The design of a solar table fan's oscillating mechanism must focus on the core objectives of "low-energy drive" and "stable transmission." By synergizing power source adaptation, simplified transmission structure, optimized motion constraints, and material selection, this approach reduces energy consumption while preventing stalling, drift, or loosening during oscillation, ensuring long-term reliability. Solar table fans rely on solar power, which has relatively limited energy output. Excessive energy consumption in the oscillating mechanism could deplete the fan's main motor, reducing wind power. Insufficient stability could lead to component wear due to long-term oscillation and even compromise overall structural safety. Therefore, the design must strike a precise balance between energy conservation and stable operation.
Low power consumption in the power source is fundamental to reducing energy consumption. Driver components must be selected that match the characteristics of solar power generation to avoid power redundancy. Micro permanent magnet DC motors or stepper motors are preferred as the drive motors for the oscillating mechanism. These motors have low starting current and low power ratings, adapting to the low voltage output of solar panels. They also maintain stable torque at low speeds, eliminating the need for additional boost or power amplifier modules, reducing energy losses in intermediate links. The motor's output torque is precisely matched to the load of the oscillating mechanism, requiring only the minimum torque required to rotate the oscillating components (connecting rod and fan head bracket). Overpowered motors are avoided, preventing energy waste caused by "a large horse pulling a small cart." Furthermore, the motor control circuit incorporates a low-power start-stop module, energizing only when the oscillating function is enabled and completely shutting off when disabled, eliminating standby power consumption and further reducing energy consumption.
The simplified transmission structure reduces energy losses during transmission and improves transmission stability. The oscillating mechanism typically utilizes a simple "motor-gear-connecting rod" transmission path, avoiding complex multi-stage transmissions (such as multiple gear meshing sets or worm gears). Multi-stage transmissions increase energy consumption due to inter-part friction, and the greater the number of parts, the greater the risk of instability caused by accumulated assembly errors. The gear transmission features an optimized tooth profile design, utilizing gears with a smaller module and a smoother tooth surface. This reduces friction during meshing and minimizes energy loss. Interference fits or set screws are used to secure the connections between the gear and the motor shaft, and between the gear and connecting rod shaft, to prevent looseness and transmission backlash. This ensures that the motor's output power is fully transmitted to the connecting rod, eliminating wasted energy. The connecting rod drive utilizes a single main connecting rod with an auxiliary support rod. The main connecting rod drives the fan head, while the auxiliary support rod limits radial deflection. This reduces the number of components and, through a two-point constraint, prevents oscillation during oscillation, balancing energy efficiency and stability.
Optimizing the motion constraints and limiter structures is key to ensuring stability, preventing excessive rotation, deflection, or jamming during oscillation. Precision bushings or miniature bearings are installed on the oscillation mechanism's rotating shaft. Bushings are made of wear-resistant engineering plastics or self-lubricating materials, while low-friction miniature ball bearings are used. This ensures smooth, non-sticking rotation over extended use, avoiding increased energy consumption and unstable rotation due to excessive friction. The connection between the connecting rod and the fan head bracket features a universal joint structure, allowing for slight angular compensation and minimizing transmission stalls caused by assembly errors or component deformation. The hinge pin is constructed of high-strength metal with a rust-resistant surface treatment to prevent increased play due to long-term wear and prevent loosening or unusual noise during oscillation. Furthermore, the oscillation angle limiter incorporates an elastic buffer design, such as a soft rubber pad wrapped around the stop block. When the oscillation reaches its maximum angle, the rubber pad cushions the impact, preventing deformation caused by hard collisions and excessive energy consumption from motor overload.
Detailed energy-optimization design must be integrated throughout the entire mechanism's motion, reducing inefficient energy consumption through precise control. The oscillation mechanism incorporates intermittent oscillation control logic, rather than continuous, constant oscillation. Based on user needs, the oscillation mechanism can be programmed to rotate at fixed intervals (e.g., every few seconds or more than ten seconds), stopping at the set angle. The motor is powered only during the rotation phase and disconnected during the stop phase. This significantly reduces motor operating time and energy consumption compared to continuous oscillation. The fan's oscillation speed is also adjusted in tandem with the fan's blade speed. When the fan is in a low speed setting (lower energy consumption), the oscillation speed is reduced, avoiding energy mismatches between high and low speeds. When the fan switches to high speed, the oscillation speed is increased appropriately, ensuring that the wind coverage and oscillation rhythm are aligned, thus minimizing energy waste. Furthermore, the lightweight design of the mechanism's moving parts reduces inertial energy consumption. For example, the connecting rod and fan head bracket are made of high-strength, lightweight engineering plastics (such as ABS and PC alloy), replacing traditional metal materials. This reduces the mass of moving parts and reduces inertial resistance during motor startup and shutdown, thereby reducing energy consumption. Furthermore, lightweight materials offer improved shock absorption, reducing vibration transmission during oscillation and improving stability.
Adapting material properties can balance energy consumption and stability, requiring a balance between lightweight, wear resistance, and rigidity. In addition to using lightweight engineering plastics for moving parts, the mechanism's fixed frame (such as the bracket connecting the base and fan head) is constructed from reinforced plastic or thin-walled metal extrusions to ensure sufficient rigidity and prevent deformation during oscillation, which could lead to transmission misalignment. Highly wearable parts (such as pins and bushings) are constructed from wear-resistant alloys or surface-hardened materials to extend service life and reduce the increase in clearance caused by component wear, thereby preventing decreased stability and increased energy consumption. Furthermore, the environmental resistance of the materials must be considered. If the solar table fan is used outdoors, the metal components of the oscillating mechanism must be rust-proofed, and the plastic components must be made from UV-resistant materials to prevent degradation from prolonged exposure to sunlight and rain. This ensures long-term stable operation and avoids abnormal energy consumption or stability issues caused by component failure.
Controlling assembly precision and debugging processes is crucial to ensuring design performance and can reduce energy waste and stability risks caused by assembly problems. The machining of the oscillating mechanism's components strictly controls dimensional tolerances, especially for transmission components (such as gear pitch and connecting rod length) to prevent transmission jams or lost motion caused by dimensional deviations. Positioning fixtures are used during assembly to ensure alignment of the centerlines of the motor shaft, gears, and connecting rods, minimizing additional friction caused by assembly deviations. After assembly, dynamic commissioning is performed, adjusting the motor's output torque, connecting rod length, or limit stops to ensure smooth, seamless oscillation and precise oscillation angles. Energy consumption is also tested under various operating conditions to ensure minimal energy consumption while maintaining stable oscillation. Ultimately, through comprehensive optimization of the design, materials, and assembly processes, the dual goals of low-energy operation and long-term stability were achieved for the solar table fan's oscillating mechanism.
