Modular Fan Blade Segmentation for Customization
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Solution Overview
Problem
Existing fan systems lack modularity and ease of customization, making it difficult to tailor aerodynamic properties and maintain fan blades efficiently, as they are often constructed as unitary components that are heavy, inflexible, and require extensive redesign for different applications.
Innovation Solution
A modular fan blade design comprising a central spine member and interchangeable leading and trailing edge components, which can be easily assembled and disassembled, allowing for varying chord lengths and aerodynamic configurations, enabling customization and maintenance by swapping out different edge components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fan blades are constructed as unitary components, then structural strength is improved, but weight increases and customization becomes difficult
Solution Approach 1:
The fan blade is divided into multiple separate components including a hub section, one or more blade sections, and optional tip sections. These segmented components are connected through attachment mechanisms such as pins, splines, or interference fits, allowing the blade to achieve the required structural strength through proper joint design while reducing overall weight by eliminating material in non-critical areas and allowing optimization of each segment independently
2Ease of manufacture
If fan blades are constructed as unitary components, then manufacturing simplicity is improved, but adaptability and ease of customization deteriorate
Solution Approach 1:
The blade is segmented into interchangeable components with standardized attachment interfaces. Different blade sections, tip configurations, or hub designs can be swapped by removing and replacing these modular components, enabling rapid customization for various aerodynamic requirements without requiring complete redesign or complex manufacturing processes
Solution Approach 2:
The attachment mechanisms and interface designs are created to be universal, allowing the same hub and connection systems to work with multiple blade section variations. This enables a single platform to support multiple aerodynamic configurations, maintaining manufacturing simplicity while achieving high adaptability across different applications
3Stability of the object's composition
If fan blades are constructed as unitary components, then structural integrity is improved, but ease of repair and maintenance deteriorates
Solution Approach 1:
The blade is designed with separable sections connected through robust attachment mechanisms that maintain structural integrity during operation. When damage occurs, only the affected segment needs to be removed and replaced, rather than replacing the entire blade. The standardized interfaces ensure that replacement components can be quickly installed while maintaining the required structural integrity
Solution Approach 2:
The modular design allows damaged blade sections to be easily discarded and replaced with new or refurbished components. The intact sections remain attached to the hub and can continue to function, reducing waste and enabling cost-effective maintenance by recovering and reusing undamaged portions of the blade assembly
Data Source
AI summary
A fan system includes a motor, a rotatable hub, and a plurality of fan blades. Each of the fan blades includes a substantially rigid spine member, a resilient leading edge member, and a resilient trailing edge member. The leading edge member and trailing edge members are removably coupled with the spine member, such that different leading edge members and different trailing edge members may be chosen to customize the leading and trailing edges of the fan blades. Each fan blade may have more than one type of leading edge member or more than one type of trailing edge member. The leading edge member and trailing edge member may each be coupled with the spine member by urging the leading edge member and trailing edge member in a direction that is substantially perpendicular to the longitudinal axis defined by the spine member.