Fan Assembly Ring Forming to Reduce Sheet Metal Scrap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for manufacturing fan assemblies 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 can replace traditional orifices and end rings, and used in conjunction with hub strips to form a hub assembly without a solid disc, minimizing scrap production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If circular parts (end rings, back disc, orifices) are stamped from rectangular metal sheets, then manufacturing precision and structural integrity are improved, but scrap material generation increases significantly
Solution Approach 1:
The patent transforms the traditional flat stamped circular parts into three-dimensional curved structures. The end rings are formed by bending metal strips into circular configurations, and the back disc is created by forming a curved surface from a metal sheet, allowing more efficient material utilization while maintaining structural integrity
Solution Approach 2:
The invention changes the manufacturing parameters from two-dimensional stamping to three-dimensional forming processes. By transitioning from flat stamped parts to curved and folded structures, the material yield is improved while achieving the required structural strength and rigidity
2Ease of manufacture
If traditional stamping methods are used for end rings and orifices, then ease of manufacture is improved, but material yield deteriorates due to corner scrap
Solution Approach 1:
Instead of stamping flat circular rings that leave corner scrap, the patent forms end rings by bending strips into curved circular configurations. This curved approach allows the metal to be utilized more completely, transforming the waste-prone stamping process into a formable process with better material yield
3Stability of the object's composition
If a solid central hub disc is used in centrifugal blower wheels, then structural stability is improved, but scrap material from stamping increases
Solution Approach 1:
The patent replaces the traditional solid stamped hub disc with a thin-walled formed structure. The hub is created by forming a metal sheet into a three-dimensional shape with controlled wall thickness, providing structural stability while utilizing material more efficiently than solid stamping
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 during fan assembly production, improving material yield and reducing manufacturing costs while maintaining or enhancing airflow efficiency.
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
A method including bending an elongate portion of a flat strip of metallic material into a ring about an axis extending parallel to a thickness of the elongate portion of the strip of metallic material. The method includes fixing end portions of the ring together to form a flat ring, the flat ring having opposite flat side surfaces, a radially inner surface, a radially outer surface, a pair of radially inner edges, and a pair of radially outer edges, wherein the pair of radially inner edges connect the radially inner surface and the opposite flat side surfaces and the pair of radially outer edges connect the radially outer surface and the opposite flat side surfaces. The method includes connecting a plurality of curved blades to the flat ring and connecting a hub support to the curved blades at a position spaced from the flat ring along the curved blades.