Ceiling fan motor adapter

Abstract

A method and apparatus for mounting a ceiling fan motor to a structure by mounting a motor shaft to a downrod with a motor adapter. The motor shaft mounts to the motor adapter with a press-fit. The motor shaft can extend beyond the motor adapter press-fit within the motor adapter such that the extended portion of the motor shaft can be swaged to provide a mounting redundancy. The motor can be encased with a motor housing, such that the motor adapter minimally extends from the motor housing, obstructing the motor adapter from view. The downrod can insertably mount to the motor adapter with a snug fit reducing fan wobble and with a set screw inserted along a ratcheting fastener to secure loosening of the set screw. A cap is slidably disposed over the downrod to cover the portion of the motor adapter extending beyond the motor housing.

What is claimed is: 
     
         1 . A ceiling fan comprising:
 a motor having a motor shaft with the motor shaft having an outer diameter;   a plurality of blades coupled to the motor;   a downrod having an outer diameter and a pair of downrod mounting apertures;   a mounting fastener; and   a motor adapter defining a cavity having an inner diameter and a pair of fastener apertures;   wherein the motor shaft is located within the cavity and the outer diameter is greater than the inner diameter to form a press-fit connection between the motor shaft and the motor adapter, and the mounting fastener passes through the pairs of downrod mounting apertures and the fastener apertures.   
     
     
         2 . The ceiling fan of  claim 1  further comprising a motor housing encasing the motor and mounted to the motor adapter. 
     
     
         3 . The ceiling fan of  claim 2  wherein the motor housing is mounted to the motor adapter. 
     
     
         4 . The ceiling fan of  claim 3  further comprising a cap slidably disposed around the downrod wherein the cap slides along the downrod to cover the motor adapter extending above the motor housing. 
     
     
         5 . The ceiling fan of  claim 1  wherein the cavity further comprises an upper cavity and a lower cavity. 
     
     
         6 . The ceiling fan of  claim 5  wherein the outer diameter of the downrod is about 0.005 inches smaller than the diameter of the upper cavity. 
     
     
         7 . The ceiling fan of  claim 5  wherein the press-fit connection is defined by the outer diameter of the motor shaft being greater than the diameter of the lower cavity by about 0.0005 inches. 
     
     
         8 . The ceiling fan of  claim 5  wherein the motor shaft extends through the lower cavity and into the upper cavity. 
     
     
         9 . The ceiling fan of  claim 8  wherein an end of the motor shaft extending into the upper cavity is swaged. 
     
     
         10 . The ceiling fan of  claim 9  wherein the swaged end of the motor shaft defines a lip. 
     
     
         11 . The ceiling fan of  claim 1  further comprising a ratcheting fastener disposed adjacent to and extending partially over at least one of the fastener apertures. 
     
     
         12 . The ceiling fan of  claim 11  wherein the mounting fastener comprises a threaded portion and the ratcheting fastener threadably receives the threaded portion. 
     
     
         13 . The ceiling fan of  claim 1  further comprising a weep hole disposed within the motor adapter providing fluid communication between the cavity and a space external of the motor adapter. 
     
     
         14 . A method for mounting a ceiling fan having a motor shaft, a motor adapter, and a downrod to a structure, the method comprising:
 press-fitting the motor shaft into the motor adapter;   inserting the downrod into the motor adapter;   fastening the downrod to the motor adapter; and   securing the downrod to the structure.   
     
     
         15 . The method of  claim 14  further comprising ratcheting a fastener to secure the downrod to the motor adapter. 
     
     
         16 . The method of  claim 14  further comprising securing a motor housing to the motor adapter. 
     
     
         17 . The method of  claim 14  further comprising swaging the motor shaft within the motor adapter. 
     
     
         18 . The method of  claim 17  wherein swaging the motor shaft and press-fitting the motor shaft occur during the same action. 
     
     
         19 . A method of coupling a motor shaft to a motor adapter for a ceiling fan with a reciprocating fixture, the method comprising:
 attaching the motor adapter to a first fitting on the fixture;   attaching the motor shaft to a second fitting on the fixture;   press-fitting a portion of the motor shaft within the motor adapter by reciprocating the fixture; and   swaging an end of the motor shaft within the motor adapter.   
     
     
         20 . The method of  claim 19  wherein the swaging and press-fitting occur at the same time. 
     
     
         21 . A machining fixture to couple a motor shaft to a motor adapter for a ceiling fan, the machining fixture comprising:
 a frame including an upper plate and a lower plate slidably coupled to one another by opposing rods;   a motor adapter mount assembly provided on the upper plate including a hub to receive the motor adapter; and   a motor shaft mount assembly provided on the lower plate including a central aperture to receive the motor shaft;   wherein the upper plate is actuable along the rods to press fit the motor shaft provided in the motor shaft mount assembly to the motor adapter provided in the motor adapter mount assembly.   
     
     
         22 . The machining fixture of  claim 21  further comprising a swaging finger extending from the hub to swage an end of the motor shaft during press-fitting of the motor shaft to the motor adapter. 
     
     
         23 . The machining fixture of  claim 21  further comprising springs provided on the opposing rods. 
     
     
         24 . The machining fixture of  claim 21  further comprising a controller operatively coupled to the machining fixture for automating actuation of the upper plate. 
     
     
         25 . The machining fixture of  claim 21  wherein the motor adapter mount further comprises a bearing for securing the attached motor adapter to the motor adapter mount assembly.