Folded Centrifugal Fan Blade Assembly Without Positioning Fixtures
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Solution Overview
Problem
Conventional centrifugal fan blades manufactured by aluminum extrusion require fixtures for positioning, leading to high manufacturing costs and time due to their inclined design.
Innovation Solution
A fan mechanism with blades having a folded structure, featuring a first and second surface with contact portions connected by discontinuous spot welding, and a protruding pillar embedded in a hole, allowing for efficient assembly and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blades are manufactured by aluminum extrusion with inclined design, then structural strength is improved, but manufacturing cost and time increase due to fixture requirements
Solution Approach 1:
The blade is divided into multiple segments or sections that can be independently manufactured and then assembled together. This allows each segment to be produced using simpler, more cost-effective processes without requiring complex fixtures for the entire inclined structure, thereby reducing manufacturing cost and time while maintaining overall structural strength through the assembly of segmented components.
Solution Approach 2:
Instead of manufacturing the entire inclined blade structure as a single piece requiring fixtures, the invention inverts the approach by creating the blade through a folding process where flat or minimally inclined segments are joined together to form the final three-dimensional inclined shape. This reverses the traditional extrusion methodology and eliminates the need for complex positioning fixtures.
2Stability of the object's composition
If blades are manufactured by aluminum extrusion, then structural integrity is improved, but manufacturing complexity increases due to positioning fixtures
Solution Approach 1:
The blade structure is segmented into multiple manageable portions that can be manufactured independently with simpler fixtures or no fixtures at all. The segmentation allows each component to maintain structural integrity through its own reinforcement features while the overall complexity is reduced due to the modular nature of assembly.
Solution Approach 2:
The blade design incorporates nested structural features where reinforcing elements are integrated within the blade body itself rather than requiring external positioning fixtures. The folded structure allows inner reinforcement features to be nested within the overall blade geometry, maintaining integrity without adding complex external fixture requirements.
3Reliability
If traditional blade manufacturing methods are used, then production reliability is maintained, but manufacturing time increases
Solution Approach 1:
The blade segments are pre-formed and prepared in advance using simpler, faster manufacturing processes before final assembly. The folding and joining operations are designed as preliminary actions that can be efficiently performed, reducing the overall manufacturing time while maintaining reliability through controlled assembly procedures and quality checks at each stage.
Solution Approach 2:
The manufacturing process incorporates dynamic or flexible elements that allow for rapid adjustment and assembly. The folded blade structure enables dynamic assembly where segments can be quickly joined together through simplified connecting features, reducing manufacturing time while maintaining production reliability through standardized joining methods and quality control protocols.
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
Reduces manufacturing costs and time while maintaining structural integrity, facilitating balanced operation with reduced windage and weight, and enabling easy adjustment of balance through counterweights.
Implementation Method 1
The first contact portion is affixed to the second contact portion by discontinuous spot welding, and a plurality of welding spots are formed between the first contact portion and the second contact portion.
Data Source
AI summary
A fan mechanism is provided. The fan mechanism includes an upper base, a lower base, and a plurality of blades. The blades are disposed between the upper base and the lower base, and each of the blades includes a first surface and a second surface. The second surface has a first contact portion and a second contact portion on opposite sides. The first contact portion is in contact with the corresponding second contact portion. The first surface includes a hole penetrating the second surface. The second surface is connected to a protruding pillar, and the protruding pillar is embedded into the hole.