabling reliable high-speed operation with reduced energy expenditure.

Implementation Method 1

The motor may be a brushless direct current motor with a non-contact fluid dynamic bearing.

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The blower may include a motor with a non-contact fluid dynamic bearing.

Methodology Applied

Scientific EffectFluid dynamic bearing: Hydrodynamic Cavitation

Data Source

PatentUS9857285B2Environmental sensor and method of operating the same

Publication Date: 2018.01.02 VENTUREDYNE LTD

AI summary

A gaseous-fluid environmental sensor having a gaseous-fluid flow system that defines a flow path coupling an intake port to an exhaust port. The gaseous-fluid flow system includes a blower and a flow sensor. The blower includes a motor and the flow sensor senses a flow-related parameter. The gaseous-fluid environmental sensor further includes a battery, an electrical sensor sensing an electrical power-related parameter, and a controller electrically coupled to the electrical sensor, the flow sensor, and the motor. The controller is configured to generate a composite drive waveform having a first component based on the sensed flow-related parameter and a second component based on the sensed electrical power-related parameter. The controller is further configured to drive the motor using the composite drive waveform. Also disclosed is a method of controlling the gaseous-fluid environmental sensor.