Blower Housing Split-Plane Assembly to Eliminate Crimping Waste
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Solution Overview
Problem
Existing blower housings in HVAC systems are fabricated using labor-intensive crimping processes, which result in high costs and scrap rates due to the need for costly crimping machines and manual pinch points.
Innovation Solution
A blower housing design comprising a first and second housing portion that are removably connectable at a central plane, formed via a deep draw process, with integral sidewalls and outer walls, and featuring flow features and a lock mechanism for secure coupling without requiring complex crimping machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crimping process is used to fabricate blower housing, then housing can be assembled from multiple pieces, but manufacturing cost increases and scrap rate increases
Solution Approach 1:
The blower housing is divided into a first housing portion and a second housing portion that can be separately formed and then assembled together. This segmentation allows each portion to be formed independently using deep draw processes, eliminating the need for complex crimping operations while maintaining the ability to assemble multiple pieces into a functional housing structure.
Solution Approach 2:
The first and second housing portions are joined together through interlocking features and fasteners to form a complete blower housing. This merging approach replaces the problematic crimping process with a more efficient assembly method that reduces material waste and manufacturing costs while maintaining structural integrity.
2Ease of manufacture
If crimping machine is used to assemble blower housing, then housing portions can be connected, but device cost increases
Solution Approach 1:
The housing is segmented into separate portions with integrated connection features that eliminate the need for specialized crimping machines. Each housing portion includes built-in flanges, ribs, and fastening features that enable simple mechanical assembly without complex equipment.
Solution Approach 2:
The housing portions are designed with self-aligning and self-securing features including interlocking ribs, flanges, and fastener holes that allow the components to connect to each other automatically during assembly, eliminating the need for expensive automated crimping machines.
3Ease of manufacture
If manual insertion into crimping machine is used, then housing can be assembled, but labor intensity increases
Solution Approach 1:
The housing is divided into pre-formed portions that can be independently manufactured and then quickly assembled. This segmentation enables parallel production of housing portions and simplifies the final assembly process, reducing both labor intensity and production time.
Solution Approach 2:
The housing portions are pre-formed with integrated connection features including flanges, ribs, and fastening elements during the deep draw forming process. This preliminary preparation of connection features eliminates the need for manual insertion and crimping operations, significantly reducing labor intensity and increasing productivity.
4Productivity
If deep draw process is used to form housing portions, then manufacturing efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The housing is segmented into separate portions that can be formed using deep draw processes. Each portion is designed with generous tolerances and features self-aligning connection elements that compensate for minor variations in forming precision, allowing efficient production while maintaining acceptable assembly quality.
Solution Approach 2:
The deep draw-formed housing portions incorporate locally optimized features such as reinforced ribs, flanges, and connection zones with enhanced material properties. These local quality enhancements ensure that critical connection areas meet precise requirements while the rest of the housing can be formed with standard tolerances, balancing manufacturing efficiency and precision.
Data Source
AI summary
A blower includes a fan wheel and a blower housing. The blower housing includes a first housing portion and a second housing portion. The second housing portion is removably connectable to the first housing portion to define a hollow interior therebetween configured to receive a fan wheel, wherein an interface between the first housing portion and the second housing portion is arranged at a central plane of the blower housing.