The solid polycarbonate body of the brush roller is nearly indestructible, high speed balanced and uses thread catchers on each end to prevent debris from entering the axel. The solid core design prevents warpage that leads to excessive vibration and noise, while the steel and bronze bushings provide lifetime wear resistance and protection from dirt and dust in the roller ends. The brush roller operates in a sealed "dirty air" cavity that is filled with negative pressure that moves debris which has been beaten, swept and pushed by the roller. In the "clean air" area of the nozzle the rollers' sprocket connects to the brush to the motor by a geared belt drive.
The geared brush roller and the geared motor are connected by a reinforced high strength geared belt. Like most quality powered nozzles, the EBK360 has a nonslip drive system that directly transfers the power of it's 250 watt brush motor. Unlike powered nozzles using flat rubber belts the EBK360 can provide ultra high speed operation, resulting in superior performance, not possible in rubber belted units. The EBK360's brush motor is also new with some very impressive features. Each end of the motors armature (spinning rotor) is carried in a full size 8mm sealed high speed ball bearing, the same sized used in many vacuums main motors. The armature also has 24 individual commutator bars, double that of most power nozzle motors, resulting in better heat dissipation and longer life. The frame of the motor is a steel skeleton instead of the usual plastic clam shell. The steel frame provides both strength and heat dissipation, the later of which is provided by a full diameter cooling fan.
In a departure from standard design the brush roller motor is protected from overheating ny use of a thermal link which is banded to the motors copper windings. The thermal link automatically severs power to the motor when a set temperature is reached and reconnects power when the motors temperature falls below a safe level. Primary cooling is provided by the motors own full diameter cooling fan which pulls clean air from under the nozzle hood to wash over the motor while running. Not content to rely solely on the motors built in cooling fan, Wessel-Werk provides an elegant engineering solution to secondary cooling for the brush motor. Within the intake throat (the dirty air side) of the nozzle housing a small port is opened and ducted across a slot and into the motor compartment and the belt drive compartment.
Using a small bit of the vacuums suction, cool air is moved through hidden vents at both rear wheels. The cool clean airflow is carried over the motors commutator and brushes where significant heat is generated. Cool clean air is also pulled through the compartment housing the brush roller sprocket, geared belt and motor pulley keeping the area both clean of debris and cool from the forces of friction. All of the critical heat generating components of the EBK360 are provided continuous cooling when connected with the vacuum system, even when the brush motor is not running. A design such as secondary brush cooling is inconceivable to vacuum cleaner manufacturers just makes common sense to a vacuum cleaner nozzle manufacturer.
The vacuum cooling and cleaning chamber is just one of the many unique features in the new EBK360, but the innovation our staff liked the most may not be something that you would immediately recognize as significantly important. The cleaning power of the EBK360 carpet nozzle is derived from it's powerful, high speed geared belt driven brush roller. Geared belt systems require control hardware and firmware to protect the motor from jamming in the brush and properly regulate performance. Like most other geared belt drive system the EBK360 will shut down the motor if an obstruction blocks the brush from spinning. If you accidently vacuum a sock into the nozzle the control system will shut down the brush in less than a second. Once you remove the obstruction and restart the powerbrush the control circuit will reset and your ready to clean - no harm, no foul.
These vacuum control systems consist of many components and most often the parts are soldered to a circuit board. Diodes, potentiometers, resisters, regulators, sensors and breakers on a match-book sized circuit board formed the heart of the geared belt control system. Most everyone whom has taken an electromechanical device in for repair has heard the words "It's the control board". Soldered circuit control boards are not the most reliable components, particularly inside the harsh environment of a vacuum powerbrush. The EBK360 has for the first time done away with the "circuit control board".
Fewer parts with lower replacement cost and higher reliability are now provided in a conectorized environment within the EBK360. In addition to the motor mounted self-resetting thermal breaker, a single circuit self-resetting overload protector takes the place of old fashioned mechanical push-button circuit breakers and sensors. To assure proper activation of the circuit protector and eliminate EMI feedback from the motor an inline electronic noise suppressor smooths out the power delivered to the system. That's it., the entire control system is held in two external modules with inline connectors. We never like circuit control boards in power nozzles, that's why the new electrical system in the EBK360 is our favourite new feature.
The same common sense engineering solutions are applied to other areas inside the power brush including the height adjuster which uses a steel reinforcement bar inside the step-on pedal to work with steel lever in the nozzle base to move the adjuster. Incredible engineering goes into every aspect of designing and using the EBK360 powerbrush right down to the rear wheels. Most other nozzle systems use a plastic axel inserted or molded as part of the wheel. The EBK360 uses a steel axel with a floating wheel the gives the nozzle easy movement and lifelong wear in a part that is often a problem for other nozzles after just a few years or normal use.
We can get an overall idea of engineering within the EBK360 by looking at the last component under the powered nozzles hood, the steel counter balance plates. While no other power nozzle manufacturer has ever considered the need to balance the weight of the motor inside the nozzle, Wessel-Werk never considered the idea of not doing so. Experience through Tradition - Performance through Innovation This is the culture of design at Wessel-Werk.
Some central vacuum cleaner companies make their own powered nozzle and it is only a smaller part of the larger machine they must produce to have a complete product offering. Wessel-Werk makes only vacuum nozzles. Each nozzle is the complete machine and the singular concern of Wessel-Werk. Every nozzle design is built to stand on it's own and increase the efficiency of the vacuum system it's customer (the vacuum cleaner manufacturer) connects it to.
In the mind of a Wessel-Werk nozzle design engineer the brushing performance, noise profile, reliability and ease of usage are all calculations based on a balanced nozzle design. An unbalanced nozzle may exhibit higher wear on one side of the brush roller or may pull the nozzle to one side during operation. Without the counter weight, side cleaning could be negatively effected, an unwelcome noise could be introduced or airflow may be shifted resulting in lower efficiency in part of the nozzle. These small deficiencies may matter very little to the manufacturer building a suction canister power unit, but are unacceptable to the manufacturer obsessed with a singular goal of building the worlds finest vacuum nozzle.
This is the reason why Wessel-Werk remains the worlds premier vacuum nozzle manufacturer. Engineering details have consequences for cleaning system performance, something often overlooked by vacuum manufacturers building those bright shinny portable vacuums who seem more concerned with winning the beauty contest on store shelves (Sorry Dyson!).