06 October, 2003

DYSON REINVENTS THE ELECTRIC MOTOR

Dyson Engineers Develop Small, High-Speed, Intelligent, and Carbon-Free Motor – “X020”

Dyson engineers have developed a fast, intelligent and carbon-free motor codenamed X020. With a power-to-weight ratio equal to that of a Ferrari sports car engine, X020 is the first ultra-high speed switched reluctance motor to incorporate turbocharger aerodynamics and aerospace materials. X020 has no brushes, no magnets and no commutator. It is up to three-times faster and much smaller than a typical vacuum cleaner motor. Though on a smaller scale, X020’s development is comparable to the step-change of the jet engine over the propeller in the aerospace industry.

X020’s embedded software gives it diagnostic capabilities and allows the motor to manage energy efficiently and safely – much like an engine management system in a car. The software also houses the motor’s ‘DNA’ – for example, build date, usage and owner information, all of which can be simply and quickly communicated to a call centre by holding a telephone handset to the device port or via the internet.

“We wanted to overcome the problems associated with existing motors, specifically brush, commutator and magnet failures,” said Simeon Jupp, Director of Research, Design and Development at Dyson. “X020 has its origins in switched reluctance motor technology, but with its speed, size and diagnostic capabilities, it takes the science to a new level - X020 has the potential to be the brain and the brawn behind Dyson innovations of the future.”

X020 was

developed over six years by a team of UK mechanical, electrical, electronic, aeronautical, materials and software engineers. X020 has several patents pending and has innovative features and advantages over conventional switched reluctance motors:

Speed:

  • At 100,000 rpm, X020 is spinning over five times faster than a Formula 1 engine (19,000 rpm)
  • X020 is the fastest and highest power density motor ever developed for domestic appliances
  • X020 derives efficiency from its high tolerances. For example, its impeller spins at over 600mph with only 0.3mm – around the thickness of a business card - between the blade tip and the impeller housing
  • The motor makes up to 1,666 revolutions every second. At this speed, the X020 control system needs to pulse the motor with energy four times per revolution: this translates into over 400,000 signals, decisions and power pulses every minute or 6,666 every second
  • It uses a three-dimensional compressor fan similar to those used in turbochargers, and runs at 2½-3 times the speed of a conventional centrifugal fan
  • X020 has increased Airwatts compared to conventional domestic appliance motors – from 300 AW to 400 AW, a 33% increase

Intelligence:

  • X020 has a 128 byte memory chip to run diagnostic tests and enhance performance
  • Dyson is currently researching the use of X020 technology in future innovations. For example, if X020 were to be used in a Dyson appliance, data could be transferred from the machine to Dyson via a telephone or Internet connection. Information including serial data, warranty status and usage data could be downloaded immediately ensuring even more efficient customer service for Dyson owners
  • 2,000 lines of code are used in the control software developed by Dyson engineers

Greener:

  • Being brushless, X020 has no polluting carbon emissions

Reliable:

  • Long life – X020 has a working life of over 1000 hours of constant use and is able to operate in ambient temperatures of up to 35C
  • Soft Start – X020’s full speed is reached in 1.5 seconds, reducing in-rush current and preventing blown trips
  • Fault diagnosis and protection features ensure safety and longevity

Lightweight:

  • X020 weighs 1000g compared to 1300g for a typical vacuum motor, giving it an excellent power to weight ratio
  • During development, Dyson engineers reduced the X020’s rotor by 50%, making the rotating assembly weigh less than 100g

Materials and Manufacturing Techniques:

  • X020 has a turbocharger style-3D impeller optimised for performance
  • X020’s impeller is made from PEEK, a material made with carbon fibre reinforcement and normally used in aerospace engineering. PEEK has been used in the wing construction of fighter aircraft
  • The impeller is aerodynamic. Its blades are continuously curving in all three dimensions. There is barely a straight 2D section to any part of the blade surface. Even previous aerospace & automotive 3D style impellers have had straight sections towards the exit of the impeller, i.e. radial blade tips
  • X020 has a square motor core, saving material and giving a stronger structure
  • To reach such high tolerances Dyson engineers have worked jointly with a bearing manufacturer to develop an exclusive ball bearing for high-speed applications similar to those used in precision measuring equipment and guidance systems
  • Dyson engineers spent 18 months researching aerodynamics, mechanical structure, vibration, electronic control, software, and manufacturing techniques. This relied on computer simulation to optimise the design

Notes to Editors:

  • Dyson has a team of over 350 engineers, scientists and industrial designers based in the UK who are innovating continually to develop new technology for the home
  • PEEK™ is a trademark of Victrex PLC

For further information please contact the Dyson Press Office:

T: 0207 833 8244

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