Abstract:
An apparatus for forming an inclined-blade blower wheel is provided. A plurality of blades are initially positioned between first and second end caps, and a first engagement member mates with the first end cap, while a second engagement member mates with the second end cap. First and second end motors are configured to independently rotate the first and second engagement members. A crimping roller coupled to a crimping motor contacts and compresses a circumference of the first and second end caps to a plurality of blades. A controller is configured to rotate the first engagement member a predetermined amount with respect to the second engagement member, a then circumferential speed of the first and second end caps and the crimping roller is synchronized, therein fixing a desired longitudinal pitch of the plurality of blades between the first and second end caps.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to a manufacturing apparatus and method, and more specifically to an apparatus and method for forming a blower wheel having blades that are non-parallel with an axis of the blower wheel. 
       BACKGROUND OF THE INVENTION 
       [0002]    Blower wheels are often utilized in cross-flow fans, also called transverse fans or centrifugal fans. One type of blower wheel comprises a plurality of fan blades that are positioned about a circumference of the blower wheel, wherein the plurality of fan blades are further axially inclined, therein mitigating to a certain degree, noise associated with the rotation of the blower wheel within a housing. 
         [0003]    Conventionally, blower wheels having inclined blades are formed by aligning blades with respect to two or more disks, wherein the blades are initially set in grooves in the disks such that the inclined blades are skewed at a predetermined angle from one end of the blower wheel to another (e.g., not parallel with an axis of the blower wheel defined by the two or more disks). The blades are subsequently fastened to the two or more disks by a pressing or weld the blades to the two or more disks, therein fixing the blades in the inclined position at the predetermined angle. Such a fastening of the blades to the two or more disks, however, can cause a variation in the predetermined angle from one blower wheel to another. 
       SUMMARY OF THE INVENTION 
       [0004]    The present disclosure overcomes the limitations of the prior art by providing an improved system, apparatus, and method forming a blower wheel having axially inclined blades. Accordingly, the following presents a simplified summary in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later. 
         [0005]    In accordance with one exemplary aspect, an apparatus for forming a blower wheel is provided, wherein the blower wheel initially comprises a first end cap, a second end cap, and a plurality of blades arranged about a circumference of the first and second end caps. The plurality of blades extend longitudinally between the first and second end caps. In accordance with the disclosure, the apparatus comprises a first engagement member rotatably coupled to a first end motor, wherein the first engagement member is configured to mate with the first end cap. A second engagement member is further rotatably coupled to a second end motor, wherein the second engagement member configured to mate with the second end cap. The first and second end motors, in one example, comprise servo motors. 
         [0006]    A crimping roller assembly is further rotatably coupled to a crimping roller motor, wherein the crimping roller assembly is configured to selectively crimp the first and second end caps to the plurality of blades. The first and second end caps, for example, each comprise a radially slotted back plate, wherein the plurality of blades initially rest in a respective plurality of radial slots disposed about the circumference of the first and second end caps. 
         [0007]    A controller is further provided, wherein the controller is configured to control a rotational speed of each of the first end motor, second end motor, and crimping roller motor. Based, at least in part, on a desired longitudinal pitch of the plurality of blades from the first end cap to the second end cap, the controller is configured to rotate the first engagement member a predetermined amount with respect to the second engagement member via the control of the first end motor and the second end motor. Once the predetermined amount of rotation is achieved, the controller is further configured to synchronize a circumferential speed of the first and second end caps and the crimping roller assembly via a control of the respective first and second end motors and crimping motor. 
         [0008]    The crimping roller assembly, in one example, is further configured to radially translate with respect to a center of the first and second end caps, therein compressing the first and second end caps circumferentially and securing the plurality of blades to the first and second end caps. Accordingly, the crimping roller assembly, in concert with the first end motor, second end motor, and crimping roller, are configured to selectively set the desired longitudinal pitch of the plurality of blades from the first end cap to the second end cap via the controller. 
         [0009]    Thus, to the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIGS. 1A-1C  illustrate front and side views of an exemplary blower wheel in a preformed state prior to having a predetermined longitudinal pitch defined therein. 
           [0011]      FIGS. 2A-2C  illustrate front and side views of an exemplary blower wheel after having a predetermined longitudinal pitch defined therein. 
           [0012]      FIG. 3  is a front plan view of an exemplary blower wheel forming apparatus according to one exemplary aspect of the invention. 
           [0013]      FIG. 4  is a perspective view of the exemplary blower wheel forming apparatus of  FIG. 3  according to another exemplary aspect of the invention. 
           [0014]      FIGS. 5A-5C  illustrate an exemplary formation of a blower wheel according to another aspect of the invention. 
           [0015]      FIG. 6  is an exemplary methodology for forming a blower wheel having a predetermined longitudinal pitch. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    The present disclosure is directed generally toward a system and apparatus for forming a blower wheel having axially inclined blades. The disclosure is further directed to a method for forming a blower wheel having axially inclined blades. Accordingly, the present invention will now be described with reference to the drawings, wherein like reference numerals may be used to refer to like elements throughout. It should be understood that the description of these aspects are merely illustrative and that they should not be interpreted in a limiting sense. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident to one skilled in the art, however, that the present invention may be practiced without these specific details. 
         [0017]    Referring now to the figures, in order to gain a better understanding of the present invention,  FIGS. 1A-1C  illustrate an exemplary blower wheel  100  in a preformed state  102 , wherein the blower wheel comprises a first end cap  104 , a second end cap  106 , and a plurality of blades  108  arranged about a circumference  110  of the first and second end caps and extending longitudinally therebetween. The first end cap  104  and second end cap  106 , for example, each comprise a plurality of radial slots  112  disposed about a circumference  113  of the first and second end caps, wherein the plurality of blades  108  initially rest in the respective plurality of radial slots in the preformed state  102 . 
         [0018]    In one particular example, the blower wheel  100  further comprises one or more intermediate plates  114  disposed along a length of the blower wheel, wherein the one or more intermediate plates further provide additional support to the plurality of blades  108 . The one or more intermediate plates  114 , for example, are similar in structure to the first and second end caps  104  and  106 . It should be noted that the number, structure, and location of the one or more intermediate plates  114  may vary, depending on design considerations, and the one or more intermediate plates may alternatively be eliminated altogether, if so desired. 
         [0019]    Positioning, arrangement, and/or loose assembly of the first end cap  104 , second end cap  106 , plurality of blades  108 , and/or the one or more intermediate plates  114  (e.g., defining the preformed state  102 ), for example, is performed in a jig or other device (not shown), wherein proper alignment and positioning of the blower wheel  100  is performed. The term “loose assembly” refers to the first end cap  104 , second end cap  106 , plurality of blades  108 , and/or the one or more intermediate plates  114  being placed together such that the plurality of blades rest in the plurality of radial slots  112 , but are not permanently fastened together, therein defining the preformed state  102  of the blower wheel  100 . 
         [0020]    In accordance with one example, as illustrated in  FIGS. 1B and 1C , the first end cap  104  and second end cap  106  respectively comprise a first engagement pattern  116  and a second engagement pattern  118  defined therein. The first engagement pattern  116  and second engagement pattern  118 , for example, are configured to provided to secure the blower wheel  100  to a rotational shaft of a blower motor (not shown), as will be understood by one of ordinary skill in the art. In accordance with another example, a first alignment feature  120  and a second alignment feature  122  are defined on the respective first end cap  104  and second end cap  106 , wherein the first alignment feature and second alignment feature are configured to aid in aligning the first and second end caps and plurality of blades  108  into the preformed state  102 . The first alignment feature  120  and second alignment feature  122 , for example, comprise one or more of a hole, pattern, indentation, marking, sticker, and any other reflective, non-reflective, or transparent feature in or on the respective first end cap  104  and second end cap  106  operable to mechanically, optically (e.g., via an optical beam), and/or electronically aid in the alignment of the first and second end caps with respect to one another along a blower wheel axis  124  defined therebetween during and/or after the preparation of the blower wheel into its preformed state  102 . 
         [0021]    In  FIGS. 2A-2C  illustrate the blower wheel  100  in a final state  126 , as will be further discussed infra, wherein the final state of the blower wheel is made possible by an exemplary blower wheel forming apparatus  200  illustrated in  FIGS. 3 and 4 . In accordance with the disclosure, the apparatus  200  of  FIG. 3 , for example, is particularly directed toward transforming the blower wheel  100  from the preformed state  102  of  FIG. 1  to the final state  126  of  FIG. 2 , wherein the blower wheel, in its final state, has a fixed longitudinal pitch of the plurality of blades  108  from the first end cap  104  to the second end cap  106 . 
         [0022]    The apparatus  200  of  FIGS. 3 and 4  for forming the blower wheel  100 , for example, comprises a first engagement member  202  rotatably coupled to a first end motor  204 , wherein the first engagement member is configured to mate with the first end cap  104  of  FIGS. 1 and 2 . The apparatus  200  of  FIGS. 3 and 4 , for example, further comprises a second engagement member  206  rotatably coupled to a second end motor  208 , wherein the second engagement member is configured to mate with the second end cap  106 . The first engagement member  202  and second engagement member  206 , for example, are generally configured to mate with the respective first end cap  104  and second end cap  106  of the blower wheel  100 , therein generally rotationally fixing the first end cap with respect to the first engagement member, and the second end cap with respect to the second engagement member. The first engagement member  202  and second engagement member  206 , for example, are further configured to rotate about the blower wheel axis  124  associated with a blower wheel  100 . The first end motor  204  and second end motor  208 , for example, each comprise a servo motor configured to provide feedback associated with the rotational position of the first engagement member  202  and second engagement member  206 . 
         [0023]    A crimping roller assembly  210  is further rotatably coupled to a crimping roller motor  212 , wherein the crimping roller assembly  210  is configured to selectively crimp the first end cap  104  and second end cap  106  to the plurality of blades  108 . For example, each of the first end cap  104  and second end cap  106  comprise a plurality of tabs  213  associated with the respective plurality of radial slots  112 , as illustrated in  FIGS. 1B and 1C . The crimping roller assembly  210  of  FIGS. 3 and 4 , for example, comprises at least one crimping roller  214  configured to rotate about a crimping roller axis  216  that is selectively offset from the blower wheel axis  124 , and wherein a circumference  218  of the crimping roller is configured to selectively contact and compress the circumference  113  of at least the first and second end caps  104  and  106  of  FIGS. 1B and 1C . In one example, a plurality of crimping rollers  214  are operably coupled to the crimping roller motor  212 , wherein the crimping motor is configured to selectively rotate each of the plurality of crimping rollers (e.g., illustrated as arrows  215  in  FIGS. 5A and 5B ) about a plurality of crimping roller axes  216 . The crimping rollers  214   FIGS. 5A-5C , for example, are configured to compress the plurality of tabs  213  associated with the respective plurality of radial slots  112 , as illustrated in  FIGS. 1B and 1C , therein selectively securing the plurality of blades  108  to at least the first end cap  104  and second end cap  106  of  FIGS. 1A-1C  and  2 A- 2 C, as will be further discussed infra. 
         [0024]    In accordance with another example, wherein the blower wheel assembly  100  further comprises one or more intermediate plates  114  disposed between the first and second end caps  104  and  106  (e.g., as illustrated in  FIGS. 1A and 2A ), the at least one crimping roller  214  of  FIGS. 3 and 4  is further configured to selectively contact and compress a circumference of the one or more intermediate plates, therein securing the plurality of blades  108  to the one or more intermediate plates. 
         [0025]    In one example, the apparatus  200  further comprises a base  217 , wherein one or more of the crimping roller(s)  214 , crimping roller motor  212 , first end motor  204 , and second end motor  208  are operably coupled to the base. According to another example, the crimping roller assembly  210  further comprises a radial positioning apparatus  218  configured to selectively position each of the crimping rollers  214  in a first position  220 , such as illustrated in  FIGS. 5A and 5C , and a second position  222 , such as illustrated in  FIG. 5B . As illustrated in  FIGS. 5A and 5C , for example, when the plurality of crimping rollers  214  are in the first position  220 , the circumference  218  of each of the plurality of crimping rollers does not contact the first and second end caps  104  and  106  (e.g., illustrated in  FIGS. 3 and 4 ). When translated (e.g., illustrated as arrows  223 ) to the second position  222  illustrated in  FIG. 5B , for example, the circumference  218  of the plurality of crimping rollers  214  are configured to contact and compress the circumference  113  of at least the first and second end caps  104  and  106  (e.g., illustrated in  FIGS. 3 and 4 ) toward the blower wheel axis  124 , therein compressing the plurality of tabs  213  associated with the respective plurality of radial slots  112  during a rotation of the crimping rollers about the crimping roller axes  216 . 
         [0026]    Thus, the compression of the plurality of tabs  213  associated with the translation of the crimping rollers  214  from the first position  220  of  FIG. 5A  to the second position  222  of  FIG. 5B  and rotation about the crimping roller axes  216  accordingly secures the plurality of blades  108  to at least the first end cap  104  and second end cap  106 . Likewise, in the case of one or more intermediate plates  114  illustrated in  FIGS. 1A and 2A  being disposed between the first and second end caps  104  and  106 , the crimping rollers  214  of  FIGS. 5A-5C  are further configured to selectively contact and compress a circumference of the one or more intermediate plates, therein similarly securing the plurality of blades  108  to the one or more intermediate plates. 
         [0027]    In accordance with another example, the crimping roller assembly  210  of  FIGS. 3 and 4  further comprises a plurality of gears  224 , wherein the plurality of gears generally synchronize a rotational speed of the plurality of crimping rollers  214 . As such, the plurality of gears  224  are further configured to translate the plurality of crimping rollers  214  between the first position  220  of  FIGS. 5A and 5C  and the second position  222  of  FIG. 5B , while further providing the above-described rotation to the crimping rollers. 
         [0028]    According to another exemplary aspect of the disclosure, a controller  226  is further provided in  FIGS. 3 and 4 , wherein the controller is configured to control a rotational speed of each of the first end motor  204 , the second end motor  208 , and the crimping roller motor  212 . The control of the rotational speed of the first end motor  204 , the second end motor  208 , and the crimping roller motor  212 , for example, is based, at least in part, on a desired longitudinal pitch of the plurality of blades  108  from the first end cap  104  to the second end cap  106 . 
         [0029]    In accordance with one aspect, the controller  226 , for example, is configured to rotate the first engagement member  202  a predetermined amount with respect to the second engagement member  206  via the control of the first end motor  204  and the second end motor  208 . For example, the controller  226  rotates the first engagement member  202  a predetermined amount via the first end motor  204  while maintaining the second engagement member  206  stationary by controlling the second end motor  208 . Alternatively, the second end motor  208  can rotate the second engagement member  206  while holding the first engagement member  202  stationary via the control of the first end motor  204 . In the case where the first end motor  204  and second end motor  208  each comprise servo motors, the servo motors are configured to provide rotational feedback to the controller  226 . 
         [0030]    Once the predetermined amount of rotation is achieved, the controller  226  is further configured to synchronize a circumferential speed of the first end cap  104 , the second end cap  106 , and the one or more crimping rollers  214  of the crimping roller assembly  210  via a control of the respective first end motor  204 , second end motor  208 , and crimping roller motor  212 . Thus, apparatus  200  is configured to secure the plurality of blades  108  to the first end cap  104  and second end cap  106 , and therefore fix the desired longitudinal pitch of the plurality of blades from the first end cap to the second end cap. 
         [0031]    The controller  226 , for example, is further configured to control the radial positioning apparatus  218 . The control of the radial positioning apparatus  218 , for example, can be based on the predetermined amount of rotation between the first end motor  204  and second end motor  208 , wherein the positioning of the at least one crimping roller  214  in the second position  224  of  FIG. 5B  and securing of the plurality of blades  108  to the first end cap  104  and second end cap  106  occurs once the predetermined amount of rotation is achieved. 
         [0032]    The present disclosure further provides a method  300  in  FIG. 6  for forming a blower wheel having axially-inclined (e.g., longitudinal pitched) blades, such as the exemplary blower wheel  100  illustrated in  FIG. 2A . It should be noted that while exemplary methods are illustrated and described herein as a series of acts or events, it will be appreciated that the present invention is not limited by the illustrated ordering of such acts or events, as some steps may occur in different orders and/or concurrently with other steps apart from that shown and described herein, in accordance with the invention. In addition, not all illustrated steps may be required to implement a methodology in accordance with the present invention. Moreover, it will be appreciated that the methods may be implemented in association with the systems illustrated and described herein as well as in association with other systems not illustrated. 
         [0033]    According to one example, as illustrated in  FIG. 6 , the method  300  comprises arranging a plurality of blades about a respective circumference of a first end cap and a second end cap in act  305 , wherein the plurality of blades extend longitudinally between the first and second end caps and generally parallel to an axis defined by respective centers of the first end cap and second end cap. The plurality of blades, for example, are arranged about the circumference of the first end cap and second end cap in a jig. In one example, one or more intermediate plates are further arranged between the first and second end caps in act  305 . 
         [0034]    In one example, arranging the plurality of blades about respective circumferences of the first end cap and second end cap of act  305  further comprises aligning a first engagement pattern associated with the respective first end cap with respect to a second engagement pattern associated with the second cap. For example, the first engagement pattern  116  and second engagement pattern  118  of  FIGS. 1A-1C  are aligned via an aligning one or more of the first alignment feature  120  associated with the first end cap  104  with respect to a second alignment feature  122  associated with the second end cap  106 . Various sensors (not shown), such as an optical sensor utilizing an optical beam can be directed toward the first end cap and second end cap, wherein once the first alignment feature and second alignment feature are aligned with the optical beam, a signal is produced indicating the alignment of the first engagement pattern with respect to a second engagement pattern. 
         [0035]    In one example, in act  310  of  FIG. 6 , a first engagement member engages the first end cap, and a second engagement member engages the second end cap. The first engagement member is rotated a predetermined amount with respect to the second engagement member in act  315 , such as via first and second servo motors  204  and  208  of  FIGS. 3 and 4 , therein skewing the plurality of blades at a desired longitudinal pitch from the first end cap to the second end cap. Once the desired longitudinal pitch as achieved in act  315  of  FIG. 6 , the first engagement member and second engagement member are rotated in unison in act  320 . In act  325 , the circumferences of the first end cap and second end cap are crimped while the first engagement member and second engagement member are rotated in unison, therein securing the plurality of blades to the first and second end caps and fixing the desired longitudinal pitch of the plurality of blades from the first end cap to the second end cap, and crimping a circumference of the one or more intermediate plates, therein securing the plurality of blades to the one or more intermediate plates. When one or more intermediate plates are provided in act  305 , for example, the circumference of the one or more intermediate plates is also crimped in act  325 . 
         [0036]    Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, circuits, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more other features of the other embodiments as may be desired and advantageous for any given or particular application.