Fan Frame Connecting Elements for Precision Assembly
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Solution Overview
Problem
Existing fan frame assembly methods often result in accuracy errors, alignment issues, and residual stresses, leading to gaps or deformation during assembly, which can cause the fan to break.
Innovation Solution
The fan frame design features a first and second frame with connecting elements where the second connecting element is bent twice to grasp the first connecting element, internally counterbalancing stresses and enhancing precision, thereby avoiding deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional screw-locking or flange-riveting junctions are used to assemble the upper and lower housings, then the fan frame can be detachably assembled, but accuracy errors and alignment errors occur during assembly, resulting in gaps or deformation
Solution Approach 1:
The fan frame is divided into an upper housing and a lower housing that can be detachably assembled. Each housing has connecting elements (protrusions and grooves) that enable precise alignment and connection without requiring complex fastening mechanisms, thus achieving both detachability and high assembly accuracy
Solution Approach 2:
Connecting elements (protrusions and grooves) are introduced as intermediary features between the upper and lower housings. These elements guide the alignment and connection process, ensuring that the housings join precisely without gaps or deformation, thereby resolving the contradiction between ease of assembly and assembly accuracy
2Strength
If force is applied to force-fit the connecting elements during assembly, then the housings can be joined, but residual stresses are generated causing deformation or fan breakage
Solution Approach 1:
The connecting elements are designed with preliminary anti-action features where the protrusion and groove geometries are optimized to distribute connection forces evenly. This preliminary design prevents stress concentration that would lead to residual stresses and deformation, allowing strong joints without compromising structural stability
Solution Approach 2:
The geometric parameters of the connecting elements (protrusion and groove dimensions, angles, and tolerances) are optimized to achieve proper fit without excessive force. By adjusting these parameters, the design achieves both strong joint strength and minimal residual stress, preventing deformation and fan breakage
Data Source
AI summary
A fan frame includes a first frame and a second frame. The first frame includes at least a first sidewall and a first connecting element, wherein the first connecting element is disposed on the first sidewall. The second frame includes at least a second sidewall and a second connecting element, wherein the second connecting element is disposed on the second sidewall and at least partially overlapped with the first connecting element. The second connecting element includes a first end and a second end in a first direction, wherein the first end and the second end are bent toward the first connecting element, respectively, for grasping the first connecting element. As a result, the accuracy error and the precision error are avoided, the stresses are internally counterbalanced, and the deformation of the fan frame is avoided.