Impeller Tab-and-Projection Assembly for Strong Blade Joints
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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 relying on welding, staking, or spinning, which can be complex and inefficient.
Innovation Solution
The impeller design incorporates a self-fixturing feature with locking projections and tabs that allow for easy assembly by securing blades to front and back plates using a pressing tool, enabling a secure connection through a simple axial staking method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding, staking, or spinning is used to connect blades to plates, then joint connection strength is achieved, but assembly complexity and manufacturing efficiency deteriorate
Solution Approach 1:
The connection system is segmented into distinct components: tabs extending from blades, locking projections on plates, and pressing tools. This segmentation allows each component to perform a specific function independently, simplifying the overall assembly process while maintaining strong joint connections through modular engagement features.
Solution Approach 2:
The locking projections are designed to automatically engage with the tabs when the blade is inserted into the plate opening, eliminating the need for complex external fastening mechanisms. The pressing tool simply applies axial force to activate the self-locking feature, making the assembly process self-contained and straightforward.
2Strength
If welding, staking, or spinning is used to connect blades to plates, then joint connection strength is achieved, but manufacturing efficiency deteriorates
Solution Approach 1:
The tabs and locking projections are pre-formed as integral features of the blade and plate components during their respective manufacturing processes. This preliminary preparation eliminates the need for complex on-site assembly operations, allowing for quick and efficient assembly through simple insertion and pressing actions.
Solution Approach 2:
The invention replaces complex mechanical connection systems (welding, staking, spinning) with a simpler mechanical engagement system based on tabs and locking projections. This substitution reduces the skill level and time required for assembly while maintaining connection strength through precise geometric engagement features.
3Ease of operation
If simple assembly methods are used, then assembly ease is improved, but joint connection strength deteriorates
Solution Approach 1:
The tab is inserted into the opening and nested within the plate structure, with the locking projection then engaging the tab from the same opening. This nested arrangement allows the connection to be formed through a simple axial pressing motion while maintaining strong joint connections through the nested engagement of multiple features.
Solution Approach 2:
The connection mechanism utilizes multi-dimensional engagement: the tab extends perpendicular to the plate surface, the locking projection engages the tab in a different plane, and the pressing tool applies force along the axial dimension. This multi-dimensional approach simplifies assembly while ensuring strong connection through engagement in multiple directions.
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.