One-piece fan hub casting and method of manufacturing a fan

Abstract

A hub assembly for constructing a fan includes a hub plate having a front surface, a back surface, and an annular surface extending between the front surface and the back surface. The hub plate defines a hub assembly axis extending through the front surface and the back surface, the hub assembly axis configured to coincide with the fan axis. The hub assembly further includes a plurality of elongated root portions circumferentially spaced about the annular surface and extending radially from the annular surface. The elongated root portions have a substantially circular cross-section. The hub plate is integrally formed with the plurality of elongated root portions.

Description

Technical Field

[0001] This patent disclosure generally relates to fans, and more specifically to fan hubs and methods of manufacturing fans. Background Technology

[0002] A fan can be a complex structure with many components that need to be assembled. A fan typically includes a hub from which multiple fan blades extend. In use, rotational input is provided to the hub via an adapter or bushing. In particular, the hub design can be a complex structure including many machined surfaces and bolted connections. Furthermore, because fans are used in a variety of applications requiring different connection arrangements and blade angles, a large inventory of components may be needed to meet the needs of various fan designs.

[0003] Ideally, fan designs should be constructed to avoid resonance at normal operating speeds. Furthermore, fan designs should prevent bending or oscillation at normal operating speeds. The challenges of manufacturing and assembling fans can be amplified in the production of large or heavy-duty fans. While large fan designs require sufficient rigidity and strength to withstand the forces exerted during use, they are still subject to weight and cost constraints.

[0004] Chinese utility model CN200978831 discloses a cast aluminum fan hub, which includes a central bushing 5 surrounded by a hub plate 4 with a hub ring 3. Multiple blade mounting plates 1 extend from the hub ring. Fan blades 7 are then mounted to the blade mounting plates using bolts 6. Summary of the Invention

[0005] In one aspect, the invention describes a hub assembly for constructing a fan comprising a plurality of fan blades, the fan being configured to rotate about a fan axis. The hub assembly includes a hub plate having a front surface, a rear surface, and an annular surface extending between the front and rear surfaces. The hub plate defines a hub assembly axis extending through the front and rear surfaces and configured to coincide with the fan axis. The hub assembly further includes a plurality of elongated root portions that are circumferentially spaced and extend radially from the annular surface. These elongated root portions have a substantially circular cross-section. The hub plate is integrally formed with the plurality of elongated spokes.

[0006] In another aspect, the present invention describes a method for manufacturing a fan configured to rotate about a fan axis. The method includes forming an integral hub assembly comprising a generally circular hub plate and a plurality of circumferentially spaced elongated root portions extending radially from the hub plate. The method further includes machining the plurality of elongated root portions to form corresponding radially extending root mounting surfaces, and attaching a plurality of fan blades to the respective radially extending root mounting surfaces.

[0007] In another aspect, the present invention describes a method for manufacturing a custom fan configured to rotate about a fan axis. The method includes providing an integral hub assembly comprising a substantially circular hub plate and a plurality of elongated root portions extending radially from the hub plate, the elongated root portions having substantially circular cross-sections. The method further includes providing a selected plurality of fan blades. The method further includes machining the plurality of elongated root portions to form corresponding radially extending root mounting surfaces arranged at desired chord angles / cord angles, and attaching the selected plurality of fan blades to the respective radially extending root mounting surfaces. The method further includes machining an axial bore along the hub assembly axis of the integral hub assembly, pressing a selected bushing including a central mounting hole into the axial bore, and securing the bushing in the axial bore. According to this method, the selected plurality of fan blades, the chord angle of the radially extending root mounting surfaces, and the selected bushing determine the operating characteristics of the custom fan. Attached Figure Description

[0008] Figure 1 This is an isometric view of an exemplary fan according to the teachings of the present invention.

[0009] Figure 2 yes Figure 1 A partial exploded view of the fan.

[0010] Figure 3 This is an isometric view of a fan hub casting according to the teachings of the present invention.

[0011] Figure 4 yes Figure 1-3 Isometric view of the front surface of the fan hub assembly.

[0012] Figure 5 yes Figure 1-4 A partial enlarged view of an exemplary root portion of the fan hub assembly.

[0013] Figure 6 yes Figure 1-5 Partial equidistant cross-sectional view of the fan hub assembly.

[0014] Figure 7 yes Figure 1 An isometric view of an exemplary fan blade. Detailed Implementation

[0015] This invention relates to fans, and more specifically to an arrangement and method for customizing a fan 100 according to the needs of a particular application. (See also...) Figure 1This illustrates a fan 100 comprising multiple fan blades 102 coupled to a fan hub assembly 104. (Example) Figure 2 As most clearly shown, the hub assembly 104 includes a hub plate 106 from which a plurality of elongated root portions 108 extend. These elongated root portions 108 are circumferentially spaced and generally extend radially from the hub plate 106. Fan blades 102 are mounted to each elongated root portion 108 to form a fan 100. The hub plate 106 defines a hub assembly axis 110 that coincides with the fan axis in use. That is, the fan 100 can be mounted to rotate about the fan axis defined by the hub assembly axis 110.

[0016] According to one aspect of the invention, the hub assembly 104 is an integral structure. While the hub assembly 104 can be manufactured by any suitable method and from any suitable material providing sufficient strength and stability, in at least one embodiment, the hub assembly 104 is cast from a metal such as aluminum or a metal alloy. However, those skilled in the art will appreciate that alternative manufacturing methods, such as 3D printing, can be utilized.

[0017] According to another aspect of the invention, the hub assembly 104 can be used in constructions of various fan sizes and designs. For this purpose, the hub assembly 104 is formed as a universal hub casting 114, such as... Figure 3 As shown. The hub casting 114 is a generally planar structure comprising a cast hub plate 116 from which a plurality of cast elongated root portions 118 extend radially. As used herein, the terms “hub casting 114,” “cast hub plate 116,” and “cast elongated root portions 118” refer to the respective structures manufactured by casting, 3D printing, or other suitable manufacturing methods, which may be machined to form a hub assembly 104 that can be used in a variety of fan sizes and / or designs. For the purposes of this invention, the finished hub assembly, hub plate, and elongated root portions are indicated by reference numerals 104, 106, and 108, respectively, while the hub casting, hub plate, and elongated root portions of the hub casting are indicated by reference numerals 114, 116, and 118, respectively. That is, finished components are labeled with 10X numbers, while components in progress are labeled with 11X numbers.

[0018] The cast wheel hub plate 116 is a substantially circular structure comprising a front surface 120 and a rear surface 122, with a substantially annular surface 124 extending between the front surface 120 and the rear surface 122. To enhance the strength of the cast wheel hub plate 116 without significantly increasing its weight, the cast wheel hub plate 116 may include a thickened region 126 adjacent to the wheel assembly axis 110. In the illustrated embodiment, for example, the thickened region 126 includes, for example, raised reinforcements 128 along the front and / or rear surfaces 120, 122 of the cast wheel hub plate 116.

[0019] Similarly, to enhance the strength of the cast wheel hub plate 116 without significantly increasing its weight, the cast wheel hub plate 116 may include a plurality of reinforcing ribs 130. While the reinforcing ribs 130 can be of any suitable design, in the illustrated embodiment, the reinforcing ribs 130 may include a plurality of radially arranged ribs 132 along the front and / or rear surfaces 120, 122. At least a portion of the radially arranged ribs 132 may be arranged to coincide with the radial protrusions of the elongated root portions 118. In the illustrated embodiment, for example, the radially arranged ribs 132 are configured to coincide with the radial protrusions of each elongated root portion 118.

[0020] The reinforcing rib 130 may additionally or alternatively include one or more annular ribs 134 arranged along the front and / or rear surfaces 120, 122. The illustrated cast wheel hub plate 116, for example, includes a pair of annular ribs 134. A first annular rib 136 is arranged along the front and / or rear surfaces 120, 122, generally adjacent to the annular surfaces 124 of the cast wheel hub plate 116. Thus, the first annular rib 136 can provide additional strength and reinforcement for the support of the elongated root portion 118. In the illustrated embodiment, a second annular rib 138 is arranged along the front and / or rear surfaces 120, 122 between the first annular rib 136 and the thickened region 126 or the raised reinforcement 128, adjacent to the hub assembly axis 110.

[0021] To facilitate the use of the hub casting 114 in the manufacture of various fan sizes and designs, the elongated root portion 118 of the casting has a thickened cross-section 140. Thus, the cast elongated root portion 118 can be machined to provide the desired cross-section 142 suitable for mounting the fan blades 102, thereby providing easily customizable fan designs. In the illustrated embodiment, for example, the cast elongated root portion 118 has a substantially circular cross-section 140. Figure 4 and Figure 5 As shown in the enlarged partial view, the cast elongated root portion 118 can be machined to provide an elongated root portion 108 having one or more radially extending root mounting surfaces 144, 146. The radially extending root mounting surfaces 144, 146 can be configured to provide a desired chord angle 148 for mounting fan blades 102, which are configured to provide a customized fan design. For the purposes of this invention, the chord angle 148 is the angle between a generally flat surface of the hub casting 114 and the radially extending root mounting surfaces 144, 146. Therefore, it should be understood that the chord angle 148 can be used to define the pitch of the blades mounted to the elongated root portion 108.

[0022] To facilitate the attachment of the fan blade 102 to the completed elongated root portion 108, the cast root portion 118 may be further machined to facilitate the attachment of the fan blade 102 to the completed elongated root portion 108. In the illustrated embodiment, for example, one or more root portion holes 150 may be drilled into the elongated root portion 118. However, it should be understood that alternative arrangements for attaching the fan blade 102 to the elongated root portion 108 may be provided.

[0023] To further facilitate the use of hub casting 114 in the manufacture of various fan sizes, designs, and applications, the cast hub plate 116 of hub casting 114 can be machined to allow the fan 100 to be coupled to a given drive element, such as an electric motor (not shown). In this manner, the cast hub plate 116 can be machined to include an axial hole 152 along the hub assembly axis 110. This axial hole 152 can be configured for mounting a bushing 154. Figure 2 The bushing can be pressed into the axial bore 152 to mount the fan to a drive element, etc. It should be understood that the bushing 154 can be a standard size configured to engage with a drive element, etc. To further secure the bushing 154 to the hub plate 106, the cast hub plate 116 can be machined to provide a plurality of plate holes 156 around the axial bore 152. Figure 2 As shown, multiple plate holes 156 can be drilled to coincide with multiple bushing holes 158, allowing fasteners 160 to advance through bushing holes 158 and be secured within plate holes 156. It should be understood that fasteners 160 can be of any suitable design. For example, fasteners 160 can be bolts, rivets, etc.

[0024] These fan blades 102 can have any suitable design and can be manufactured by any suitable manufacturing method (e.g., molding or extrusion). See reference. Figure 7By way of example only, the fan blade 102 may have an elongated, relatively flat structure. It should be understood that the chord angle 148 of the root mounting surfaces 144, 146 largely determines the angle of the fan blade 102 when coupled to the elongated root portion 108. These fan blades 102 may be coupled to these elongated root portions 108 in any suitable manner. In the illustrated embodiment, for example, the fan blade 102 includes a housing 162 defining an outer surface of the fan blade 102. The fan blade 102 also includes an elongated, longitudinally extending blade aperture 164. The longitudinally extending blade aperture 164 includes at least one blade mounting surface 166 configured to conform to at least one of the corresponding radially extending root mounting surfaces 144, 146 of the plurality of elongated root portions 108. In the illustrated embodiment, the elongated, longitudinally extending blade aperture 164 closely aligns with the machined, elongated root portion 108, such that the fan blade 102 includes a plurality of blade mounting surfaces 166 (i.e., the cross-section of the root portion 108 substantially corresponds to the shape of the longitudinally extending blade aperture 164). While the blade mounting surfaces 166 shown are arranged internally in the illustrated embodiment, those skilled in the art will understand that in alternative embodiments, the blade mounting surfaces may be arranged along the outer surface of the fan blade. In other words, instead of utilizing the blade aperture 164 extending longitudinally through the interior of the fan blade 102, the fan blade 102 may include mounting surfaces (not shown) along the outer surface of the blade, configured to engage the root mounting surfaces, such as those shown at 144 or 146.

[0025] It should be understood that the fan blade 102 may further include an end cap 167. While the end cap 167 may be integrally formed with the housing 162, alternatively, the end cap 167 may be coupled to the housing 162 by any suitable arrangement. For example, in the case of an extruded housing 162, the separately formed end cap 167 may engage with the longitudinally extending blade aperture 164 or the end of the housing 162.

[0026] To further secure the fan blade 102 to the elongated root portion 108, the fan blade 102 may further include a plurality of blade holes 168. Root portion holes 150 may be configured to be arranged in a straight line with the blade holes 168. Therefore, it is understood that a stock of fan blades 102 with pre-drilled blade holes 168 of preset, standardized dimensions (e.g., length and width) can be maintained to construct various fan designs. These elongated root portions 108 of the fan hub assembly 104 may be machined to include root portion holes 150 configured to be arranged in a straight line with the blade holes 168. In this way, the cast hub plate 116 can be further customized for a given application. Fasteners 170 may advance through the blade holes 168 and be secured within the root portion holes 150. It should be understood that fasteners 170 can be any suitable design. For example, fasteners 170 may be bolts, rivets, etc.

[0027] Industrial applicability

[0028] Some embodiments of the integral hub casting 114 can provide flexibility to facilitate the manufacture of custom fan designs. For example, some embodiments facilitate the use of fan blades 102 of desired size, and the arrangement of fan blades 102 at a desired chord angle 148 for a given application.

[0029] Some embodiments can minimize the number of parts required to assemble fan 100. For example, some embodiments can facilitate the use of standardized components, such as standardized bushing 154 and / or standardized fan blade 102 designs.

[0030] Some embodiments may offer certain economic advantages, including economic advantages in manufacturing fan 100 and economic advantages in inventory costs. Some embodiments of the integral hub casting 114 can be manufactured economically while allowing for design flexibility in the resulting fan 100. Some embodiments of the fan hub assembly 104 and the resulting fan 100 can provide sufficient rigidity and strength for the fan 100 at a reasonable cost.

[0031] It should be understood that the foregoing description provides examples of the disclosed systems and techniques. However, it is conceivable that other implementations of the invention may differ in detail from the foregoing examples. All references to the invention or examples thereof are intended to refer to the specific examples discussed at that point and are not intended to imply any limitation on the scope of the invention in a more general sense. All distinctions and inconsistencies in language regarding certain features are intended to indicate a lack of preference for those features, but not to exclude them entirely from the scope of the invention, unless otherwise specified.

[0032] In the context of describing the invention (particularly in the context of the appended claims), the use of the terms “a” and “an,” as well as “the,” “at least one,” and similar indicators, should be interpreted to cover both the singular and the plural, unless otherwise stated herein or obviously contradicted by the context. The use of the term “at least one” following a list of one or more items (e.g., “at least one of A and B”) should be interpreted to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise stated herein or obviously contradicted by the context.

[0033] Unless otherwise stated herein, descriptions of numerical ranges herein are intended only as a shorthand for individually referring to each individual value falling within that range, and each individual value is incorporated into the specification as if it were described separately herein. All methods described herein may be performed in any suitable order unless otherwise stated herein or clearly contradicted by the context.

[0034] Therefore, this invention includes all modifications and equivalents of the subject matter described in the appended claims as permitted by applicable law. Furthermore, any combination of the foregoing elements in all possible variations is covered by this invention, unless otherwise stated herein or clearly contradicted by the context.

Claims

1. A hub assembly for constructing a fan comprising a plurality of fan blades, the fan being configured to rotate about a fan axis, the hub assembly comprising: A hub plate having a front surface, a rear surface, and an annular surface extending between the front surface and the rear surface, the hub plate defining a hub assembly axis extending through the front surface and the rear surface, the hub assembly axis being configured to coincide with the fan axis; Multiple elongated root portions, circumferentially spaced and extending radially from the annular surface, each elongated root portion having a substantially circular cross-section, wherein each of the multiple elongated root portions is machined to form two opposing radially extending root mounting surfaces arranged at a desired chord angle, wherein the fan blade includes elongated longitudinally extending blade apertures that coincide with the machined elongated root portions, such that the fan blade includes multiple blade mounting surfaces; The hub plate and the plurality of elongated root portions are integrally formed; At least one of the front surface and the rear surface includes a plurality of reinforcing ribs, the plurality of reinforcing ribs including a plurality of radially arranged ribs extending from the axis of the hub assembly; the plurality of radially arranged ribs respectively coincide with a radial protrusion of each of the plurality of elongated root portions.

2. The wheel assembly of claim 1, wherein the wheel plate includes a thickened region adjacent to the axis of the wheel assembly.

3. The wheel assembly of claim 2, wherein the thickened region includes a raised reinforcement along at least one of the front surface and the rear surface.

4. The wheel hub assembly of claim 1, wherein the plurality of reinforcing ribs comprises a plurality of annular ribs arranged around the axis of the wheel hub assembly.

5. The wheel assembly according to any one of claims 1-4, wherein the wheel plate and the plurality of elongated root portions are integral castings.

6. A method for manufacturing a fan according to any one of claims 1-5, the method comprising: To form an integrated wheel hub assembly; Each of the plurality of elongated root portions is machined to form two opposing root mounting surfaces that extend radially. as well as Multiple fan blades are respectively connected to corresponding radially extending root mounting surfaces, wherein the fan blades include elongated longitudinally extending blade holes that coincide with the machined elongated root portion, such that the fan blades include multiple blade mounting surfaces.

7. The method of claim 6, further comprising machining an axial hole along the hub assembly axis of the integral hub assembly, and pressing a bushing into the axial hole.

8. A method of manufacturing a custom fan configured to rotate about a fan axis, the method comprising: Provide an integral wheel hub assembly according to any one of claims 1-5; Offers a selection of multiple fan blades; Each of the plurality of elongated root portions is machined to form two opposing root mounting surfaces that extend radially and are arranged at a desired chord angle. Selected fan blades are respectively connected to corresponding radially extending root mounting surfaces, wherein the fan blades include elongated longitudinally extending blade holes that are consistent with the machined elongated root portion, such that the fan blades include multiple blade mounting surfaces. Machine axial holes along the axis of the integral wheel hub assembly; Press the selected bushing, including the center mounting hole, into the axial bore; and The bushing is fixed in the axial hole; The selected fan blades, the chord angle of the radially extending root mounting surface, and the selected bushing determine the operating characteristics of the custom fan.

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