Fan Wheel Tips Alignment and Diffuser Contour for Motor Cooling
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Solution Overview
Problem
Existing fan wheels used in electric motors for cooling purposes lack efficiency and manufacturability, with protruding tips and blades that complicate demolding and assembly, leading to suboptimal performance and assembly challenges.
Innovation Solution
A fan wheel design with fan wheel tips aligned in a common plane transverse to the axis of rotation, where 20-50% of the blade area protrudes above the base body, and a diffuser region formed by the base body's conical contour, allowing for efficient airflow and simplified manufacturing through plastic injection molding without overlapping blades and slide demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fan wheel tips protrude beyond the base body to improve airflow efficiency, then cooling performance is improved, but manufacturing complexity increases due to demolding difficulties
Solution Approach 1:
The fan wheel tips protrude in the axial direction (another dimension) beyond the base body, creating a three-dimensional structure that improves airflow efficiency while the base body's conical contour provides the necessary demolding clearance in the radial direction
2Reliability
If fan wheel blades are arranged to protrude beyond base body levels to optimize airflow, then cooling efficiency improves, but assembly difficulty increases
Solution Approach 1:
All fan wheel tips are arranged in a common plane at the same axial level, creating an equipotential surface that simplifies assembly and alignment while the blades protrude at different radial positions to optimize airflow patterns
3Productivity
If fan wheel blades overlap in projection to maximize blade area, then airflow generation improves, but manufacturing precision requirements increase
Solution Approach 1:
The fan wheel blades are arranged asymmetrically in the radial direction with different protrusion distances from the base body, preventing overlap in top view projection while maintaining effective blade area for airflow generation, thus reducing manufacturing precision requirements
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
The design enhances efficiency and manufacturability by optimizing airflow and reducing noise, while ensuring proper assembly and cooling of electric motors, with improved alignment and reduced tonal noise.
Implementation Method 1
a fan wheel (8) designed to rotate about an axis of rotation (y) by means of the electric motor, with an air flow being generated by the fan wheel (8) during operation of the electric motor. In particular, this air flow serves at least partially to cool the electric motor
Implementation Method 2
this results in advantages in terms of demoulding after the injection process. Rather, in a preferred embodiment, the shaped elements located between the fan wheel blades in the course of the spraying process are screwed out in a helical manner in the direction of the fan wheel tips
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The impeller (8) has impeller blades (23) connected with a base body (19) on a bottom side. The blades form impeller tips (29) facing away from a bottom relative to an extension of the impeller in a direction of a rotational axis (y). The tips overlap the body, and/or the blades end with a distance to an edge lap of the body at the bottom side by forming a diffuser region (30). A radius of a maximum extension of the blades lies in a range between 1.5 to 0.6 times of a radius of a maximum extension of the base body in a top view. An independent claim is also included for an electric motor.