Impeller Blade Locking Structure for Simple Strong Assembly
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Solution Overview
Problem
Existing impellers for HVAC systems face challenges in achieving simple assembly while maintaining a strong joint connection between blades and plates, often requiring complex methods like welding or spinning, which can be inefficient and costly.
Innovation Solution
The impeller design incorporates self-fixturing features with locking projections and tabs that allow for easy assembly by securing blades to front and back plates using a pressing machine, enabling a secure connection through a simple axial staking method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or spinning methods are used to connect blades to plates, then joint connection strength is improved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The connection system is segmented into distinct functional elements: tabs on blades, corresponding openings in plates, and locking projections that engage with the tabs. This segmentation allows each component to be independently manufactured and assembled through simple insertion and locking actions, eliminating complex welding or spinning operations while maintaining connection strength.
Solution Approach 2:
The locking projections are designed to automatically engage with the tabs when inserted into the openings, creating a self-securing connection. The geometry of the locking projections and tabs is configured so that proper insertion automatically triggers the locking action without requiring additional tools, operators, or complex assembly procedures.
2Ease of operation
If simple assembly methods are used to connect blades to plates, then assembly ease is improved, but joint connection strength deteriorates
Solution Approach 1:
The tab is inserted into the opening, and the locking projection nests within the tab structure to engage and secure it. This nested configuration allows the simple insertion motion to result in a secure, interlocked connection where the locking projection becomes embedded in the tab-opening assembly, providing strong mechanical attachment through straightforward assembly actions.
Solution Approach 2:
The locking projection acts as an intermediary element between the tab and the plate opening. It mediates the connection by engaging with the tab while being constrained by the opening geometry, translating the simple insertion motion into a secure, strength-providing mechanical bond without requiring complex welding or spinning processes.
3Reliability
If multiple components are used to secure blades to plates, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The locking projection serves multiple functions simultaneously: it guides the tab into proper alignment during insertion, secures the tab in the correct position, and provides the mechanical locking force for reliable connection. This multi-functionality eliminates the need for separate alignment features, fasteners, or securing mechanisms, reducing manufacturing complexity and cost while maintaining high connection reliability.
Solution Approach 2:
The alignment guide and locking mechanism are merged into a single integrated locking projection structure. Rather than using separate components for alignment and securing, the geometry of the locking projection combines both functions, reducing the number of parts, assembly steps, and manufacturing operations required while ensuring reliable blade-to-plate connection.
Data Source
AI summary
An impeller includes a front plate, a back plate, and a plurality of blades. The front plate has one or more first openings and one or more first locking projections, and the back plate has one or more second openings and one or more second locking projections. Each blade has one or more first and second tabs. The first tabs extend through the first openings of the front plate, and the first locking projections exert a force on the first tabs to secure the blades to the front plate. The second tabs extend through the second openings of the back plate, and the second locking projections exert a force on the second tabs to secure the blades to the back plate.