Single-Part Bladed Disk Rotor for Low-Noise Air Moving
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Air-moving devices, such as leaf blowers and air vehicles, are often noisy and inefficient, leading to restrictions on their use and potential health and economic impacts due to noise pollution.
Innovation Solution
The design of air-moving devices incorporates a single-part bladed disk rotor with specific geometric and operational parameters, including a high blade count, controlled blade passage frequency, and low tip speed, manufactured via methods like injection molding, to reduce noise levels while maintaining sufficient air flow and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional air-moving devices are used, then air flow capability is provided, but noise level increases and efficiency decreases
Solution Approach 1:
The patent applies parameter changes by optimizing the rotor blade geometry parameters including blade count (12-100 blades), blade aspect ratio (1-10), tip solidity, and operational parameters (tip speed 200-500 fps, blade passage frequency 8-16 kHz). These parameter optimizations enable the rotor to achieve low noise levels (30-70 dBA) while maintaining sufficient air flow capability (500-1,100 cfm) for leaf blowing applications.
Solution Approach 2:
The patent employs dynamics by designing the rotor with multiple blades (12-100) that create controlled airflow patterns. The dynamic operation at specific tip speeds (200-500 fps) and blade passage frequencies (8-16 kHz) optimizes the balance between noise reduction and air moving performance, allowing the system to maintain effectiveness while reducing noise pollution.
2Productivity
If rotor operates at high tip speed, then air moving capability improves, but noise level and power demand increase
Solution Approach 1:
The patent identifies and applies optimal parameter ranges including tip speed (200-500 fps) and blade passage frequency (8-16 kHz) that maximize air moving capability while minimizing noise. The blade count (12-100) and aspect ratio (1-10) are specifically selected to achieve this balance, demonstrating parameter optimization to resolve the contradiction between performance and noise.
3Ease of manufacture
If single-part rotor construction is used, then manufacturing efficiency and mass production capability improve, but structural complexity increases
Solution Approach 1:
The patent merges the hub and blades into a single integrated rotor structure that can be manufactured as one piece using injection molding. This consolidation eliminates the need for separate hub and blade components, simplifying the manufacturing process and enabling mass production while the geometric design manages the inherent structural complexity through optimized blade arrangements (12-100 blades with aspect ratio 1-10).
Solution Approach 2:
The patent applies parameter changes in the rotor design including blade count (12-100), blade aspect ratio (1-10), and tip solidity to optimize the single-part construction. These parameter selections balance the structural complexity requirements with manufacturability, enabling injection molding production while maintaining the necessary aerodynamic performance and structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves noise levels of 30-70 A-weighted decibels at 50 feet, with improved air-moving capabilities and reduced power demands, facilitating mass production and broader application of air-moving devices.
Implementation Method 1
aerodynamic rotor... air velocities in the range of about 90-290 miles per hour (mph), and volumetric air flows in the range of about 500-1,100 cubic feet per minute (cfm)
Data Source
AI summary
An air-moving device may include an aerodynamic rotor in the form of a bladed disk. The aerodynamic rotor may include a physical geometry that constrains a noise level of the air-moving device.