Rotating Downrod Assembly for Compact Ceiling Fan Packaging
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Solution Overview
Problem
Current methods for packaging and transporting ceiling fans either result in a large volume when assembled, leading to inefficient use of space, or in loss of small parts when disassembled, causing handling and transportation challenges.
Innovation Solution
A downrod assembly connected to an electric motor with an adapter subassembly that allows the downrod to rotate, reducing the overall volume of the ceiling fan during transportation and handling, thus improving packaging efficiency and preventing loss of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional downrod assemblies are used, then the ceiling fan can be installed, but the assembly requires multiple separate components (downrod, adapter, mounting bracket) that increase installation complexity and potential misalignment
Solution Approach 1:
The patent combines the downrod, adapter, and mounting bracket into a single integrated downrod assembly. The adapter is formed as one piece with the mounting bracket, eliminating the need for separate components and simplifying installation to a single attachment operation.
Solution Approach 2:
The integrated downrod assembly serves multiple functions simultaneously: it provides the hanging rod function, the adapter connection function, and the mounting bracket attachment function. This multi-functional design reduces the number of separate parts needed while maintaining all necessary installation capabilities.
2Manufacturing precision
If traditional separate components are used, then manufacturing is straightforward, but alignment accuracy between the downrod, adapter, and mounting bracket is difficult to achieve
Solution Approach 1:
By forming the adapter and mounting bracket as a single integrated component, the patent eliminates alignment errors between separate parts. The fixed geometric relationships within the integrated assembly ensure precise alignment without requiring manual adjustment during installation.
3Productivity
If multiple separate components are used, then each component can be manufactured independently, but the overall assembly time increases
Solution Approach 1:
The integrated downrod assembly reduces installation to a single attachment operation rather than multiple sequential steps. The pre-assembled unit eliminates the time required to connect separate components, significantly reducing overall installation time.
Solution Approach 2:
The adapter and mounting bracket are pre-assembled into a fixed configuration during manufacturing, so that during installation, no alignment or connection adjustments are needed. This preliminary assembly of components before installation accelerates the overall process.
4Reliability
If traditional assemblies are used, then standard manufacturing processes can be applied, but the risk of improper installation and safety issues increases
Solution Approach 1:
By reducing the number of connection points from multiple separate component interfaces to a single integrated assembly attachment, the patent minimizes potential failure points. The integrated design ensures proper installation through its fixed geometric relationships, reducing the risk of improper assembly.
Data Source
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AI summary
The present disclosure provides a downrod assembly and a ceiling fan. The downrod assembly includes: an electric motor, an adapter subassembly and a downrod. The adapter subassembly is connected with an electric motor shaft of the electric motor; and the downrod is connected with the adapter subassembly and is capable of rotating with respect to the electric motor by means of the adapter subassembly. For the ceiling fan provided by the present disclosure, the downrod is able to rotate with respect to the electric motor, and the downrod is folded during transportation and handling to reduce the volume of the ceiling fan, thereby reducing the packaging volume. On the one hand, it is possible to avoid loss of small parts caused by detaching and packaging individual parts of the ceiling fan. On the other hand, it is possible to avoid an inconvenient handling and a low transport efficiency of the ceiling fan caused by a large volume of the downrod and the electric motor in the assembled ceiling fan. The volume of the ceiling fan is relatively small after the downrod rotates with respect to the electric motor, such that more ceiling fans can be transported without changing the space for transportation in a transport device, thereby improving the transport efficiency, and moreover, manual handling may be convenient, thereby improving handling efficiency.