Stamped Low Carbon Steel Snow Thrower Impeller
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Solution Overview
Problem
Existing snow thrower impellers are inefficient and costly to manufacture due to complex manufacturing processes and high production costs.
Innovation Solution
A simple and inexpensive impeller design formed by stamping a sheet of low carbon steel, featuring a central portion with angularly spaced scoops or shovels, which are formed by bending or deforming the material without welding, reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex manufacturing processes are used for existing impellers, then manufacturing precision and reliability are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single stamping process. The impeller is formed by stamping a sheet of low carbon steel in one operation, eliminating the need for separate welding, assembly, and finishing operations that characterize traditional impeller manufacturing. This consolidation reduces device complexity while maintaining manufacturing precision through the inherent accuracy of stamping processes.
Solution Approach 2:
The patent replaces complex mechanical assembly processes with a single stamping operation. Instead of using multiple mechanical steps including welding, bolting, or riveting to assemble impeller components, the entire impeller structure is formed by applying mechanical pressure through a stamping die to the steel sheet, simplifying the manufacturing system while preserving precision.
2Strength
If traditional impeller designs are used, then structural strength is maintained, but manufacturing cost and production time increase
Solution Approach 1:
The patent changes the material parameter by specifying low carbon steel with a carbon content of 0.05% to 0.25%, which provides adequate strength for impeller application while being more formable and less expensive than higher carbon steels. Additionally, the stamping process parameters are optimized to achieve the required structural strength through controlled deformation, enabling single-step production that increases manufacturing efficiency while maintaining strength requirements.
3Reliability
If welding and complex assembly processes are used, then impeller reliability is improved, but manufacturing cost and production time increase
Solution Approach 1:
The patent combines forming, strengthening, and final shaping operations into a single stamping process. The impeller is formed, strengthened through work hardening during stamping, and finalized in one continuous operation, eliminating multiple separate manufacturing steps. This integration maintains reliability by ensuring consistent material properties throughout the impeller while dramatically reducing manufacturing time.
Solution Approach 2:
The stamping process performs preliminary strengthening through work hardening during the forming operation itself, rather than requiring subsequent heat treatment or additional strengthening steps. The material is pre-worked to achieve the required strength and dimensional accuracy during the primary forming operation, reducing total manufacturing time while ensuring reliable impeller performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The impeller efficiently throws snow with reduced manufacturing time and cost, enhancing the overall performance and affordability of snow throwers.
Implementation Method 1
formed by stamping a sheet of low carbon steel, featuring a central portion with angularly spaced scoops or shovels, which are formed by bending or deforming the material without welding
Data Source
AI summary
A snow thrower impeller includes a layer of material comprising blade support walls and blades extending from the blade support walls.