Support module for a fan, and fan having a support module

Abstract

The invention relates to a support module for a fan, in particular for a centrifugal fan or diagonal fan, which comprises a motor and a fan impeller wheel which is rotatingly driven by the motor, for fastening the fan impeller wheel between an inflow-side nozzle plate and a support plate which is opposite the nozzle plate at a distance, the motor being mounted, together with the fan impeller wheel, approximately centrally on the support plate so as to be rotationally fixed, and being held on the nozzle plate by means of struts extending between the support plate and the nozzle plate, the support plate having a flow-guiding outer region and an inner connection region for fastening the stator of the motor, and an axial offset being defined between the regions. A fan is equipped with a corresponding support module.

Description

[0001] SUPPORT MODULE FOR ONE FAN AND FAN WITH ONE SUPPORT MODULE

[0002] The invention relates to a support module for a fan comprising a motor and a fan impeller driven by the motor, particularly for a radial or diagonal fan. The support module serves to secure the fan impeller between an inflow-side nozzle plate and a support plate spaced apart from the nozzle plate. The motor and the fan impeller are mounted on or in the support plate in a rotationally fixed manner and are held to the nozzle plate by struts extending between the support plate and the nozzle plate.

[0003] Furthermore, the invention relates to a fan with a corresponding support module.

[0004] Essentially, this is a support structure used to mount a motor with a fan impeller. The motor and fan impeller are usually attached to a support plate on the support structure. While the motor is mounted on the support structure with its stator in a rotationally fixed manner, the fan impeller rotates with the motor's rotor. The support plate of the support structure with the motor and fan impeller is mechanically connected to the nozzle plate, which usually includes an inlet nozzle, and is thus held to the nozzle plate. This is usually done using struts that extend between the support plate and the nozzle plate. These are fastening elements in the broadest sense that space the nozzle plate from the support plate and stabilize the arrangement with the fan impeller located between them. By providing the struts, the arrangement of the previously discussed components can be understood as a structural unit.

[0005] Support modules, each with a support plate at the level of the stator-side motor mounting plane, are known in practice. Since the flow-carrying part of the support plate is quite far from the impeller outlet, these support modules result in efficiency losses. It is also already known in practice to shift the stator-side mounting plane toward the impeller. This applies particularly to compact designs. However, this has the disadvantage of blocking the motor rotor in radial or diagonal impellers.

[0006] As an example, reference is made to DE 10 2020 200 363 A1 for the state of the art.

[0007] The invention is based on the object of providing an efficiency-enhancing support module for radial or diagonal fans. This support module should be simple in design and assembly. Furthermore, it should be cost-effective and resource-efficient to manufacture. Furthermore, it should differentiate itself from competitive products.

[0008] Furthermore, a radial or diagonal fan with a corresponding support module should be specified.

[0009] The above object is achieved with respect to the support module by the features of claim 1. According to this, the support plate has a flow-guiding outer region and an inner connection region for fastening the motor, wherein an axial offset is defined between the regions.

[0010] With regard to the fan according to the invention, the object is achieved by the features of the independent claim 19.

[0011] To achieve increased efficiency with special compact support modules, a defined position of the flow-guiding support plate of the support module is advantageous, particularly axially, and should not be too far away from the flow outlet on the base plate side of the impeller. However, in many radial or diagonal fans with external rotor motors, the connection plane is located axially quite far from the outlet on the base plate side in order to minimize blocking effects of the motor rotor in the impeller. Therefore, this plane does not represent a suitable position for the flow-guiding support plate of the support module if maximum efficiency is to be achieved. This represents a "stalled" development and even a prejudice among experts. The essential features of the invention can be described as follows:

[0012] The invention comprises the development of a support plate with an axial offset between a flow-guiding outer region and the motor mounting plane. In sheet metal construction, the axial offset is advantageously created by folded sections of the main sheet metal, with a resulting opening in the central region of the support plate advantageously being covered with covers, for example, in the form of one or more cover plates.

[0013] The support plate can advantageously be stiffened with stiffening brackets that are screwed or riveted on, especially in the case of heavy engines.

[0014] A cooling fan wheel, which serves to cool the motor, can advantageously be arranged outside the main flow area assigned to the impeller, i.e. axially beyond the flow-guiding area of ​​the support plate.

[0015] Advantageously, the stiffening brackets are designed to minimize their interaction with the airflow from the engine's cooling fan. The stiffening brackets can be recessed in an axial area at the level of the cooling fan.

[0016] In plastic solutions for the support plate, the struts are injected or screwed in place. Reinforcing elements such as ribs, honeycombs, or similar elements are integrated into the back of the plastic plate. Additional metal parts such as stiffening brackets can also provide strength for a plastic part.

[0017] In advantageous embodiments, the struts (support struts) can serve an aerodynamic function in the downstream area of ​​the impeller; in particular, they can be designed with a profiled cross-section similar to that of an airfoil. For example, such struts can contribute to increasing static efficiency. Furthermore, it is conceivable to implement the axial offset between the flow-guiding outer area and the motor mounting plane with an adapter made of cast iron or sheet metal, for example, a plate-like adapter.

[0018] There are now various possibilities for advantageously embodying and developing the teachings of the present invention. For this purpose, reference is made, on the one hand, to the claims subordinate to claim 1 and, on the other hand, to the following explanation of preferred embodiments of a support module according to the invention with a fan according to the invention, based on the drawings. In conjunction with the explanation of the preferred embodiments of the invention based on the drawings, generally preferred embodiments and developments of the teachings are also explained. The drawings show:

[0019] Fig. 1 shows a perspective view from the downstream side of an embodiment of a fan according to the invention with a support module according to the invention, which has an optimized support plate,

[0020] Fig. 1 b is an enlarged section of Fig. 1 in the area of ​​the motor connection to the support plate,

[0021] Fig. 2 in perspective view from the inflow side the fan according to Fig. 1 ,

[0022] Fig. 3 shows the fan from Fig. 1 and 2 in a side view,

[0023] Fig. 3b is an enlarged section of Fig. 3 in the area of ​​the motor connection to the support plate,

[0024] Fig. 4 in a side view of a section on a plane through the axis and perpendicular to the offset areas in the support plate, the fan according to Figures 1 to 3, Fig. 4b an enlarged section of Fig. 4 in the area of ​​the motor connection to the support plate,

[0025] Fig. 5 in a side view of a section through the axis and parallel to the offset areas in the support plate, the fan according to Figures 1 to 4,

[0026] Fig. 5b an enlarged section of Fig. 5 in the area of ​​the motor connection to the support plate,

[0027] Fig. 6 In a section on a plane approximately perpendicular to its longitudinal direction or approximately perpendicular to the fan axis, a strut of an embodiment of a support module designed with a profiled cross-section,

[0028] Fig. 7 shows a perspective view from the downstream side of another embodiment of a fan with a support module according to the invention with an optimized support plate, wherein stiffening brackets are designed which have freed-up areas towards the main plate,

[0029] Fig. 8 shows the fan from Fig. 7 in a side view,

[0030] Fig. 9 shows a perspective view from the downstream side of another embodiment of a fan with a support module according to the invention with an optimized support plate, wherein the cover plates have a folded area,

[0031] Fig. 10 shows a perspective view from the downstream side of another embodiment of a fan with a support module according to the invention with an optimized support plate, wherein the cover plates have a folded area with a rounded outer edge, Fig. 11 shows a perspective view from the downstream side of another embodiment of a fan with a support module according to the invention with an optimized support plate, wherein additional, narrow offset areas are provided,

[0032] Fig. 12 shows a perspective view from the downstream side of another embodiment of a fan with a support module according to the invention with an optimized support plate, wherein the support plate with the flow-guiding area and the motor connection area is manufactured integrally in a casting process,

[0033] Fig. 13 in a side view on a section through the axis, the fan according to Figure 12,

[0034] Fig. 14 shows a perspective view from the downstream side of another embodiment of a fan with a support module according to the invention with an optimized support plate, wherein the support plate has a motor mounting adapter to which the motor is attached with its stator,

[0035] Fig. 15 in a side view of a section on a plane through the axis, the fan according to Figure 14.

[0036] Fig. 1 shows an embodiment of a fan 29 with an embodiment of a support module 1 in a perspective view seen from the downstream side. In a central area, the fan impeller 3 can be seen, advantageously of radial or diagonal design, which is essentially made up of a base plate 9 (see Fig. 2), a cover plate 19 and blades 18 extending between them. On an upstream side facing away from the viewer in Fig. 1, the inlet nozzle 2 attached to a nozzle plate 5 can also be seen. The inlet nozzle 2 can be a separate component and fastened to the nozzle plate 5, or formed integrally with the nozzle plate. The fan 29 can be installed or fastened to a higher-level system.Advantageously, the fan 29 is attached with its nozzle plate 5 to a higher-level system, such as an air handling unit or a cooling device, for example, for a data center. For this purpose, fastening devices 17, such as holes for screws or rivets, are provided on the nozzle plate 5.

[0037] The nozzle plate 5 advantageously has a beveled area 22 on its outer region, where the sheet metal of the nozzle plate 5 is bent, advantageously towards the impeller 3. The beveled area 22 improves the dimensional stability of the nozzle plate 5, the aerodynamic stability properties of the fan 29 and also provides a certain degree of protection from the potentially sharp outer edge of the nozzle plate 4. An axial bevel height of the beveled area 22 of 3% - 8% of the largest diameter of the impeller 3 has proven to be ideal.

[0038] In addition to the nozzle plate 5, the support module 1 consists in particular of the support plate 6 and 3 to 12 (advantageously 4, 6, or 8) lateral struts 8, which are arranged radially outside (downstream) of the flow outlet from the fan impeller 3. In the exemplary embodiment, the struts 8 are designed with a cross-sectional contour similar to that of an airfoil profile and are therefore sometimes referred to below as profile struts 8.

[0039] In other embodiments, the struts can also have a different design, for example simply as a tube or rod or as a sheet metal support with an L- or U-shaped cross-section or similar.

[0040] When the fan 29 is in operation, the impeller 3, driven by a motor 4, rotates about its axis and transfers power to a fluid flowing through the impeller 3. The fluid is first sucked in through the inlet nozzle 2, then passes through a central opening in the cover plate 19 (see Fig. 2, 4) into the impeller 3, where it flows past the blades 18 before initially exiting the impeller 3 radially outwards, then flows further radially outwards past the struts 8 before exiting the fan 29 approximately radially outwards. The motor 4 is attached to the support module 1 with its stator 24. The impeller 3, in turn, is attached to the rotor 23 (see Fig. 4) of the motor 4, which is mounted on the stator 24. Thus, the impeller 3 is also held indirectly to the support module 1 via the motor 4. The support module 1 is therefore advantageously designed to be particularly dimensionally stable (rigid), for example in order to withstand increased vibration values ​​that can occur during operation due to the support module 1 orthe fan 29 comes into vibration resonance, or to prevent the impeller 3 from grazing the inlet nozzle 2 as a result of undesired deformations during operation.

[0041] The struts 8 are advantageously made of extruded profiles and, more preferably, of aluminum. The arrangement of the struts 8, in this case eight, continuously rotates around the fan axis and is always rotated at a certain angle to each other, thus covering all angular positions from 0° to 360° relative to any reference point approximately evenly, allows for very good rigidity of the support module 1.

[0042] It has been shown that it can be advantageous to use a specifically optimized number of struts to optimally adjust the natural frequencies of a particular fan with the corresponding support module. For example, different, individually adjusted numbers of struts can be used depending on the motor, size, impeller, or higher-level device.

[0043] In an advantageous implementation, a support module with 8 struts is provided, in which 2 or 4 of the struts are omitted depending on the vibration-related requirements, for example the upper and lower ones, seen from the downstream side, or every second of the struts.

[0044] The design of the support plate (6) has proven to be particularly important for achieving maximum efficiency.

[0045] The design of support plate 6 is crucial. In this example, it is advantageously made predominantly of sheet metal, in this case sheet steel. A sufficient sheet thickness is selected, for example, 4 mm to 6 mm for a wheel diameter of 500 mm - 630 mm.

[0046] In the exemplary embodiment, the support plate 6 is designed as a sheet metal construction. The main element of the support plate 6 is the main sheet 7, which, in the formed state, defines the entire circumferential contour of the support plate 6 by means of its radial outer edge 33.

[0047] In the exemplary embodiment, the outer folds 27 are integrated into the main sheet 7 of the support plate 6. These serve primarily to stiffen the support module 1. Here, they are only attached to two partial areas of the radial outer edge, advantageously to the more vertically extending ones. Depending on the design or stiffness requirements, such folds may not be implemented at all, may be implemented in partial areas of the radial outer edge 33, or may extend over the entire circumference 33.

[0048] The main sheet 7 also features fastening devices 26 for attaching the struts 8. These may include, in particular, holes to which the struts 8 are screwed into their front ends. Prefabrication of the fastening devices or drill holes 26 on a processing machine ensures precise, easy assembly of the struts 8 to the support plate 6.

[0049] For the design of the support plate 7 in the area of ​​the motor 4, reference is also made to the enlarged detailed illustration in this area in Fig. 1 b.

[0050] The offset regions 10 are also integrated as a single piece into the main sheet metal 7 of the support plate 6. The offset regions 10 are particularly advantageously achieved here by trimming the main sheet metal 7 in a central region 31 and suitable double folds with the corresponding trimmed regions, so that the motor 4 or its stator 24 with its stator flange 46 can be fastened in an axially offset position (away from the nozzle plate 5) relative to the radially outer regions of the support plate. In the exemplary embodiment, the offset regions 10 have an approximately Z-shape in cross-section. The integral production of the offset region 10 from the main sheet metal 7 by double folds in a central region 31 is also particularly material- and cost-saving.

[0051] The particularly advantageous configuration of the motor mounting plane being axially offset from a radially further outer section of the support plate 6 has proven to be particularly advantageous in terms of efficiency, material usage, and system rigidity. For example, the axial length of the struts 8 can be shortened, given a comparable axial position of the motor 4.

[0052] To avoid excessively large openings in the vicinity of the motor 4 or the central area 31 of the main sheet 7 of the support plate 6, which would result in efficiency disadvantages, cover plates 11 are advantageously installed. Fastening devices 37 are also provided for their attachment in the main sheet 7. A type of connecting tab and the use of screws are advantageous here. The cover plates can have very thin sheet thicknesses, e.g., 1-1.5 mm. They then also constitute part of the support plate 6.

[0053] As a result of the axial offset relative to the radially outer regions of the support plate 6, in particular the regions near the outer edge 33, the screw-on plane of the motor 4, to which the flange 46 of its stator 24 is fastened to the corresponding outer end of the offset region 10 by means of a fastening device 39 provided there, the motor projects axially rearward (away from the nozzle plate 5) beyond the other regions of the main plate 7 as well as beyond the cover plates 11. The cooling system of the motor 4, comprising in particular the cooling fins 47 integrated on the stator flange 46 and the cooling fan impeller 48 fastened to the rotor 23 of the motor 4 and rotating during fan operation, can now be located on the side of the support plate 6 facing away from the impeller 3, as in the exemplary embodiment.This can be advantageous for motor cooling, for example, if the fluid temperature on the side of the support plate 6 facing the impeller is higher than on the rear side facing away from the impeller 3. In the exemplary embodiment, the cover plates 11 are located axially approximately at the level of the rotor 23 of the motor 24, here advantageously designed as an external rotor motor. This makes it necessary to provide a gap between the cover plates 11 and the rotor 23 of the motor 4 to prevent streaks. The gap forms a leakage channel 35 between the support plate 6 or its cover plates 11 and the rotor 23 of the motor, through which leakage flow typically flows from the outside to the inside due to pressure differences during operation of the fan 29. Since this flowing leakage fluid absorbs heat from the cooling system of the motor 4, particularly from its cooling fins 47, this is advantageous for motor cooling.

[0054] Cable connections 32 are provided on the motor 4, its stator 24, and in the area of ​​the integrated control electronics. The protrusion of the motor 4 with an axial offset from the main areas of the support plate 6 makes cable connection particularly easy.

[0055] In the exemplary embodiment, the support plate 6 also has the stiffening brackets 12, which are attached to the main sheet 7 of the support plate 6 using fastening devices 38 provided there, e.g., by screws or rivets. Advantageously, the stiffening brackets run approximately vertically along the rear side of the support plate 6 when installed. They serve, in particular, to increase the rigidity of the support plate 6 or the support module 1.

[0056] In the exemplary embodiment, eyelets 36 are provided on the stiffening brackets 12, to which, for example, the fan 29 or its support module 1 can be attached to a crane or the like for transport or assembly purposes.

[0057] In certain embodiments, it may also be advantageous to attach the stiffening brackets on the side of the support plate 6 or its main plate 7 facing the impeller 3.

[0058] The support plate 6 or the main sheet 7 have the chamfered corners 45 along their outer edge 33. Such a design has proven particularly advantageous in an installation situation of the fan 29 in which the fan is connected on the pressure side to a duct which has an approximately rectangular cross-section, or in which several fans are arranged parallel next to and above one another.

[0059] It is also conceivable that the outer edge 33 of the support plate 6 has a square, polygonal or even round or rounded shape.

[0060] Fig. 2 shows a perspective view of the fan 29 with support module 1 according to Fig. 1, viewed from the inflow side. The cover plate 19 of the impeller 3 can be seen through the inlet nozzle 2, which protrudes into a central opening in the cover plate 19 and through which the conveying fluid flows into the impeller 3 during fan operation. The inlet nozzle 2 can be attached to the nozzle plate 5 by means of fastening devices 49, as in the exemplary embodiment, or, for example, can be integrated into a nozzle plate as a single piece. It can generally be made of sheet metal or plastic.

[0061] One can also see here the fastening provisions 25 for fastening the struts 8 to the nozzle plate 5, typically holes for screws with which the struts can be fastened in a similar way to the support plate.

[0062] The view according to Fig. 2 shows the side of the support plate 6 facing the impeller 3 or its base plate 9. This side, particularly in a radially outer region near the outer edge 33 of the support plate 6, has a fluidic effect during operation of the fan 29 and contributes to its particularly high efficiency. This is because this radially outer region, the flow-guiding region 28 of the support plate 6, advantageously guides the flow exiting the impeller 3 during fan operation, possibly in interaction with the struts 8. Thus, the support plate 6 also has a fluidic, efficiency-enhancing effect, and to some extent also a noise-reducing effect.

[0063] Fig. 3 shows a side view of the fan 29 with the support module 1 according to Figs. 1 and 2, whereby reference is also made to the detailed illustration in Fig. 3b in the area of ​​the motor 4 and the offset area 10 of the support plate 6. The flow-guiding area 28 of the support plate 6 faces the impeller 3 and is opposite its base plate 9. The axial distance (distance measured in a direction parallel to the axis of rotation of the impeller 3) between the flow-guiding area 28 and the impeller 3 or base plate 9 is small in the area of ​​the flow outlet from the impeller 3 at the radially outer edge of the base plate 9. It has proven crucial that this distance must be selected to be sufficiently small in order to achieve maximum efficiency. In concrete terms, a distance of less than 15% based on the maximum diameter of the impeller 3 has proven necessary and advantageous.

[0064] It is therefore advantageous if the flow-guiding region 28 of the support plate 6 is located axially closer to the impeller 3 or its base plate 9 than the screwing plane of the motor between the flange 46 of its stator 24 and the offset region 10 of the support plate 6. As a result of the design of the offset region 10, which has a type of Z-shape in cross-section, the required small axial distance between the flow-guiding region 28 of the support plate 6 and the impeller 3 or its base plate 9 is realized.

[0065] It can be clearly seen that the main cooling system of the motor 4, consisting in particular of the cooling fins 47 integrated on the flange 46 of the stator 24 and the cooling fan wheel 48 fastened to the rotor 23 of the motor 4, is located with an axial projection on the side of the support plate 6 facing away from the impeller 3.

[0066] In the exemplary embodiment, the cooling fan impeller 48 of the motor 4 or its rotor 23 projects axially beyond the stiffening brackets 12 in a direction facing away from the impeller 3. This is particularly advantageous because the flow flowing out of the cooling fan impeller 28 can flow radially outward largely unhindered, at least where the outflow is not obscured by the offset region 10.

[0067] Fig. 4 shows a side view of the fan 29 with support module 1 according to Figures 1 to 3, taken along a plane through the rotational axis of the impeller 3 (axis) and perpendicular to the offset regions 10 in the support plate 6. The motor 4 with its stator 24 and rotor 23 is not shown in section for the sake of clarity. Fig. 4b is an enlarged detailed view of Fig. 4 in the area where the motor 4 or its stator 24 is connected to the support plate 6.

[0068] It is initially clearer than in the previous illustrations how the inlet nozzle 2 protrudes into a central opening in the cover plate 19 of the impeller 3, so that the inflowing fluid flows through the inlet nozzle 2 into the impeller 3 during operation. The inlet nozzle 2 forms a radial gap 44 with the surrounding cover plate 19, whereby it must be ensured that a strip cannot occur between the cover plate 19 and the inlet nozzle 2 during operation. This requires a sufficiently dimensionally stable, rigid design of the support module 1, so that the impeller

[0069] 3 is mounted with the motor 4 via the struts 8 and the support plate 6 with a largely fixed relative position to the nozzle plate 5 or inlet nozzle 2.

[0070] The offset regions 10 are integrally integrated into the main sheet 7 of the support plate 6. In cross-section, the offset regions 10 have an approximately Z-shape. Thus, the offset regions 10 of the main sheet 7 of the support plate 6 serve to connect the motor 4 or its stator 24 to its stator flange 46, with a radial outer region 28 of the support plate 6 or, in this case, its main sheet 7, performing advantageous fluidic functions.

[0071] A central flow channel 35 (leakage channel 35) is formed between the rotor 23 of the motor 4 and the support plate 7, which, however, is rather minimized by the cover plates 11, for example, the gap 35 is less than 10 mm wide.

[0072] The stiffening brackets 12 shown in the embodiment run transversely to the viewing plane.

[0073] The axial position of the motor 4 results from the objective of maximizing the efficiency of the fan 29. For this purpose, the rotor 23 of the motor

[0074] 4 has been placed so far to the left in the view that it does not exert an efficiency-reducing blocking effect inside the impeller 3 within its blades 18. Because the rotor 23 of the motor 4 is not arranged in the flow area within the impeller blades 18, the impeller blades 18 can extend radially very far inward with their leading edges, since a possible collision with the rotor 23 of the motor 4 does not have to be considered. This is advantageous for the efficiency and low noise generation during operation of the fan 29.

[0075] The placement of the motor 4 or its screwing plane on the stator flange 46 axially offset from the impeller 3, in such a way that the rotor 23 does not protrude, or only slightly, beyond the base plate 9 into the impeller, is thus per se a measure to increase the efficiency of the fan 29 and reduce its noise emissions. At the same time, also for efficiency reasons, the flow-guiding region 28 of the support plate 6 should not be located too far axially offset from the impeller 3 or the radially outer edge of the base plate 9. Such decoupling of the axial position of the flow-guiding region 28 of the support plate 6, rather at a radially outer region in the region of the radially outer edge 33 of the support plate 6, and the motor connection region of the support plate 6 in the region of the stator flange 46 is therefore particularly advantageous.

[0076] In the exemplary embodiment, the axial positional decoupling of the flow-guiding region 28 and the motor connection region in the region of the stator flange 46 is achieved by the design of the offset region 10, which is thus decisive for the construction of a fan 29 with maximum overall efficiency.

[0077] The impeller 3 is connected to the rotor 23 of the motor 4 by means of fastening devices 50 (Fig. 4b), which can be designed in a variety of ways.

[0078] The cooling fins 47 on the flange 46 of the stator 24 of the motor 4 and the rotating cooling fan 48 are arranged radially within the offset region 10 of the support plate 6, at least as seen in the sectional view shown, thereby providing a certain degree of shielding of the cooling flow flowing radially from the cooling fan 48. However, viewed in the viewing direction (depth direction), this shielding is not present (see also Fig. 5), so the outflow is not problematically inhibited.

[0079] In conjunction with the leakage channel 35, through which a flow is induced as a result of pressure differences, which promotes the cooling effect, a particularly advantageous engine cooling can be realized.

[0080] Fig. 5 (for a detailed illustration in the area of ​​the motor 4, see Fig. 5b) shows the fan 29 with support module 1 according to Figures 1 to 4 in a side plan view of a section on a plane through the axis of rotation of the impeller 3 (abbreviated to: axis) and approximately parallel to the offset areas 10 in the support plate 6. It can be clearly seen in this view that in particular the cooling fan wheel 48 projects axially over the stiffening brackets 12 in a direction away from the impeller, whereby a trouble-free outflow of the cooling fan flow in the radial direction is at least not hindered by the stiffening brackets.

[0081] A measuring nipple 30 is provided on the inlet nozzle 2 for pressure tapping in a narrow cross-section of the inlet nozzle 2.

[0082] Fig. 6 shows an advantageous embodiment of a strut 8 of possible embodiments of a support module (1), as seen in a section along a plane approximately perpendicular to its longitudinal direction or approximately perpendicular to the fan axis, such as that shown in Figs. 1-5. As far as the outer contour is concerned, the strut 8 has a cross-section similar to that of an airfoil, which is why such a strut 8 can also be referred to as a profile strut. It has a rounded leading edge region 40 (inflow edge region 40) on the outer contour, and the outer contour tapers off rather thinly towards its trailing edge region 41 (outflow edge region).

[0083] However, the trailing edge region 41 is advantageously sufficiently thick so that a structure consisting of two wall thicknesses of the aluminum material with a remaining intermediate region (cavity) can still be implemented relatively far up to the trailing edge region, at least up to 90% of the profile length in cross-section, measured from the leading edge 40. The leading edge region 40 and the trailing edge region 41 are connected to each other at the outer contour by a suction side 42 and a pressure side 43. The suction side 42 is typically more convexly curved.

[0084] An imaginary, symbolically represented straight chord 51 connects the center of the leading edge 40 with the center of the trailing edge 41. The outer contour is clearly not symmetrical to this profile chord 51; in particular, the suction side 42 does NOT result from a reflection of the pressure side 43 on the profile chord 51. Thus, an imaginary profile centerline (centerline between the suction side 42 and the pressure side 43) has a curvature or camber; one says that the profile strut 8 is curved in cross-section.

[0085] Struts 8 are advantageously not solid in their interior, but rather characterized by a structure made up of thin walls with a largely constant wall thickness, which has cavities. Such an embodiment is also shown in Fig. 6. The wall thicknesses of the profile struts 8, which are advantageously manufactured using the extrusion process and advantageously from an aluminum alloy, are kept constant over a wide range and are advantageously between 0.5 mm and 2 mm. This allows for a material-saving lightweight construction, and the manufacturing process functions ideally. Nevertheless, as far as the outer contour is concerned, a relatively thick cross-section with a highly variable thickness profile can be realized if necessary.

[0086] The walls, which form the pressure side 42 on the one hand and the suction side 43 on the other hand, are advantageously connected and mutually supported at several points over the length of the profile cross-section, which leads to a very stable and dimensionally rigid property of the profile strut 8.

[0087] In the exemplary embodiment of a strut 8, as in the embodiment according to Fig. 6, fastening devices 25, 26 are provided for fastening the profit struts 6 to a nozzle plate 5 or a support plate 6, respectively, which partially simultaneously connect the walls of the suction side 46 and the pressure side 43. During assembly of the support module 1, suitable, advantageously self-tapping screws can now be screwed into the front side of the struts 8.

[0088] The fastening areas 25, 26 on the strut 8 are open circles in cross-section (and not closed circles) so that no cracks occur when screwing in.

[0089] Struts 8, especially profile struts, are advantageously manufactured by the meter using the extrusion process and can be cut to size for mounting a support module. This allows the struts to be used flexibly for support modules with different strut lengths simply by cutting them to the appropriate length. Thus, support modules for various impellers, for example, can be manufactured using a single extrusion tool for struts.

[0090] Fig. 7 shows a perspective view from the downstream side of another embodiment of a fan 29 with a design of a support module 1 with an optimized support plate 6, wherein stiffening brackets 12 are provided which have cut-out areas 14 towards the main sheet 7. Otherwise, the embodiment shown is very similar to the embodiment according to Figures 1 to 5, which is why reference can be made to the descriptions of Figures 1 to 5 with regard to many features.

[0091] In the embodiment according to Fig. 7, the stiffening brackets 12 have the cutout areas 14. In the assembled state with the main sheet 7 of the support plate 6, elongated openings are formed in some areas between the main sheet 7 and the stiffening brackets 12. Cooling air flowing out of the cooling fan impeller 48 attached to the rotor 23 of the motor 4 can flow through these openings without being excessively deflected by the stiffening brackets 12.

[0092] Compared to the embodiment shown in Figs. 1 to 5, an axially shorter motor is used here. Therefore, the axial offset between the flow-guiding region 28 (see Fig. 8) on the one hand and the motor connection plane between the stator flange 46 and the offset region 10 on the other hand is less pronounced. As a result, the cooling fan impeller 48 has a different axial position compared to the embodiment shown in Figs. 1-5, namely closer to the cover plates 11 and also closer to the axial position of the flow-guiding region 28 of the support plate 8.

[0093] Fig. 8 shows a side view of the fan with support module 1 from Fig. 7. Due to the illustrated design with the cut-out areas 14, the stiffening brackets 12 have a greater overall axial extension. This does not impair the rigidity of the structure; on the contrary, the axially higher design actually increases rigidity.

[0094] Figure 8 clearly shows that the fluid flowing radially out of the cooling fan impeller 48 can flow unhindered through the cut-out areas 14, at least over large areas. This has proven to be very advantageous for cooling and also for the efficiency of the fan.

[0095] In the embodiment shown, suspension eyes 36 for fastening the fan 29, for example to a crane, are also integrated into the stiffening brackets 12.

[0096] It may also be advantageous to make the attachment eyelet in similar embodiments considerably larger and, for example, extend completely or almost completely to the main sheet 7, so that they also have a similar effect to the cut-out area 14, namely to improve the permeability of the stiffening brackets for cooling fan flows; but not least also to obtain a fan that is as light as possible.

[0097] Fig. 9 shows a perspective view from the downstream side of another embodiment of a fan 29 with another embodiment of a support module 1 with an optimized support plate 6, wherein the cover plates 11 have a folded region 52. The folded region 52 here runs approximately perpendicular to the main plate 7 and extends in the axial direction away from the main plate 7. In other embodiments, it can also extend obliquely to the main plate 7. In any case, on the side of the support plate 6 facing away from the impeller 3, it advantageously extends further away from the base of the cover plate or the flow-guiding region 28 of the support plate 6 than do the stiffening brackets 12, viewed in the axial direction, in a direction away from the impeller 3.Such a design can be advantageous because the folded regions 52 influence the fluid flowing out from the cooling wheel 48 of the motor 4 in a manner that is favorable for the efficiency of the fan 29.

[0098] In the embodiment according to Fig. 9, the cover plates 11 have an outer edge 53 due to their design with a folded region 52. This edge is advantageously designed with a corrugated profile.

[0099] Fig. 10 shows a perspective view from the downstream side of a further exemplary embodiment of a fan 29 with a further exemplary embodiment of a support module 1 with an optimized support plate 6, wherein the cover plates 11 have a folded region 52 and a rounded outer edge 53. The folded region 52 here runs obliquely to the main plate 7 and extends in the axial direction away from the main plate 7. Advantageously, on the side of the support plate 6 facing away from the impeller 3, it extends further away from the base of the cover plate or the flow-guiding region 28 of the support plate 6 than the stiffening brackets 12, as seen in the axial direction, in a direction away from the impeller 3.Such a design can be advantageous because the folded area influences the fluid flowing out from the cooling wheel 48 of the motor 4 in a manner that is favorable for the efficiency of the fan 29.

[0100] In the embodiment according to Fig. 10, the cover plates 11 have an outer edge 53 due to their design with a folded-over region 52. This edge is advantageously designed to be more rounded. This reduces the risk of injury during assembly and also reduces the risk of electrical cables chafing against the outer edge 53. Designing the cover plates with folded-over regions 52 as shown in Fig. 9 or Fig. 10 generally facilitates the assembly or disassembly of the cover plates 11, since they can be gripped more easily due to this design with the rounded outer edge 53.

[0101] Fig. 11 shows a perspective view from the downstream side of another embodiment of a fan 29 with another embodiment of a support module 1 with an optimized support plate 6 made of sheet metal, wherein, in addition to the offset regions 10 integrated into the main sheet metal 7, there are also narrower offset regions 10a that are integrated into the main sheet metal 7 in a similar way and have a Z-shaped contour in cross-section. The motor 4 or its stator 24 is fastened to the offset regions 10, 10a by its stator flange 46, for which fastening provisions 29 are provided there. Specifically, in the exemplary embodiment, the fastening provisions 29 are drill holes to which the motor 4 is fastened to the offset regions 10, 10a with screws.

[0102] In the embodiment shown in Fig. 11, no stiffening brackets are present. The stiffening effect of the offset regions 10 is sufficient for sufficient dimensional and vibration stability in this embodiment. For this reason, the approximately vertically extending offset regions 10 are designed to be quite long in the vertical direction.

[0103] In the exemplary embodiment, the attachment eyes 36 are advantageously integrated into the offset areas 10.

[0104] In embodiments with additional narrow offset regions 10a, it is advantageous if the cover plates 11 have additional recesses 54 in order to be able to be arranged past the narrow offset regions 10a and to cover the opening created inside in the main plate 7 as well as possible.

[0105] It is also conceivable that in designs without narrow offset areas no stiffening brackets are required or that their function can be taken over by suitable offset areas that are designed to be rather long in the vertical direction.

[0106] It is also conceivable that 3-8 identical, wide or narrow, offset areas are distributed over the circumference.

[0107] Fig. 12 shows a perspective view from the downstream side of a further embodiment of a fan 29 with an embodiment of a support module 1 according to the invention with an optimized support plate 6, wherein the support plate 6 is manufactured integrally in a casting process, preferably in plastic injection molding, with a flow-guiding region 28 facing the impeller 3 and a motor connection region with fastening provisions 39 for fastening a motor 4 or its stator 24.

[0108] It should also be expressly mentioned that, in similar designs, the support plate can be manufactured from die-cast aluminum.

[0109] The motor connection plane running perpendicular to the fan axis, characterized by the interface between flange 46 (Fig. 13) of the stator 24 and the support plate 6, is axially offset from the flow-guiding area 28, the axial position of which is characterized approximately by the outer edge 33 of the support plate 6, or by the axial position of the interface between the struts 8 and the support plate 6 (see Fig. 13).

[0110] In a cast construction, as in the exemplary embodiment, the advantageously required axial offset between the motor connection plane and the flow-guiding region 28 can be easily integrated into the integrally manufactured component of the support plate 6, which is also carried out here.

[0111] In order to achieve the required dimensional stability of the support plate 6 without requiring excessive wall thicknesses for the casting process, stiffening provisions 16 are advantageously formed on the outer side of the support plate 6 facing away from the impeller 3. In the exemplary embodiment, these are approximately honeycomb-shaped webs projecting from a base wall and having a suitable axial height relative to the base wall, for example, 15 mm to 50 mm.

[0112] Other forms of integrated stiffening measures on a cast support plate 6 are also conceivable, for example advantageously vertically extending ribs, fan-shaped structures, etc.

[0113] In the case of particularly heavy motors or impellers, i.e. in the case of particularly high requirements, it may also be advantageous to stiffen a support plate, in particular one cast from plastic, with stiffening brackets similar to those shown in Figures 1-10, which are then fastened to the support plate from the rear side of the support plate facing away from the impeller using appropriate provisions.

[0114] The struts 8, advantageously manufactured using the extrusion process, are fastened in the embodiment according to Fig. 12, quite similarly to the embodiments according to Figs. 1-11, advantageously by screwing from the rear side of the support plate 6 facing away from the struts 8 through appropriately provided fastening devices 26, in particular holes, into the end face of the struts 6. The struts can have a cross-sectional design similar to that shown in Fig. 6.

[0115] In further embodiments, it is conceivable to integrate the struts manufactured as extruded profiles into the plastic component in a hybrid casting process (plastic injection molding) (casting).

[0116] For small, lightweight fans, an integral one-piece production of the support plate 6 with the struts made of injection-molded plastic is also conceivable.

[0117] In the embodiment shown, the outer edge 33 of the support plate 6 has a round outline. A hexagonal or 12-sided outline is also conceivable.

[0118] Fig. 13 shows a side view of the fan 29 with support module 1 according to Figure 12 in a section along a plane through the axis. The sectional view clearly shows the axial offset between the flow-guiding outer region 28 of the support plate 6, near its outer edge 33 or near the interface of the support plate 6 to the struts 8, and the motor connection area, which is present at the interface between the stator flange 46 and the support plate 6.

[0119] It is advantageous if a flow-guiding region 28, as in the exemplary embodiment, is at least partially flat and runs perpendicular to the fan axis, because then the struts 8 can be cut straight, perpendicular to their longitudinal direction.

[0120] The cooling fan wheel 48 of the motor 4, which is attached to its rotor 23, runs in this embodiment on the side of the support plate 8 facing the impeller.

[0121] There is no leakage in the radial inner area between the side of the support plate 6 facing the impeller 3 and the side facing away from the impeller 3.

[0122] Even in variants with a cast support plate, it can be advantageous for engine cooling purposes to deliberately design leaks between the side of the support plate 6 facing the impeller 3 and the side facing away from the impeller 3 in order to enable effective cooling flows.

[0123] Regarding the interface between the support module 6 and the struts 8 in the flow-guiding area 28, it is particularly advantageous to provide recesses in the cast part of the support plate that correspond to the shape of the advantageously extruded struts 8. This ensures good guidance and centering of the struts 8 on the support plate 6. For example, the negative contour of the corresponding profile cross-section (see Fig. 6 as an example) can be provided as a recess for inserting the struts 8 on the support plate 6.

[0124] It may also be necessary to place metal discs between struts 8 and a plastic support plate 6 to prevent the profile struts 8 from "cutting" into the plastic over time. Overall, the embodiment shown in Fig. 12 and Fig. 13 also demonstrates a very resource- and cost-efficient design of a highly efficient support module 1 with a support plate 6 manufactured essentially integrally using a casting process.

[0125] Fig. 14 shows, in a perspective view from the downstream side, another embodiment of a fan 29 with an embodiment of a support module 1 with an optimized support plate 6, wherein the support plate 6 has a motor mounting adapter 13 to which the motor 4 is fastened with its stator 24 or its stator flange 46. The motor mounting adapter 13 is a separate component from the main plate 7 shown here, which is fastened to the main plate 7 by means of fastening devices 21, for example by rivets or screws.

[0126] Regarding an outer region, the outer edge 33, the flow-guiding part 28 facing the impeller 3 and the connection to the struts 8 by means of the fastening devices 26, the design of the main sheet 7 can be very similar to that according to Figures 1-10.

[0127] However, in the embodiment according to Figs. 14 and 15, the main sheet 7 terminates radially inward with a connection area to the motor mounting adapter 13, wherein fastening provisions 21 for fastening the motor mounting adapter 13 are also provided on the main sheet 7 in the inner area.

[0128] In the illustrated embodiment, the motor mounting adapter 13 is made of sheet metal. It must be manufactured using a forming technology, such as stamping, deep drawing, or rolling; folding alone would not be sufficient or would result in an unfavorable design.

[0129] The axial offset between the outer region at the outer edge 33 of the support plate 6 or the connection area of ​​the struts 8 with the support plate 6 or the flow-guiding area 28 and the motor mounting plane, to which the support module 6, here with the motor mounting adapter 13, is attached to the flange 46 of the stator 24 of the motor 4, must be created by the motor mounting adapter. This is why, for example, the "plate-like" or "truncated cone" cross-sectional shape of the motor mounting adapter is created (see Fig. 15).

[0130] In another embodiment, a motor mounting adapter can also be a cast part. In such a case, especially if it is cast from plastic, it can have stiffening structures such as ribs, raised honeycomb walls, or the like on the side facing away from the impeller, similar to the integrally manufactured support plate shown in Figs. 12 and 13.

[0131] A motor mounting adapter 13, as in the embodiment according to Figs. 14 and 15, simultaneously also represents a stiffening element for the support plate 6. In most cases, therefore, when using a mounting adapter, any additional stiffening brackets can be dispensed with.

[0132] In the embodiment according to Figs. 14 and 15, vertically extending outer edges 27 are provided on the support module 6 or its main plate 7.

[0133] Fig. 15 shows a side view of the fan 29 with support module 1 according to Figure 14, taken along a plane through the axis. The contour of the motor mounting adapter 13, which has the shape of a truncated cone in its main area, is clearly visible in the cross-section. Nearer the edge areas of the motor mounting adapter 13, the connection areas to the main plate 7 (radially outside) and to the flange 46 of the stator 24 of the motor 4 (radially inside) are formed.

[0134] The main cooling system of the motor 4 with the cooling fins 47 attached to the flange 46 of the stator 24 of the motor 4 and the cooling wheel 48 attached to the rotor 23 of the motor 4 is located entirely on the inner side of the support plate 6 facing the impeller 3.

[0135] There is no leakage in the radial inner area between the side of the support plate 6 facing the impeller 3 and the side facing away from the impeller 3. Even in variants with a support plate with a motor mounting adapter, it can be advantageous for motor cooling purposes to deliberately create leaks between the side of the support plate 6 facing the impeller 3 and the side facing away from the impeller 3 in order to enable effective cooling flows. For this purpose, the motor mounting adapter can have provisions in its interior, especially if it is manufactured as a cast component.

[0136] Overall, the embodiment according to Fig. 14 and Fig. 15 also provides a very resource- and cost-efficient design of a highly efficient support module 1 with an optimized support plate 6 with a motor mounting adapter 13.

[0137] With regard to further advantageous embodiments of the support module according to the invention and of the fan according to the invention comprising the support module, reference is made to the general part of the description and to the appended claims in order to avoid repetition.

[0138] Finally, it should be expressly pointed out that the above-described embodiments of the support module according to the invention together with the fan according to the invention serve only to explain the claimed teaching, but do not limit it to the embodiments.

[0139] List of reference symbols

Claims

Claims 1. Support module for a fan, in particular for a radial or diagonal fan, which comprises a motor and a fan impeller driven in rotation by the motor, for fastening the fan impeller between an inflow-side nozzle plate and a support plate located at a distance from the nozzle plate, wherein the motor with the fan impeller is mounted approximately centrally on the support plate in a rotationally fixed manner and is held on the nozzle plate by means of struts extending between the support plate and the nozzle plate, wherein the support plate has a flow-guiding outer region and an inner connection region for fastening the stator of the motor and wherein an axial offset is defined between the regions.

2. Support module according to claim 1, characterized in that the flow-guiding outer region is located radially outwards, extends to the radially outer edge of the support plate and, viewed in the radial direction, preferably extends entirely outwards beyond the impeller.

3. Support module according to claim 1 or 2, characterized in that the offset between the flow-guiding region, characterized by the (mean) axial position of its radially outer edge, and the motor connection region, characterized by the mean axial position of a contact surface of the stator of the motor on the support plate, can have at least 3% of the impeller diameter.

4. Support module according to one of claims 1 to 3, characterized in that the struts are designed as extruded profiles, preferably made of aluminum, into which self-tapping screws can be screwed from the support plate side and from the nozzle plate side into a region provided for this purpose in the cross section of the extruded profiles in order to connect the struts to the support plate or the nozzle plate.

5. Support module according to one of claims 1 to 4, characterized in that the struts are profiled in cross-section and can have a cross-sectional shape similar to that of an airfoil, with a rounded inflow edge and a rather thin outflow edge that differs significantly from the shape of the inflow edge.

6. Support module according to one of claims 1 to 5, characterized in that the support plate is essentially a molded part produced in a casting process, advantageously in plastic injection molding with a thermoplastic material.

7. Support module according to claim 6, characterized in that stiffening structures are formed on the outer side of the support plate facing away from the impeller, for example in the form of straight, round or corrugated ribs, honeycomb structures or the like.

8. Support module according to claim 6 or 7, characterized in that on the outer side of the support plate facing away from the impeller, stiffening structures, for example stiffening brackets, made of metal are attached, for example screwed on or connected to the injection-molded part by casting, which ensure the dimensional stability of the support plate.

9. Support module according to one of claims 1 to 8, characterized in that the support plate is made of sheet metal and in particular has a main plate made of sheet metal which essentially defines the radial outer contour of the support plate, which is fastened externally to the struts and which has a supporting function within the support plate.

10. Support module according to claim 9, characterized in that the offset in the axial direction between the aerodynamically acting region of the support plate and the motor connection is realized by means of a shaped, for example embossed or cast, adapter part which is fastened in an inner region of the main plate and can, for example, have a plate-like shape.

11. Support module according to claim 9, characterized in that the offset in the axial direction between the aerodynamically acting region of the support plate and the motor connection is realized in that the main plate itself is shaped, for example by a stamping, deep drawing, folding or other process, in such a way that the motor - axially offset to the aerodynamically acting region - is connected directly to the main plate.

12. Support module according to claim 11, characterized in that the offset in the axial direction between the aerodynamically acting region of the support plate and the motor connection is realized by a sheet metal cutting process, for example with a laser, and in each case double folding of the cut-out sheet metal regions, so that two or more offset regions are created in the main sheet, which are approximately Z-shaped in cross-section, wherein the motor with its stator can be fastened to the respective free-standing leg of the offset regions, for example with screws.

13. Support module according to claim 12, characterized in that an opening in the support plate in the region of the motor resulting from the use of regions of the main sheet for the design of the offset regions is covered as far as possible with additional, advantageously thinner, cover plates.

14. Support module according to one of claims 1 to 13, characterized in that the rotating part of the motor and in particular also a cooling fan wheel integrated on the motor is arranged axially beyond the aerodynamically acting outer region of the support plate or the main sheet, as seen from the impeller.

15. Support module according to one of claims 14 or 15, characterized in that the rotating part of the motor and in particular also a cooling fan wheel integrated in the motor are arranged axially beyond the cover plate as seen from the impeller.

16. Support module according to one of claims 9 to 15, characterized in that on the outer side facing away from the impeller, stiffening brackets made of upright sheet metal are attached to the support plate or to the main sheet, at for example screwed or riveted, which advantageously run vertically, rather centrally but to the left and right of the motor connection, which increase the rigidity of the support module and / or reduce the susceptibility to vibration.

17. Support module according to claim 16, characterized in that a possible harmful effect of an interaction between the cooling fan of the engine and the stiffening brackets is avoided; in particular by offsetting the axial region in which the stiffening brackets act and the axial region in which the cooling fan acts, or by a corresponding additional edge on the cover plates generating a blocking device for the cooling fan radiation.

18. Support module according to one of claims 9 to 17, characterized in that the outer regions of the support plate or the main sheet are folded completely or partially away from the impeller.

19. Fan with a motor and a fan impeller driven by the motor, in particular a radial or diagonal fan, with a support module according to one of claims 1 to 18.

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