Fan Wheel Profile Blade Rigidity via Sheet Metal Embossing
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Solution Overview
Problem
Existing profile blades for fan wheels lack sufficient rigidity while maintaining cost-effective production methods, leading to potential aerodynamic disadvantages and thermal distortion during connection processes.
Innovation Solution
Incorporating embossings in the end regions of the sheet metal strips to create a larger contact surface for material bonding, which increases rigidity and supports welding or adhesive processes, while maintaining aerodynamic efficiency by aligning embossings parallel to the end region edges or forming beads that stabilize the profile without causing transverse flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sheet metal strip is bent to form a profile blade with connected end regions, then the profile blade structure is formed, but the rigidity of the profile blade is insufficient
Solution Approach 1:
Embossings are formed in the end regions of the sheet metal strip before the bending process. This preliminary action creates raised structures that will later provide enhanced rigidity and larger contact surfaces for connection, without interfering with the subsequent bending operation to form the profile blade geometry
Solution Approach 2:
The embossings are localized specifically to the end regions of the sheet metal strip where connection and rigidity are needed, while leaving the main body of the profile blade with its aerodynamic geometry unchanged. This ensures local reinforcement without compromising overall aerodynamic performance
2Reliability
If the end region edges are connected by welding or gluing, then the profile blade structure is stabilized, but thermal distortion occurs during welding
Solution Approach 1:
The embossings are formed in advance before the connection process, creating a structural framework that distributes thermal stresses during welding. The raised embossed structures act as stress distributors that mitigate thermal distortion propagation throughout the profile blade
Solution Approach 2:
The embossing process changes the physical parameters of the end regions by creating raised structures with increased surface area and altered geometry. This parameter change enables larger contact surfaces for welding and gluing, improving connection reliability while the distributed structure reduces thermal concentration and distortion
3Reliability
If the contact surface for end region connection is enlarged, then connection reliability is improved, but aerodynamic performance may be compromised
Solution Approach 1:
The embossings are confined to the end regions of the profile blade where they serve connection purposes, while the main aerodynamic surfaces remain smooth and unchanged. This localized modification ensures that aerodynamic performance is not compromised by the presence of embossed structures
Solution Approach 2:
The embossings extend the contact surface area in the thickness dimension of the profile blade, creating raised structures that increase welding and gluing surface area without expanding the planar dimensions that would interfere with aerodynamic flow. This dimensional approach allows connection surface enlargement perpendicular to the aerodynamic surface
Data Source
Figure 1~2
Figure 3~3a
Figure 4~5
AI summary
The invention relates to a profile blade for a fan wheel (90), comprising a profile body (27; 47; 47a; 67; 107; 127; 142) made from at least one bent sheet metal strip (22; 42; 42a; 62; 102; 122; 142), wherein adjacent end regions (30, 31; 50, 51; 50a, 51a; 70, 71; 110, 111; 130, 131; 150, 151) of the at least one sheet metal strip (22; 42; 42a; 62; 102; 122; 142) are connected to each other by material bonding and/or form-fitting. According to the invention, a second end region (31; 51; 51a; 71; 111; 131; 151) is spaced apart from a second end region edge (26; 46; 46a; 66; 106; 126; 146) and is provided with at least one indentation (52; 52a; 72; 112; 132; 152) for forming a contact surface (56; 56a; 76; 116; 136; 156) for at least partial contact of a first end region (30; 50; 50a; 70; 110; 130; 150).