JP3074863B2 - Method of manufacturing vortex blower impeller - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an impeller of a vortex blower and a method of manufacturing the same, and more particularly to an impeller suitable for a vortex blower having three-dimensionally shaped blades and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, various studies have been made on the shape and structure of an impeller in response to increasing demands for a small and lightweight vortex blower, high discharge pressure, and low noise. One of them is to make a blade of an impeller three-dimensional.

[0003] With the practical use of the vortex blower provided with such a three-dimensionally shaped blade, a method of manufacturing the vortex blower has become a major problem. In other words, the conventional impeller of a vortex blower having a two-dimensional blade is manufactured mainly by casting such as die-casting because of its relatively simple shape, but the impeller having a three-dimensional blade is This is because if casting is used, manufacturing becomes difficult due to the three-dimensional shape of the blade.

Therefore, as a solution to these problems, there is a method of eliminating the core of the mold by dividing the structure into two parts in the rotation direction of the impeller and joining them after casting to complete the impeller. JP-A-51-57011 proposes a method of attaching the blade to the blade casing by using the blade and the blade casing as separate members.

[0005]

In the above-mentioned conventional manufacturing method in which the blade and the blade casing are formed as separate members and the blade is attached to the blade casing, an energization overheating caulking method, which is one of plastic deformation methods, is used.

As the electrode material used in this caulking method, chromium copper generally used for spot welding, stainless steel, heat-resistant steel, and the like are used. However, these materials have a short life due to lack of high-temperature strength, and have a short blade life. The eutectic reaction with aluminum, which is a material, causes a problem of caulking, which also depends on the shape of the tip of the electrode.

Further, the joint between the blade and the blade casing needs to have a joint force capable of withstanding the tensile stress and vibration generated when the impeller rotates, and in the bending method, the roll diameter of the rotating roll and the blade diameter are changed. Due to the relationship with the pitch of insertion into the blade casing,
Poor bending occurs. Also, burrs may occur depending on the shape of the projecting portion to be bent.

[0008] In addition, it is necessary to consider a method of forming the blade shape to improve the aerodynamic performance of the impeller.

An object of the present invention is to provide a manufacturing method for improving the performance and reliability of an impeller manufactured by combining a blade and a blade casing.

[0010]

In order to achieve the above object, the present invention relates to a method for manufacturing a swirl blower manufactured by assembling a blade casing and a plurality of blades. In addition, in a working process of using an electrode having an appropriate shape and performing current caulking, after the electrode was separated from the caulked portion, the clamp of the blade was released. The connecting portion between the blade casing and the blade had a cross-sectional shape in which the insertion groove was rounded at four corners, and the depth direction of the insertion groove used was parallel to the rotation axis direction and tapered.

[0011] In the bending method, before the roll bending by the rotating roll, the bending projection portion of the blade is provisionally bent by about 5 to 45 degrees, and then the diameter is changed with respect to the insertion pitch of the blade. Bending is performed using a rotating roll that is twice or less. Further, the bending projection has a rectangular shape with rounded corners at the tip, and is bent in a direction opposite to the rotation direction of the impeller. In addition, the thickness of the edge portion serving as the air inlet / outlet to the blade impeller is reduced to 1 / th of the blade thickness.
Press processing is performed so as to be 2 or less.

[0012]

By using alumina-dispersed copper as the electrode material for the caulking method, the life of the electrode is extended, and the shape of the tip of the electrode is determined by setting the area of the contact surface with the caulking protrusion of the blade to 1. From 2x to 7.1x, tip angle 30
By setting the angle from 110 degrees to 110 degrees, the pushability of the metal into the insertion groove is improved.

Further, by releasing the clamp after the electrode is separated, it is possible to reduce defects caused by raising the swaged portion due to seizure of the electrode. In addition, the shape of the blade insertion groove portion of the blade casing was improved in accordance with the shape of the blade to improve the reliability of the joint between the blade and the blade casing.

After the temporary bending of about 5 to 45 degrees, the bending failure is eliminated by using a rotating roll that is twice or less the bending pitch. The aerodynamic performance of the impeller was improved by reducing the thickness of the blade edge to half or less of the blade thickness.

[0015]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a vortex blower according to the present invention.

FIG. 1 is a sectional view of an embodiment of an eddy-current blower using an impeller according to the present invention, wherein 1 is an impeller, 2 is a casing forming a boosting path 3, and 4 is an electric motor for driving the impeller 1. . The step-up path 3 is a rotation center of the impeller 1, that is, an electric motor 4.
Are formed in an arc shape centered on the rotation axis center line 5, and are opened in parallel with the rotation axis center line 5, and are formed as semi-circular grooves as shown in the figure. 6 is a blade casing, 7 is an annular groove, and 8 is a blade. After being manufactured as a separate member from the blade casing 6 and the blade 8, they are combined to form the impeller 1 as shown in FIG.

The annular groove 7 formed in the blade casing 6 is formed as an annular groove formed of a concentric circle centered on the rotation axis center line 5, in which a plurality of blades 8 extend in a direction crossing the groove. Installed.

The method of attaching the blade 8 to the blade casing 6 is a caulking method or a bending method, which is one of the plastic deformation methods. As shown in FIG. 3A, a blade 8 having a projection 9a at the bottom and projections 9b at both ends is prepared. As shown in FIG. 3B, the blade casing 6 is also provided with a through hole 10a and an insertion groove 10b.

As shown in FIGS. 4 (a) and 4 (b), the protrusion 9a of the blade 8 is inserted into the through hole 10a, and the protrusion 9b is inserted into the insertion groove 10b.
With the blade 8. Next, as shown in FIG. 3C, the projection 9b is energized to perform caulking as shown in FIG. Next, temporary bending is performed as shown in FIG.
The protruding portion 9a of the blade 8 is slightly bent as shown in FIG. Finally, as shown in FIG. 7 (g), bending is performed by the rotating roll 13, and FIG.
The projection 9a is bent along the outer surface of the blade casing 6 as shown in FIG.

FIG. 5 shows a caulking method and a bending method. In the current caulking method, as shown in FIG. 1A, current is applied to the protrusion 9b while the blade 8 is held by the work presser 12, and caulking is performed. It is fastened by caulking the tip of the. In the bending process, the upper part of the blade 8 and the blade casing 6 are pressed by the blade holder 14 as shown in FIG. Bending is performed by moving in the direction of a.

FIG. 6 shows the structure of the electrode 11 used in the energized overheating caulking method for performing caulking hot, and the protrusion 9 b of the blade 8.

Conventionally, the material used for the electrode 11 is chromium copper used for spot welding or the like, stainless steel, or heat-resistant steel. Further, molybdenum, tungsten, and silver-tungsten alloys which are considered to be effective in terms of high-temperature strength can be given. However, since the impeller 1 is made of aluminum for weight reduction, any of the above-mentioned materials is not an optimal electrode material because eutectic alloys and seizure easily occur with aluminum.

Therefore, in the present invention, alumina-dispersed copper developed for galvanized steel sheets is used as a new electrode material.
Alumina-dispersed copper has a high strength at high temperatures, so that it is possible to dramatically increase the number of continuous uses in current caulking. In addition, since the eutectic reaction with aluminum hardly occurs, the possibility that the caulked portion is pulled up when the electrode 11 separates from the caulked portion is reduced, and more effective energization and overheating caulking can be performed.

Depending on the shape of the tip of the electrode 11, the blade projection 9b is inserted into the insertion groove 10b of the blade casing 6.
The indentation of the material changes. This is because when the electrode tip area c is too small, the protrusion 9b softened by energization is
No. 1 deviates from the tip and cannot be pushed well.
Conversely, if the area c at the tip end is large, the crushed protrusion 9b is sandwiched between the electrode 11 and the pushability is reduced.

Therefore, the shape of the electrode tip is shown in FIG.
As shown in (a), the angle b at the tip is 30 degrees to 110 degrees, and the area c at the tip of the electrode 11 shown in (a ') is 1.2 times the cross-sectional area of the blade projection 9b shown in (b). From 7 to 7.
It can be said that the range of 1 time is a shape that can perform good caulking. FIG. 6B shows a side surface of the protrusion 9b.

Although the electrode material may be a round bar having a cross-sectional area at the tip end, a material corresponding to this cross-sectional area is not always available on the market and has a practical problem.

FIGS. 7 (a) to 7 (e) are views showing a work procedure for energizing and caulking. After the current is swaged as shown in FIG. 9A, the electrode 11 is separated according to the procedures shown in FIGS. 9B and 9C.
Thereafter, the work holder 12 is released.

Although it is possible to perform the caulking work without using the work holder 12, as described above, when the eutectic reaction occurs and the electrode 11 and the caulked portion are seized, the electrode 11
However, the caulking portion may be lifted because the blade 8 is pulled up.

Therefore, in this embodiment, in order to prevent the blade 8 from being lifted, when the electrode 11 is separated, the blade 8 and the blade casing 6 are pressed by the work holder 12 so that even if seizure occurs, Blade 8
Is difficult to lift. Needless to say, the electrodes 11 may be separated at multiple points or one point at a time.

Next, FIGS. 8 and 9 show the blade casing 6.
3 shows various shapes of an insertion groove 10b provided on the inner and outer peripheral edges of the annular groove 7 of FIG. (B), (c),
If the cross-sectional shape of the insertion groove 10b has no corners as in (d), the metal which is softened and crimped when the current is swaged is easily filled into the peripheral portion. Further, since the shape is simplified by forming the same cross-sectional shape from the inlet portion to the lower portion of the insertion groove portion 10b, the die-cast mold for manufacturing the blade casing 6 is easily formed. FIG. 5E shows a tapered groove shape in which the entrance portion of the insertion groove portion 10b is widened. With this shape, the insertability of the blade 8 can be improved. However, with this shape, the fastening force of the swaged part is low,
There is a drawback that caulking failure easily occurs.

Next, the improvement of the reliability of the bending work will be described. First, FIG. 10 shows an embodiment in which a small-diameter bending roll 13 is used for the blade pitch P.
The bending roll diameter D is 2 with respect to the blade insertion pitch P.
If a roller having a diameter twice or more is used, the bending protrusion 13 of the blade 8 will be
Since the contact points a are simultaneously contacted at multiple points, the bent projections 9a do not bend in the rotation direction of the rotary roll 13, but are raised upward. Therefore, in the present invention, the diameter D of the rotating roll 13 is set to be less than twice the insertion pitch P of the blade 8 into the blade casing 6. This makes it possible to reduce bending failure.

FIG. 11 shows an embodiment for further preventing the occurrence of bending failure. As shown in FIG.
Presser 15a using air pressure, hydraulic pressure, etc.
And the blade casing 6 is fixed, and as shown in FIG. 4B, the blade 8 is mounted on a table having the same rotation axis 5 as the impeller 1 between the protrusions protruding from the blade casing 6. The jig having the claws 15c radially arranged so as to be inserted is rotated in the direction indicated by the arrow G, and the bending projection 9a is angled from 5 degrees to 45 degrees as shown in FIG. It is said that you can only tilt. Thereby, the bending failure can be completely eliminated.

FIG. 12 shows the bent projection 9a of the blade.
Are examples showing various shapes. In the examples so far, as shown in FIG. 3A, the bent projection 9a has a trapezoidal shape with a thin tip, and is inserted into the through hole 10a of the blade casing 6 by press fitting. However, with this shape, when the blade 8 is inserted, burrs are generated at the base of the projection 9a, and there is a safety problem in view of the situation where the vortex blower is used.

In this embodiment, as shown in FIG. 3B, the width of the bent projection 9a of the blade is made narrower than the width of the through hole of the blade casing 6 so that the angle of the tip is reduced. In addition, it is possible to insert without generating burrs without changing the insertability. Also, the bent projection 9a of the blade
Since the width of the inside of the bent portion becomes larger than the protrusion before bending when bent, the spread of the bent portion is adjusted by adjusting the width of the protrusion portion and the width of the through hole 10a of the blade casing 6. It is possible to make use of the hole to penetrate the through hole 10a to obtain a larger fastening force.

It is needless to say that the shape of the tip may be rounded as shown in FIG. 3C or semicircular as shown in FIG.

FIG. 13 shows the bending direction of the blade bending projection 9a. The bending direction is to be bent in a direction opposite to the rotation direction of the impeller 1. This is the bent projection 9
surface receiving the wind in a, drag portion is received in a plane when the bent direction of rotation projecting portion 9a of the impeller 1, which receives the wind pressure to become a curved surface when the bent <br/> reversed Direction Since the coefficient decreases, the pressure received from the air can be reduced.

Next, another embodiment of the present invention is shown in FIG.
In the above description, the method of improving the reliability of the caulked portion by the working means and the shape of the groove at the joint portion of the blade 8 and the blade casing 6 by caulking has been described. In this embodiment, the centrifugal force generated when the impeller 1 rotates prevents the tensile stress from being concentrated on the swaged portion,
In addition, as shown in FIG. 3A, a part of the blade 8 is reduced by 0.05 W or more with respect to the width W of the blade 8 in order to relax the width.
A bent portion having a depth H in a range of 0.5 W or less is provided. When the blade 8 is actually subjected to centrifugal force, the blade 8 is deformed in a direction in which the bent portion expands, so that concentration of stress on the swaged portion can be avoided. Needless to say, a shape having a plurality of curved portions as shown in FIG.

FIG. 15 shows an embodiment in which the blade 8 and the blade casing 6 are assembled only by bending without crimping the protruding portion 9b of the blade 8. The swaged portion 9b of the blade 8 shown in FIG.
As shown in FIG. 7, only the insertion is performed, and even if the impeller 1 is deformed in the outer peripheral direction, the protrusion 9b can slide, so that the generation of the tensile stress at the caulked protrusion 9b can be reduced to zero. .

Further, as a countermeasure against the pressure generation in the direction in which the blade 8 rises, the edge of the air outlet portion of the blade 8 can be slightly lower than the surface of the blade casing 6.

FIG. 16 shows another embodiment of the present invention.
As shown in FIG. 3A, the thickness T ′ of the blade 8 at the outlet of the air is made not more than １ ／ of the thickness T of the blade 8. With such a shape, the discharge pressure of the impeller 1 can be increased as shown in FIG. It is needless to say that the thickness T ′ of the exit portion of the blade 8 should be as small as possible as shown in FIG.

Therefore, as a method of forming this shape, when the blade 8 is punched at the stage of manufacturing the blade 8 by a conventional press, the punching direction is made parallel to the surface to be cut, so that the thickness of T ′ is initially set. There is a method of forming the shape and then bending the caulking projection 9b, or a method of crushing to a thickness T 'at the stage of forming the shape.

Another embodiment of the present invention will be described with reference to FIG. In this embodiment, a punch is further struck on the swaged portion to improve the tightening force.

FIG. 7A is a perspective view showing the structure of the swaged portion. FIG. 1B shows the AA cross section of FIG. 1A, and FIG. 1B shows the upper surface thereof. In this embodiment, the insertion groove 10 is used.
b has a width larger than the width of the protrusion 9b.
The protruding portion 9b inserted into Ob is caulked at its upper portion and expanded to the same width as the width of the insertion groove 10b, and the blade 8 and the blade casing 6 are fastened at a depth of K from the surface of the blade casing.

By increasing the length of the K portion, the fastening force of the swaged portion can be increased. As a method of increasing the K portion, it is conceivable to increase the height I of the protruding portion 9b of the blade 8. However, if the I is too high, buckling occurs at the time of energizing and the K decreases conversely. I will. Therefore, in order to increase K without increasing the height of the projection, it is conceivable to perform cold plastic working after caulking.

(C), (c '), (d), (d') of FIG.
Punching was performed on the swaged portion as cold plastic working after swaging. Accordingly, the swaged portion can be pushed and expanded, the length of K can be increased, and the fastening force can be improved. The tip shape of the punch may be a conical shape as shown in FIGS. (C) and (c ′) or a wedge shape as shown in FIGS. (D) and (d ′). It goes without saying that the shape may be a quadrangular pyramid or a polygonal pyramid.

Although punching without punching has been considered, in this case, it is necessary to drop the punch to the width of the plate thickness J of the projection 9b.
It is difficult to position the punch from the point of the dimensional accuracy of the above, and there is a practical problem.

In this embodiment, since the protrusion 9b of the blade 8 is first crushed by current caulking to increase the area, the area where the punch can be punched is increased, and the workability can be improved.

[0048]

According to the present invention, it is possible to obtain an impeller of a vortex blower which is excellent in productivity and can improve reliability or aerodynamic performance and a method for manufacturing the same.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a vortex blower provided with an impeller according to an embodiment of the present invention.

FIG. 2 is a perspective view showing an impeller in the present embodiment.

FIGS. 3A and 3B are explanatory views of a blade casing and a blade in the present embodiment. FIG. 3A is a side view of the blade, and FIG. 3B is a cross-sectional view of the blade casing.

FIG. 4 is a view showing a manufacturing process of the present embodiment, and FIG.
(C), (e) and (g) show the impeller in each step, and (b), (d), (f) and (h) are perspective views respectively showing the processing state of the blade in each step. It is.

FIG. 5 shows a fixing method of the blade in the present embodiment,
FIG. 7A is a cross-sectional view showing a caulking step, and FIG. 7B is a cross-sectional view showing a bending step.

6 (a) is a side view of the electrode, FIG. 6 (a ′) is a bottom view of the electrode, FIG. 6 (b) is a top view of the blade, and FIG. 6 (b ′). () Is a side view of the blade.

7A to 7E are cross-sectional views illustrating the relationship between the electrode and the work press from the start to the end of the caulking in each of FIGS.

FIG. 8 shows a caulking projection of the blade according to the present embodiment;
It is a perspective view showing the insertion groove part of a blade casing.

FIG. 9 is an explanatory view showing a structure of an insertion groove portion of the blade casing in the present embodiment, and (a), (b),
(C), (d), (e) are top views, (a ′),
(B ′), (c ′), (d ′), (e ′) are side views.

FIG. 10 is a side view illustrating a roll rotation bending method in the present embodiment.

FIG. 11 is a view for explaining temporary folding in the present embodiment;
2A is a sectional view, FIG. 2B is a plan view, and FIG.
Is a sectional view of a main part.

FIGS. 12A and 12B are diagrams showing various shapes of protrusions at the bottom of the blade in this embodiment, wherein FIG. 12A is a trapezoidal shape, FIG. (C) is a plan view showing a rectangular shape with rounded corners, and (d) is a plan view showing a semi-circular end.

FIG. 13 is a cross-sectional view showing a bending direction of a blade bent portion of the present invention in the present embodiment.

14A and 14B are diagrams showing a curved shape of a blade used in the present invention in the present embodiment, wherein FIG. 14A is a plan view showing one curved portion, and FIG. 14B is a plan view showing two curved portions. is there.

15A and 15B are cross-sectional views illustrating a method of assembling a blade casing to a blade without performing caulking in the present embodiment. FIG. 15A is a side view of the blade, and FIG. 15B is a side cross-sectional view of the blade casing. It is.

16A and 16B are cross-sectional views showing a blade shape for the purpose of improving aerodynamic performance in this embodiment. FIG. 16A is a diagram in which the thickness of the tip is １ ／ of the blade thickness, and FIG. It is the figure which made the board thickness of the tip thin.

17 is a characteristic diagram showing aerodynamic performance by the blade of FIG.

18 (a) is a perspective view, FIG. 18 (b) is a top view, FIG. 18 (b ′) is a side sectional view, and FIG. Figure (c)
Is a top view, FIG. (C ′) is a side sectional view, FIG. (D) is a top view, and FIG. (D ′) is a side sectional view.

[Explanation of symbols]

1 ... impeller, 2 ... casing, 3 ... booster path, 4 ...
... Electric motor, 5 ... Center line of rotating shaft, 6 ... Blade casing, 7 ... Circular groove, 8 ... Blade, 9 ... Protrusion,
10 insertion grooves and through holes, 11 electrodes, 12
... Electric caulking work holder, 13 ... Rotating roll, 14
…… Roll rotating / folding work holder, 15… Temporary bending jig

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Eiichi Ito 7-1-1, Higashi Narashino, Narashino City, Chiba Pref. Hitachi, Ltd. Narashino Plant (56) Kaihei 2-215997 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) F04D 23/00

Claims (6)

(57) [Claims] A blade of an impeller having a plurality of blades is formed separately from a blade casing having an annular groove centered on a rotation axis of the impeller. the insertion groove rectangular with rounded corners at a position where the blade is fixed with an axial section parallel to the shape of the impeller is provided, the ends of the blade is inserted into the insertion groove, during energization caulking work The above blur
Hold the over-de, the blades fixed to the blade housing by plastic deformation due to energization caulking using an electrode to the alumina dispersion copper and material, the electrode is divided from the blade
A method of manufacturing an impeller for a vortex blower, comprising releasing the work retainer after being released . 2. An electrode having a shape in which the cross-sectional area of the tip is 1.2 to 7.1 times the cross-sectional area of the insertion groove and the tip angle is 30 to 110 degrees. The method for producing an impeller of a vortex blower according to claim 1, wherein 3. A blade of an impeller having a plurality of blades is formed separately from a blade casing having an annular groove centered on the rotation axis of the impeller, and projections are provided at both ends and a bottom of the blade. An insertion groove portion having a rectangular shape with four rounded corners and a cross-sectional shape parallel to the axial direction of the impeller is provided at a position where the blade is fixed on each edge of the inner and outer peripheries in the annular groove, and a bottom portion of the annular groove is provided. a through hole is formed, the protruding portion of the bottom thereof with a projecting portion of the both end portions of the blade inserted into the insertion groove is inserted into the through hole, energization however
Pressing the blade with a work press during the work , fixing the blade to the blade casing by plastic deformation by current caulking using an electrode made of alumina dispersed copper,
Workpiece after the electrode is separated from the blade
A method for manufacturing an impeller of a vortex blower, wherein the presser is released, and the protrusion protruding from the through hole is pressed by a rotating roll and bent along the outer surface of the bottom of the blade casing. 4. A ratio of an interval at which the blade is inserted into the blade casing to a diameter of a rotary roll used in a bending method is 1: 2 or less, and a bending direction of the protrusion of the blade is set to be equal to that of the impeller. 4. The method according to claim 3 , wherein the rotation direction is opposite to the rotation direction. 5. The method according to claim 1 , wherein after inserting the projection at the bottom of the blade into the through hole, the projection is bent in advance by 5 to 45 degrees in the bending direction, and then bent by the rotating roll. The method for producing a vortex blower according to claim 3, wherein 6. The impeller for an eddy blower according to claim 1, wherein said blade is fixed to said blade casing by plastic deformation due to said current caulking, and then cold plastic working is applied to said current caulked portion. Manufacturing method.