Fan Hub Ring Assembly to Reduce Stamping Scrap
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Solution Overview
Problem
Traditional fan assembly manufacturing methods result in significant scrap material due to the stamping of circular parts from rectangular metal sheets, leading to increased costs and inefficiencies in recycling and handling.
Innovation Solution
A method involving the formation of a narrow strip of material into a helix, which is then bent and trimmed to create a rigid annular member that replaces traditional orifices and end rings, and hub assemblies composed of hub strips and rings, eliminating the need for solid discs and minimizing scrap production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular parts (end rings, back discs, orifices) are stamped from rectangular metal sheets, then the fan assembly components are manufactured, but significant scrap material is generated
Solution Approach 1:
The patent applies curvature by forming annular members from bent strips of material rather than stamping circular shapes from rectangular sheets. The strip is bent into a curved annular configuration, which eliminates the corner waste inherent in stamping circular parts from rectangular material, thereby significantly reducing scrap generation while maintaining the required circular/annular geometry of fan components
Solution Approach 2:
The invention transitions from two-dimensional stamping (rectangular sheet to circular part) to a three-dimensional forming process where a strip is bent and shaped into an annular configuration. This dimensional change allows the material to be formed into the required shape without generating scrap, as the strip can be contoured to match the exact perimeter of the annular component
2Object-generated harmful factors
If scrap material is recycled, then environmental sustainability is improved, but costs for cutting, storing, and handling scrap material increase
Solution Approach 1:
The patent converts the harmful effect of scrap generation into a benefit by eliminating the scrap creation step entirely. The bent strip forming method produces minimal to no scrap, transforming the waste management burden into a material efficiency advantage, thereby improving environmental sustainability without incurring the associated handling and processing costs
Solution Approach 2:
The manufacturing process serves itself by being inherently scrap-minimizing. The bent strip forming method automatically produces components with minimal material waste, eliminating the need for separate scrap collection, storage, and recycling operations, thereby saving time and resources that would otherwise be dedicated to waste management
3Productivity
If the number of blades is increased to enhance airflow, then fan performance is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent merges the manufacturing of multiple blade attachment points into a single integrated hub assembly formed from bent strips. The hub assembly incorporates multiple attachment features for blades, and the annular members provide continuous support structures, allowing multiple blades to be attached to a unified structure rather than individually to separate components, thereby simplifying the overall manufacturing process while supporting enhanced airflow capability
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
This approach significantly reduces scrap material generation, improves manufacturing efficiency, and allows for more effective recycling, while enabling the production of fan assemblies with enhanced airflow capabilities using fewer blades or the same number of blades as traditional designs.
Implementation Method 1
a narrow strip of material is advanced from a coil and bent along a longitudinal edge of the strip to form a helix
Data Source
AI summary
In one aspect, a fan assembly is provided that can be manufactured while producing a significantly reduced amount of scrap material. More specifically, the fan assembly utilizes a hub ring and one or more hub strips to support a plurality of blades rather than a solid center disc or end disc used by some prior approaches. In another aspect, a method is provided that includes bending a member into an annular configuration and joining end portions of the member together to rigidly fix the member in the annular configuration. The rigid annular member may be used as an end ring, a hub ring, an orifice, or other component, while producing significantly less scrap material than traditional approaches.