Mixed Flow Fan Wheel Mechanical Assembly
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Solution Overview
Problem
The manufacturing of mixed flow fan wheels is arduous, time-consuming, and costly due to the need for metallurgical bonding processes like welding, which increases material thickness, mass, and operational inefficiencies.
Innovation Solution
A mixed flow fan wheel design that uses mechanical interlocking features and fasteners for assembly, reducing the need for metallurgical bonding and allowing for thinner materials, lower mass, and improved alignment during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallurgical bonding processes like welding are used to assemble fan wheel components, then structural strength and reliability are improved, but manufacturing complexity, time, and cost increase significantly
Solution Approach 1:
The fan wheel is divided into separate components (hub, fan blades, shroud) that are manufactured independently and then assembled using mechanical fasteners. This segmentation allows each component to be optimized and manufactured separately, reducing overall manufacturing complexity while maintaining structural integrity through the fastening system.
Solution Approach 2:
The patent replaces metallurgical bonding processes (welding, brazing) with a mechanical fastening system consisting of fasteners, mounting tabs, and mounting surfaces. This substitution eliminates the need for complex thermal processes, reduces manufacturing time, and allows for easier assembly and disassembly while maintaining reliable structural connections.
2Reliability
If metallurgical bonding processes are used to assemble fan wheel components, then structural integrity is improved, but assembly time and manufacturing cost increase
Solution Approach 1:
The patent replaces time-consuming metallurgical bonding processes with a mechanical fastening system that allows for rapid assembly. The mounting tabs and fasteners enable components to be joined quickly without requiring heating, cooling, or specialized welding equipment, significantly reducing assembly time and increasing manufacturing productivity.
Solution Approach 2:
The hub and shroud are designed with pre-formed mounting surfaces and attachment features that facilitate quick alignment and fastening of fan blades. This preliminary preparation of mounting interfaces eliminates the need for complex alignment procedures during assembly, further reducing assembly time while ensuring proper structural integrity.
3Strength
If metallurgical bonding processes are used, then material thickness must be increased to ensure structural strength, but this increases mass and reduces operational efficiency
Solution Approach 1:
The patent applies material and thickness variations locally rather than uniformly throughout the fan wheel structure. The hub, fan blades, and shroud are designed with optimized local thicknesses and material properties specific to their functional requirements, allowing for strength where needed while minimizing mass in non-critical areas. The mechanical fastening system provides localized reinforcement at connection points without requiring increased thickness throughout the entire structure.
Solution Approach 2:
The fan wheel assembly utilizes different materials for different components (hub, fan blades, shroud) optimized for their specific functions. This composite approach allows each component to be made from the most suitable material with appropriate thickness, achieving overall structural strength while minimizing total mass compared to a uniform metallurgical bonding design.
4Productivity
If conventional fan wheel manufacturing methods are used, then manufacturing is arduous and time-consuming, but alternative methods may compromise structural rigidity and performance
Solution Approach 1:
The patent replaces arduous metallurgical bonding processes with a mechanical fastening system that is both easier to implement and maintains structural rigidity. The fasteners, mounting tabs, and precision mounting surfaces create rigid connections that preserve the structural integrity and performance of the fan wheel while dramatically simplifying the manufacturing process and reducing assembly time.
Data Source
AI summary
A fan wheel includes a hub having a passage extending along an axis, where the passage is configured to receive a shaft. The hub includes a first mounting surface positioned at a first location along the axis and a second mounting surface offset from the first mounting surface and positioned at a second location along the axis. The fan wheel also includes a fan blade having a first mounting tab and a second mounting tab, where first mounting tab is configured to engage with and couple to the first mounting surface and the second mounting tab is configured to engage with and couple to the second mounting surface.