Fan Blade Manufacturing via Segmented Cutting and Chamfering
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Solution Overview
Problem
Current methods of manufacturing ceiling fan blades focus more on design rather than improving their structure and function, resulting in a need for more efficient and cost-effective manufacturing processes that enhance air movement.
Innovation Solution
A method involving cutting and chamfering fan blade blanks to create angled parts that are adhesively affixed, or using bending devices to form fixed-angle flaps, allowing for efficient and cost-effective production of fan blades that can move more air than conventional designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fan blade manufacturing methods are used, then design variety can be achieved, but manufacturing efficiency and air movement performance remain limited
Solution Approach 1:
The fan blade blank is divided into multiple sections along its length, with each section being independently shaped or bent to different angles. This segmentation allows for optimized aerodynamic profiles in different zones of the blade, improving air movement performance while using standard manufacturing processes on each segment.
Solution Approach 2:
Different portions of the fan blade are given different geometric characteristics - specifically, the blade is divided into sections with varying angles relative to the plane of rotation. Each section has locally optimized geometry for its specific position on the blade, enhancing overall aerodynamic efficiency without requiring specialized equipment.
2Manufacturing precision
If specialized equipment is used to manufacture fan blades, then manufacturing precision can be improved, but manufacturing cost and complexity increase
Solution Approach 1:
The manufacturing method uses standard, widely-available equipment to perform the shaping operations. The process relies on conventional cutting tools and bending equipment that are already present in most workshops, eliminating the need for specialized fan blade manufacturing machinery while maintaining good precision through proper technique and tooling.
Solution Approach 2:
The manufacturing process uses multi-functional, standard equipment that can perform multiple operations. Common woodworking or metalworking tools are used for cutting, shaping, and bending the blade blank, making the same equipment useful for various manufacturing tasks beyond just fan blade production.
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 method results in fan blades that are low-cost, require no specialized equipment, are safe, and efficiently move more air than conventional blades, addressing the need for improved manufacturing and performance.
Implementation Method 1
The step of affixing the chamfered one of the first and second cut edges to the other of the first and second cut edges further includes adhesively affixing the chamfered one of the first and second cut edges to the other of the first and second cut edges
Data Source
AI summary
A method of manufacturing a fan blade includes providing a fan blade blank including opposed major faces, opposed inner and outer extremities, and opposed first and second sides defining opposed first and second edges, respectively. The method further specifies cutting the fan blade blank asunder into first and second parts along a cut line extending from the inner extremity of the fan blade blank to the outer extremity of the fan blade blank inboard of one of the first and second edges forming a first cut edge of one of the first and second parts and a second cut edge of the other of the first and second parts, chamfering one of the first and second cut edges forming a chamfered one of the first and second cut edges, and affixing the chamfered one of the first and second cut edges to the other of the first and second cut edges forming a fan blade consisting of the first part affixed to the second part, the first part being angled relative to the second part.