Segmented Outer Ring for Windmill Ceiling Fan Blade Mounting
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Solution Overview
Problem
Windmill style ceiling fans face challenges in shipping due to the large and massive size of their fan blades, requiring secure support structures that are difficult and costly to assemble and transport, while existing solutions are complex and time-consuming.
Innovation Solution
A blade mounting assembly featuring a smaller diameter inner support ring and a larger diameter outer support ring, with the outer ring formed as separable segments that interlock to form a solid ring, allowing for disassembly during shipping and easy assembly using upper and lower support arms and gussets for secure blade attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a solid outer support ring is used to securely support the large and massive fan blades, then the structural integrity and stability are improved, but the shipping cost and complexity increase due to the large size and mass
Solution Approach 1:
The outer support ring is divided into multiple separable segments that can be disassembled for shipping and reassembled for installation. This segmentation allows the large-diameter ring to be broken down into smaller, more manageable pieces that occupy less shipping space and cost less to transport, while still forming a complete structural ring when assembled.
2Stability of the object's composition
If a solid outer support ring is used to securely support the fan blades, then the structural integrity is improved, but the device complexity increases due to the need for special blade mounting assembly
Solution Approach 1:
The blade mounting assembly is segmented into modular components including the outer support ring segments, inner support ring, support arms, and gussets. Each component is designed to be independently manufactured and assembled, simplifying the overall assembly process while maintaining structural integrity.
Solution Approach 2:
The inner support ring is nested within the outer support ring structure, with support arms connecting the two rings. This nested arrangement allows the components to be compactly stored during shipping and efficiently assembled during installation, reducing both shipping volume and assembly complexity.
3Stability of the object's composition
If a large diameter outer support ring is used to support the fan blades, then the fan blade stability is improved, but the shipping space and cost increase
Solution Approach 1:
The large-diameter outer support ring is segmented into multiple sections that can be disassembled into smaller components for shipping. When assembled at the installation site, these segments form the complete large-diameter ring necessary for supporting the fan blades, thus reducing shipping volume while maintaining the required structural stability.
4Strength
If a massive blade support structure is used to support the large fan blades, then the structural strength is improved, but the ease of manufacture and assembly deteriorates
Solution Approach 1:
The massive blade support structure is divided into standardized modular segments including outer ring sections, inner ring sections, support arms, and gussets. These modular components can be manufactured independently using standardized processes and then assembled together, making the manufacturing and assembly process more efficient while maintaining the required structural strength.
Solution Approach 2:
The support arms serve multiple functions: they connect the inner and outer rings, provide structural support for the fan blades, and enable the modular assembly of the segmented rings. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process.
Data Source
AI summary
A blade mounting assembly is used to produce a completed windmill ceiling fan having fan blades that extend out from a fan motor body that rotates about a motor shaft. The blades are mounted using an inner and outer support ring. The inner support ring includes a series of blade receiving pockets. The outer support ring is initially shipped as a series of separable segments which are subsequently locked together to form the complete ring. Each of the outer ring segments also carries a gusset which receives a portion of a fan blade for further supporting the fan blade.