HVACR Blower Sectioned Manufacturing
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Solution Overview
Problem
The manufacturing of centrifugal fans for HVACR systems is complex and costly, especially as the diameter increases, and existing methods like injection molding face challenges in scalability and warping, while 3D printing processes are not readily applicable due to size and assembly complexities.
Innovation Solution
The blower is manufactured in a plurality of sections, each comprising a first shroud, a blade, and a second shroud, which are assembled with a band to form a unitary structure, utilizing 3D printing processes like selective laser sintering or injection molding, reducing each piece's size and complexity, and simplifying assembly through projections and openings for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If centrifugal fans are manufactured as two pieces joined together using traditional methods, then the structural integrity is maintained, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The blower is divided into multiple sections (e.g., 6 sections for a 6-blade blower), with each section containing a portion of the blades, first shroud, and second shroud. This segmentation reduces the size and complexity of each individual piece, making manufacturing more feasible while maintaining overall structural integrity through standardized joining mechanisms.
2Volume of moving object
If the blower diameter increases, then the airflow capacity improves, but the manufacturing complexity and cost increase
Solution Approach 1:
Large diameter blowers are divided into multiple sections, allowing each section to be manufactured independently at a manageable size. The sections are then assembled to form the complete large-diameter blower, enabling production of large airflow capacity units without proportionally increasing manufacturing complexity.
Solution Approach 2:
Each blower section is designed as a standardized modular unit that can be used in various configurations. The same section design can be replicated and assembled to create different blower sizes and capacities, reducing tooling costs and manufacturing complexity for different product variants.
3Productivity
If traditional injection molding is used for manufacturing, then production efficiency is maintained, but warping issues occur during the process
Solution Approach 1:
By dividing the blower into smaller sections, each section can be molded independently with reduced warping risk. The smaller size allows for better control of cooling rates and stress distribution during injection molding, minimizing warping while maintaining production efficiency.
4Adaptability or versatility
If 3D printing processes are applied to the entire blower, then design flexibility improves, but the process is not readily applicable due to size constraints
Solution Approach 1:
The blower is divided into smaller sections that can be manufactured using 3D printing processes. Each section's reduced size makes it compatible with 3D printing technology, while the modular design allows the complete blower to achieve the desired size and airflow capacity. This enables design flexibility through 3D printing while maintaining manufacturability.
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 reduces the overall size of each piece by a factor of the number of blades, minimizes warping, and simplifies assembly, resulting in a more efficient and cost-effective manufacturing process for HVACR blowers.
Implementation Method 1
a blade, the blade being formed such that a first end of the blade is joined with the first shroud and a second end of the blade is joined with the second shroud
Data Source
AI summary
A blower and method of manufacturing a blower for a heating, ventilation, air conditioning, and refrigeration (HVACR) unit is disclosed. The blower includes a plurality of blower sections. Each section includes a first shroud, a second shroud spaced from the first shroud in a direction of a longitudinal axis of the blower, and a blade. The blade is formed such that a first end of the blade is joined with the first shroud and a second end of the blade is joined with the second shroud. A band is secured to the plurality of blower sections.