1) Conventional barrel vacuum cleaners can be difficult to maneuver, often colliding with obstacles or drifting in unintended directions. 2) Dyson engineers sought to apply the ball shape to a barrel vacuum cleaner to improve maneuverability, but faced challenges in integrating the internal components within a spherical shape. 3) Through extensive prototyping and testing, including tracking vacuum paths around corners, the engineers were able to create a ball-shaped barrel vacuum cleaner that follows the user in a smooth, controlled manner without snagging or toppling over obstacles.

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3. Heavy to pull
Snag Topple
Uncontrollable
Conventional barrel vacuum cleaners can be awkward – heavy to
pull, head the wrong way and collide with obstacles. Some drift
about on casters and others use wheels that oversteer. It can be a
constant battle to keep your machine moving in the direction that
it should. You zig-zag around, twisting behind to check that your
machine is following.

4. “ aving an idea is different to the infinitely
H
harder and longer process of invention.”
James Dyson
Inventor of Dyson cyclone technology
Timeline showing the development of the Dyson Ball™ barrel vacuum cleaner
from idea to finished product.

5. Placing an axle in the ball without
compromising its manoeuvrability.
To make a manoeuvrable barrel vacuum cleaner,
Dyson engineers first needed to go back to basic
engineering principles.
A ball is a very manoeuvrable shape. It can pivot
360° on the spot and rotate in any given direction.
It is perfectly symmetrical and has no edges or corners.
A ball is also efficient - no other shape with the same
surface area has as great an interior volume. And
all points on the surface are the same distance
from the centre.
How could Dyson engineers apply the ball shape to
a barrel vacuum cleaner? The challenge had begun.

6. Ways of reducing rolling resistance
on the axle.
Fitting the internal components of a barrel
vacuum cleaner inside a ball – the motor,
cable rewind and filter.
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7. 1 2 3 4 5 6 7
DYSON BALL™ VACUUM
A A
B B
Spring loaded cuff
C C
Acts as a shock-absorber –
re-aligning the machine to
keep it on course when pulled.
D D
E E
Controlled steering F F
A ball is a very manoeuvrable shape, but a steering
mechanism is needed to stop it from free rolling.
A good starting point is Ackermann steering geometry.
G G
The principles of Ackermann steering geometry are used 44° 27°
in most road vehicles to prevent the wheels from slipping
sideways when following the path around a curve.
H H
To get true Ackermann steering, the steering wheels
have to be at right angles to the centre of the turning
circle. Therefore the inner wheel has a greater angle Articulating chassis
Moves in the direction of the user.
to turn than the outer wheel. I Steering is smooth and controlled. I
Centre of turning circle
J J
1 2 3 4 5 6 7
Fully functioning prototypes
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8. Prototyping
When they’re developing a new machine, Dyson engineers make
a lot of prototypes. Building prototypes helps them to quickly get
a feel for how a design is working, and uncovers subtle design
flaws that aren’t apparent on a computer screen.
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9. Follows obediently
-100
Radial Pull Rig Test Results
The data shows a clear difference between
the path taken by a Dyson Ball™ barrel Dyson Ball™ Competitor
vacuum cleaner, and a competitor
barrel vacuum cleaner. -50
Dyson engineers created the ‘Radial Pull Rig Test’ to simulate the
short interrupted tugs around a corner experienced by a barrel
CORNER
vacuum during cleaning. They tested a range of barrel vacuum -150 -100 -50 0 50 100 150
cleaners, tracking their position using an overhead camera.
The data was plotted and analysed for smoothness and the
repeatability of the path followed by each barrel vacuum cleaner.
50
100
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10. Stable and light to pull
To help with the development of Dyson Ball™ barrel vacuum cleaners, Dyson engineers
devised the ‘Cornering Pull Test’. In this test, a vacuum cleaner is placed on one of nine
marked squares, and then pulled around the corner at a constant speed.
Stability and manoeuvrability were key considerations during the development of
Dyson Ball™ barrel vacuum cleaners. Geometry, materials, mass and the position of
the centre of gravity were all fine-tuned to deliver the desired result.
Dyson engineers also set up a ‘Set Pull Rig Test’ and used a digital force gauge to
determine the force needed to pull a Dyson Ball™ barrel machine. The ball’s smooth
underside and axle bearings help reduce friction with the floor surface. The result?
A barrel vacuum cleaner that is light to pull.
Design complete and frozen
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11. +
Project transferred to Malaysia – engineering drawings and validation completed
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12. Question. Test. Develop.
For the past 20 years, Dyson engineers have found ways
of improving their cyclone technology. Fine-tuning vortex finders
for greater cyclonic efficiency. Diffusing pressure drop to reduce
energy consumption. Every angle and dimension interrogated.
1993
Dual Cyclone™ technology
Frustrated with bagged vacuum cleaners
clogging and losing suction, James Dyson
set out to invent something better. 5 years and
5,127 prototypes later he had it – the first
cyclonic vacuum cleaner with no loss of suction.
2001
Radix Cyclone™ technology
By replacing DC01’s large inner cyclone
with several smaller ones, Dyson increased
vacuum cleaner suction by 45%.
2008
Radix Cyclone™ technology +
intermediate cyclone
An intermediary cyclone removes 50%
of dust down to 0.7 microns in size (that’s
James Dyson’s original cyclone technology sketch. 1/1000th of a pin head). The result is
a boost in cyclone efficiency.
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13. Controlling
aerodynamic flow
Airflows colliding in the cyclone Air leaks into seams
cap create turbulence
Sharp edges restrict flow
Suction is created by drawing air through the vacuum cleaner at Dyson cyclones capture more dirt than any other. Dyson Ball™
speed. Cyclone components are designed to separate dust particles, barrel vacuum cleaners have Radial Cyclone™ technology.
while maintaining air velocity. Competitor vacuum cleaner cyclone The cyclone components have been designed to reduce air
systems lose air pressure when the flow is restricted by tight bends, pressure losses and maintain airflow velocity throughout the
leaky seams or air turbulence. The slower the airflow through the cyclone pack. Simplified ducting and fewer obstacles and tight
machine, the less efficient the cyclones are at separating dust. bends have reduced turbulence and ensured smoother air
movement. Suction is maximised and high levels of dust
separation are maintained.
Engineering builds and FRACAS completed
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14. Radial Cyclone™
technology
The latest cyclone technology from Dyson. Reconfigured air channels and
improved flow efficiency reduce turbulence and preserve air pressure, so the
inner cyclones can extract more microscopic particles.
These refinements help remove more dirt, dust, allergens and pet hair
from the airflow.
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15. “ e look at every detail: how machines move,
W
how people use them, how to reduce raw
materials while staying strong. The priority
is always the same – improvement.”
James Dyson
Inventor of Dyson cyclone technology
Start of production
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16. 1 2 3 4 5 6 7
A A
No loss of suction. No awkward moves.
B B
C C
D D
E E
F F
G G
H H
I I
J J
1 2 3 4 5 6 7
LAUNCH
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