LOW NOISE AND HIGH EFFICIENCY BLADE FOR AXIAL FANS AND ROTORS AND AXIAL FAN OR ROTOR COMPRISING SAID BLADE

Abstract

Today the low noise blades and especially the super low noise blades for large diameter axial fans which are employed in the big cooling machines and cooling plants are so costly and are requiring so many extra costs on the other related equipment, that the noise pollution abatement can increase the whole cooling apparatus cost by up to a 35%. This invention, provides a new technology to make low noise fans able to transform any common blade into a low noise or very low noise at very low cost, preserving the same high efficiency and tip speed, as opposite to all the other low noise blades at actual status of art. As the fans for the big cooling apparatus are generally their main noise source, this invention will offer the opportunity to dramatically reduce the noise pollution produced by big cooling machines and cooling plants.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent application claims benefit and priority to U.S. patent application Ser. No. 15/776,024 filed on May 14, 2018, European Patent Application No. PCT/EP2015/076713 filed on Nov. 16, 2015, and from International Patent Application No. PCT/EP2016/077874 filed Nov. 16, 2016, which is hereby incorporated by reference into the present disclosure.

FIELD OF THE INVENTION

The present invention relates to a low noise and high efficiency blade for axial fans; in particular, the present invention relates to a low noise and high efficiency blade for industrial axial fans, and more particularly for large diameter axial fans. The present invention further relates to an axial fan, particularly a large diameter industrial axial fan, equipped with a low noise and high efficiency blade.

PRIOR ART

Axial fans as used in commercial air cooled apparatuses have to be distinguished in two main groups comprising small size cooling fans and big size cooling fans, respectively.

In fact, the size of a cooling fan can vary from few millimeters (as in the case of a fan of the kind used to cool electronic devices), to few decimeters (as in the case of a fan used to cool an automotive motor), and even up to the 20 meters of diameter of a fan used in an ACC or a water cooling tower plant.

The boundary limit of the two groups of course cannot be rigidly fixed but it is usually located, among those skilled in the art, approximately at a fan diameter of about 900 mm, meaning that fans with a diameter less than 900 mm belong to the first group, whilst fans with a diameter more than 900 mm belong to the second group.

The technical characteristics of a fan strongly depend on its size (diameter) and differ depending thereon whether the fan belongs to the first group or the second group, essentially due to the fact that the performances to be provided by fans belonging to the two groups are different.

The above means that large diameter axial fans have technical characteristics which are deeply different from those of small size fans, irrespective of the fact that even fans with different dimensions (diameter) are provided for the same purpose, namely moving the air in order to cool apparatuses and/or equipment or the like.

The main reason why the technical characteristics change so dramatically with the increasing of the fan size relates to the fact that the forces, and powers, acting on the fan depend on its diameter. As an example, the absorbed power of a few mm size fan is a small fraction of kW whereas a very large fan can absorb a few hundred kW.

In the same way, during the operation, the forces acting on the blades of a large diameter fan, are very high so that the structural design of large size fans (heavily loaded during rotation) becomes very complicated, essentially due to the fact that complicated shapes which, in the case of small fans would allow to reduce noise and improve efficiency level, may not be taken into consideration in the case of large fans.

Moreover, the efficiency of a fan must be considered as well, due to the large amounts of power consumption involved; in fact, in the case of large fans, few percentage points of higher efficiency may result into tenths of kilowatts being saved.

It has moreover to be noted that, in general terms, small fans, in view of both their small size and their technical characteristics, can usually be realized in one piece casting, and can include a peripheral ring binding all the blades to add strength to the fan.

A fan according to the prior art comprising a peripheral ring is depicted in FIG. 1 as an example of a fan with improved stability, but wherein even the efficiency is improved by the peripheral ring (which help to prevent the backflow at the tip of the blades).

It is well known among those skilled in the art that large fans may usually not be provided with a peripheral ring of the kind depicted in FIG. 1, essentially due to structural reasons. Moreover, even assuming that it would be technically possible to realize said peripheral ring also for a large fan, the provision of the ring would not match with a further need arising in case of large fans, namely that of adjusting the pitch in view of the circumstances.

In fact, most of the cooling apparatuses served by said fans are custom tailored and the fan operative conditions are very variable, meaning that, in order to satisfy said operative conditions a pitch adjustment is mandatory. Secondly, it is important to have the possibility to adjust the pitch because customers require to have the possibility to adjust the pitch on site. However, an adjustable pitch implies an open space between the blade tip and the fan ring, but the mandatory open space negatively affects the fan efficiency.

The dimension of this space has been limited by the international standard to 3 to 5 thousandths of the fan diameter; however, the above mentioned standard can be met, in the case of adjustable pitch, only when the blades are oriented at a predefined pitch angle whilst, for all the other pitch angles (other than the predefined one), the standard is met only in the area where the pitch angle adjustment axis is located; accordingly, by increasing or decreasing the pitch angle it cannot be avoided that the leading and trailing edge are moved away from fan ring, mainly in function of the blade chord, thus increasing the backflow. Moreover, as to the need of keeping the noise at low values in the field of large fans, further information and definitions are provided below for the purpose of both better clarifying the state of the prior art and better appreciating the present invention.

Generally speaking, it is possible to divide the large fans requirements according to the noise level requested in three categories:

First noise level: there are no special requirements as to the noise level. The fans have rather narrow chord and are operating at the maximum tip speed accepted by the standards, which is about 60 m/s. In general, this is the condition allowing the fans to provide their best efficiency at the lowest costs. Today there are three main typical blades commonly used in large fans in the market and they are depicted in FIGS. 2a, 2b and 2c. In the case of these three blades, high efficiency is obtained by using an aerodynamically efficient profile and having a uniform air velocity over the entire radius. The uniform air distribution is obtained by each blade type in a different way: the blade of FIG. 2a is twisted, the blade of FIG. 2b is tapered, the blade of FIG. 2c comprises on the profile a trimmed flap so that the blade finally results to be both twisted and tapered.

Second noise level: when medium low noise requirements have to be met, meaning that the noise level must be reduced by around 5 dB(A). According to the known solutions, this is obtained by extending the chord width in order to decrease and distribute the forces acting on the blade surface and to compensate the loss of performance due to speed reduction to 45 m/s. A typical chord increase ratio could be 2.5 times with respect to a first noise level fan. It is however easy to imagine that the costs are strongly affected (increased) by the need of increasing the chord width. But the cost increase is not the only negative effect. In fact, also the extension as such of the chord width all along the blade span has some detrimental effects on the blade aerodynamic performance: in fact, as it is well known to a technician skilled in aerodynamics, the increasing of the ratio width/length of the blade, according to the wing theory, reduces the aerodynamic efficiency.

A further negative effect of this condition relates to the fact that the ratio total-chord-at-tip/circumference, called solidity, assumes values that negatively affects the efficiency of the fan. Additionally, it has to be reminded that the fans as referred to herewith belong to the large fans category that are required to have adjustable pitch angle, meaning that the same blade can be used in situations where the pitch angle is very large, typical for low speed, wherein however the big tip clearance on leading and trailing edge reduces the efficiency and increases the noise.

In a 10 m fan, increasing the chord from 0.6 m (typical for a first noise level fan) to 1.4 m (typical for a second noise level fan), would mean that the tip clearance at both the leading and trailing edge would increase up to 5.5 times, meaning that this solution therefore would have as a consequence a big cost increase and an important efficiency loss. Furthermore, there would be also a big cost increase of the power transmission equipment due to the higher speed ratio increase, along with a cost increase of the motor because the lower efficiency requires a higher power motor.

In the FIGS. 3a and 3b is possible to see in a real case how different is the solidity on the fans of first and second noise level.

Third noise level: generally called in the field super low noise, requires a further reduction of about 4 dB(A) of the noise value with respect to low noise fans. According to the methods used today to obtain this noise reduction, the tip speed is further reduced, the tip chord is increased, and the blades are swept forward in the direction of fan rotation in order to decrease the local pressure fluctuations generated by the impingement of the flow, to mistune the sound emission and to decrease the accumulation of the boundary layer over there. There are essentially three known methods to realize said forward sweeping of the blade: sweeping the leading edge in the space as depicted in FIG. 4a, sweeping the leading edge in the plane as depicted in FIG. 4b, sweeping according to a line as depicted in FIG. 4c (and further disclosed in U.S. Pat. No. 8,851,851 B2).

As depicted, all these types of blades clearly have a very large chord at the tip and, especially the blade of FIG. 4a.

All these prior art systems, but in particular the first of them, have a very complicated shape. As already disclosed above, the large tip chord brings to a further efficiency loss compared to the blades of the second noise level. But there is even another important reason of inefficiency: the very large shape of the blade does not allow efficient aerodynamic section distribution because their size decreases toward the hub and the high increase in twist at root does not allow to compensate what has been lost due to chord decrease.

In view of the above it may be stated that all the systems and methods today available on the market to reduce the noise of large fans have a very important drawback, namely a very large amount of energy loss and very high costs of the whole machine or plant, even more than 30% than a second noise level fan.

SUMMARY OF THE INVENTION

It is therefore the main aim of the present invention that of providing a blade, in particular for super low noise large diameter axial fans which allows, to overcome the drawback left unsolved by the prior art.

Within this aim, it is an object of the present invention to provide a blade, in particular for super low noise fans and rotors which still has high aerodynamic efficiency when compared with super low noise fans of the known type, in the same functioning conditions.

It is also an object of the present invention to provide a blade, in particular for super low noise large diameter axial fans or rotors which has reduced manufacturing costs with respect to the blades known for the same applications.

The present invention is therefore based on the main consideration that the drawbacks affecting both blades and fans according to the prior art can be efficiently overcome or at least drastically reduced by providing a blade which, when fixed to the rotor at a zero pitch-angle, has a V-shaped projection on a plane parallel to the rotation plane π.

Moreover, according to a further consideration, the V-shaped blade is preferably obtained by joining a first, inner, blade part with a second, outer blade part, having either approximately the same length or even different lengths (depending on the embodiment), so as to form an obtuse angle on the leading edge of the blade.

In view of both the above considerations and the drawbacks affecting blades and fans according to the prior art, disclosed in the following is a blade for low noise and or high efficiency axial fans, said blade comprising a front edge and a rear edge, the front edge being the leading edge of the blade facing the direction of rotation of the fan in an operative condition and said rear edge being the trailing edge of the blade, said blade comprising a first blade part and a second blade part, said first and second blade part forming on said leading edge an obtuse angle V so that the projection of the blade profile on a plane parallel to the rotational plane π of the fan, is a V-shaped profile.

As disclosed, the same angle V may be present at said trailing edge and at said leading edge of said blade, at the joint of said first part with said second part.

Still as disclosed, with reference to the line X joining the points where a pitch adjustment axis is crossing the blade root section and the blade tip section, the vertex on the leading side may lie on one side and the root and the tip leading edges on the other side, or the vertex V may lie on the one side along with the root and the tip leading edges.

Still as disclosed, said first and said second blade parts have approximately the same length or different length depending on the needs and/or circumstances.

Still as disclosed, said obtuse angle V may be comprised between 90° and 170°, in particular between 100° and 120°.

As disclosed, at the portion of the blade where said first part and said second part are joint, an angle of about 195° is formed between the suction surfaces of first and the second portion in the vertical plane. Such angle is defined as the sum of 180° and a dihedral angle α.

Still as disclosed, the first, inner part is obtained starting by a rectilinear blade by rotating a part of the blade profile backwards counterclockwise, around the vertical axis passing where the pitch adjustment axis is crossing the blade root section, and the second, outer part is obtained by rotating a part of the blade profile backwards clockwise around the vertical axis passing where the pitch adjustment axis is crossing the blade tip section.

As disclosed, the blade or its airfoil part may be a one piece blade, made of casting aluminum or steel or plastic or any other suitable material.

As disclosed, said first blade part and second blade part may form on said leading edge a rounded angle.

Still as disclosed, said first blade part and second blade part may form on said trailing edge a rounded angle.

As disclosed, one or both of said blade part and second blade part may have slightly curved leading edges.

Still as disclosed, said first blade part and second blade part may have slightly curved trailing edges.

Further disclosed is a super low noise industrial axial fan, comprising the blade according to one or more of the above embodiments.

In particular, according to a first embodiment of the present invention there is provided a blade according to claim 1.

Further embodiments of the present invention are defined by the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following, description will be given of the embodiments of the present invention as depicted in the drawings wherein, however, the present invention is not limited to the embodiments as depicted in the drawings and disclosed below.

In the drawings:

FIGS. 1, 2a, 2b, 2c, 3a, 3b, 4a, 4b, 4c, 7a, 7b, show different examples of blade assemblies for axial fans according to the prior art. More in details:

In FIG. 1, there is depicted a perspective view of a small diameter axial fan according to the prior art provided with a ring on its periphery;

In each of FIGS. 2a, 2b, and 2c, there is depicted a blade according to the prior art of the kind commonly used in known large fans: in FIG. 2a there is depicted a twisted blade, in FIG. 2b there is depicted a tapered blade, in FIG. 2c there is depicted a trimmed blade;

In FIG. 3a, there is depicted an example of first noise level large diameter (10 meters) fan according to the prior art;

In FIG. 3b, there is depicted an example of second noise level large diameter (10 meters) fan according to the prior art;

In FIGS. 4a, 4b, and 4c, there are depicted corresponding examples of blades of super low noise axial fans according to the prior art. More in details:

In FIG. 4a, there is depicted a blade having a leading edge both curved and swept into the space;

In FIG. 4b, there is depicted a blade having a leading edge swept in a plane;

In FIG. 4c, there is depicted a blade having a leading edge swept according to a straight line;

In FIG. 5, there is depicted a top (plan) view of a blade according to a first embodiment of the present invention;

In FIG. 6, there is depicted a schematic top view of a super low noise large diameter axial fan equipped with blades according to an embodiment of the present invention;

In FIG. 7a, there is depicted an example of a super low noise axial fan according to the prior art, having trailing and leading edge extension at outer third of the radius;

In FIG. 7b, there is depicted an example of super low noise axial fan according to the prior art, having trailing and leading edge extension at outer third of the radius;

In FIG. 8, there is depicted a top (plane) view of a blade according to a second embodiment of the present invention wherein the blade is a tapered and twisted blade;

In FIG. 8a. there are compared the angles at tip leading edge and the air relative velocity of blades according to the prior art and an embodiment of the present invention, respectively;

In FIG. 8b, there are compared the angles at tip trailing edge and the air relative velocity of blades according to the prior art and an embodiment of the present invention, respectively;

FIG. 9 schematically shows the second mode of vibration of the blade according to an embodiment of the present invention;

In FIG. 10, there is depicted a blade according to the present invention, the dihedral angle being visible;

In FIG. 11, there is depicted a blade according to a further embodiment of the present invention;

In FIG. 12, there is depicted a blade according to a further embodiment of the present invention;

In FIG. 13, there is depicted a blade according to a further embodiment of the present invention;

FIG. 14 shows a view of the cross section taken along line XIV-XIV in FIG. 13;

FIG. 15 shows a view of the cross section taken along line XV-XV in FIG. 13;

FIG. 16 is a plan view of a fan comprising three blades similar to the one of FIG. 13;

FIG. 17 is a side view of the fan of FIG. 16;

FIG. 18 is a perspective view of the fan of FIG. 16;

In FIG. 19, there is depicted a blade according to a further embodiment of the present invention;

FIG. 20 shows a view of the cross section taken along line XX-XX in FIG. 19;

FIG. 21 shows a view of the cross section taken along line XXI-XXI in FIG. 19;

FIG. 22 is a plan view of a fan comprising four blades similar to the one of FIG. 19;

FIG. 23 is a side view of the fan of FIG. 22;

FIG. 24 is a perspective view of the fan of FIG. 22;

FIG. 25 shows a plan view of a blade according to a further embodiment of the present invention;

FIG. 26 shows a front view of the blade of FIG. 25;

FIG. 27 schematically shows some geometric characteristics of the blade of FIG. 26;

FIG. 28 schematically shows a plan view of a semifinished product used for manufacturing a blade according to the invention;

FIG. 29 shows a view of the cross section taken along line XXIX-XXIX in FIG. 28;

FIG. 30 schematically shows a front view of the semifinished product of FIG. 28;

FIG. 31 schematically shows a plan view of a step of manufacturing a blade according to the invention;

FIG. 32 schematically shows a plan view of another step of manufacturing a blade according to the invention;

FIG. 33 schematically shows a front view of the manufacturing step of FIG. 32; and

FIG. 34 schematically shows a root portion of a blade according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

It will become apparent, in view of the following description, that the main task of the present invention is to provide a blade, in particular for large diameter super low noise industrial axial fans, this being the reason why, in the following, description will be given of a blade for super low noise large diameter industrial axial fans which can be also used with industrial fan of the type already known in the art to obtain noise reduction while preserving at least the same aerodynamic efficiency.

In FIG. 5, the blade according to the embodiment of the present invention as depicted therein is identified by the reference numeral 1. The blade 1 comprises in particular a root portion 1r provided for the purpose of fixing the blade 1 to an axial rotor (not depicted in FIG. 5); in particular, the blade may be fixed to the axial fan 30 at different orientation angles (pitch angles) with respect to the axis X-X as identified by the dashed line in FIG. 5. The rotor 32 is supposed to be rotated, during operation of the fan 30, in the clockwise direction as depicted by the arrow, the axis of rotation R-R of the fan 30 corresponding to the axis of rotation of the rotor. With respect to FIG. 5, the axis of rotation R-R is perpendicular to plane of the figure; the smallest pitch angle is the angle at which the projection of the blade on a plane perpendicular to the axis of rotation occupies the largest area or surface. Pitch angles of larger amounts result in the projections of the blade on the plane perpendicular to the axis of rotation (also referred to, in the following, as the plane of rotation π) occupying corresponding smaller areas or surfaces. As depicted, with the blade 1 oriented at the smallest pitch angle, in particular at zero pitch angle, the projection of the blade on the rotation plane π, is such that a V shape is formed along the span of the blade (see FIG. 5). In particular, the blade 1 comprises a first, inner, portion 1a close to the rotational axis and extending from the root portion 1r, along with a second, outer, portion 1b, having approximately the same length of the first portion 1a, and extending from the first portion 1a. With respect to the axis X-X, the first portion 1a extends along a first direction (forming an angle with the axis X-X), whilst, still with respect to the axis X-X, the second portion 1b extends along a second direction other than the first direction (forming an angle with the axis X-X other than the angle formed by the first portion 1a).

Moreover, with respect to the direction of rotation of the blade 1 (identified by the arrow in FIG. 5), in the blade 1 two edges can be identified, namely the leading edge 1I (impinging against the air during rotation of the blade 1), and the trailing edge 1t (opposite to the leading edge 1l).

Still as depicted, the first portion 1a and the second portion 1b are oriented one with respect to the other so that an obtuse angle V (more than 90° and less than 180° is defined by the leading edge 1I, whilst a bigger angle V′ (more than 180°) is defined by the trailing edge 1t. Such angles V and V′, as can be seen in the attached FIG. 5, are considered outside the blade 1.

Still with reference to the embodiment of FIG. 5, the axis X-X which, as depicted, crosses both the blade portion 1a and the blade portion 1b, the vertex Vv of the angle V defined by the leading edge 1l is located on one side of the axis X-X, whilst the opposite tips (points B and C) of the leading edge 1l are located on the opposite side.

The above disclosed feature is a unique, distinguishing feature of the blade according to some embodiments of the present invention and has been ideally obtained according to the following way: starting from a substantially rectilinear blade as depicted for instance in FIG. 3a, the inner part 1a is obtained by ideally rotating (bending) the blade backwards with respect to the root portion 1r (counterclockwise with respect to FIG. 5), in particular around the vertical axis passing where the pitch adjustment axis X-X is crossing the blade root section 1r, whilst the outer part 1b is obtained by ideally rotating (bending) the blade backwards with respect to the first portion 1a (clockwise with respect to FIG. 5), in particular around the vertical axis passing where the pitch adjustment axis X-X is crossing the blade tip section.

The blade 1 has a very particular behavior with respect to noise and efficiency. Carrying out an extensive test program on a 10 feet diameter axial flow fan equipped with blades of the kind disclosed above and depicted in FIG. 5, starting first with a V angle of 170° and decreasing same to 90°, the inventor discovered that, as a result of the reduction of the angle V the fan noise also decreased. In particular, with angles between 120° and 100° it is possible to obtain a noise reduction equal or better than that of noise levels 2 and 3 of the prior art low noise fans described ahead. But, and this is extraordinary, it has been discovered that the high efficiency of common blades belonging to noise level 1 can be maintained and, in some cases, increased, meaning that, according to the needs and/or circumstances, the present invention can even be used just to increase the fan efficiency.

A further improvement has been obtained with a blade as depicted in FIGS. 10, 26 and 27 wherein, at the joining section, the inner portion 1a and the outer portion 1b defines a dihedral angle α, meaning in particular that, in the projection of the leading edge 1l on a plane perpendicular to the rotation plane π, the projections of the leading edges of the first portion 1a (X) and the second portion 1b (X′) are oriented along different directions. Preferably, the dihedral angle α, as defined in FIG. 27, is comprised between 0° and 20°. Based on the above tests it has even been verified that the above disclosed design remains essentially advantageous, as compared with that of blades according to the prior art, even if the vertex Vv and/or the points B and C are shifted to positions other than those depicted in FIG. 5 as depicted, by way of example, in FIGS. 11, 12, 13, 19, and 25 (relating to further embodiments of the blade 1 according to the present invention). As depicted in FIG. 11, the tip leading edge point C is forward translated with respect to the root leading edge point B. Moreover, the above disclosed geometry (design) remains effective even if the size ratio between inner and outer portions is changed.

The above changes can be very helpful for the optimization of different types of blades and also because they are acting in a different way on noise and efficiency, therefore, depending on whether noise improvement or efficiency improvement is preferred, different solutions can be preferred.

The main reasons why the above disclosed, indeed quite extraordinary results can be obtained with a blade according to the present invention are related to the fact that the above disclosed geometry and/or design is affecting not just one but several among the noise generating and efficiency reducing factors. Some of these factors are mentioned herewith; however, there are additional factors helping to get these results which are not mentioned because it is not yet very clear how important they are.

Herewith explanation is essentially given of the main reason why the low noise levels are achieved and secondly why it was possible to preserve or improve the fan efficiency. Moreover, some more information is given as to additional advantages of the present invention such as, for instance, those related to the reduction of costs. With reference to FIGS. 6, 7a, and 7b, the outer portion of the blade 1 according to the present invention (FIG. 6) will be compared in the following with that of a blade according to the prior art (FIGS. 7a and 7b) considering that, as it is well known, the outer portion of a blade is interested by over 70% of air volume, meaning that the outer portion is the most important part of the blade. The design of the blade according to the present invention can be applied to any type of common blade of the prior art and also to their combination of inner or outer part. Of course, both final noise and final efficiency values are greatly conditioned by the type of blade selected to apply the invention. An optimization must follow, different case by case, depending also if low noise or better efficiency is preferred. The common, prior art blade which was selected to be modified according to the present is of the kind as depicted in FIG. 2c, which is consisting essentially of a profile with a trimmed flap on the trailing edge. However, blades as depicted in FIG. 2b have been also briefly tested to have evidence that the invention can be really applied to any type of blades.

The reason why the type c blade has been preferred for the test program, was that there were several options as to the dimensions of the V angle and the locations of the points Vv, B and C relative positions to be tested and it was requiring a large number of different blades. This type of blade appeared ideal to be manufactured in a very fast and simple way. In fact, this blade can be made out of extruded or pultruded profile and to make a different execution it is only matter of cutting and drilling and joining in a different way. Actually, this is a preferred embodiment for its simplicity. Other embodiments foresee to add on this blade prior art systems which are particularly effective on the invented design like winglets on tip or saw teeth on the trailing edge.

Extrusion and pultrusion are well known industrial processes, both resulting very advantageous in the method for manufacturing the blade of the invention. In particular, extrusion is used to manufacture elongated semi-finished products (also called profiles) by pushing a ductile material through a die of the desired cross-section. With respect to the invention, extrusion is advantageously used for metal, in particular for aluminum. Extrusion also creates excellent surface finish. Similarly, pultrusion is used to manufacture elongated semi-finished products by pulling a curable material through a die of the desired cross-section. With respect to the invention, pultrusion is advantageously used for composite material, in particular for fiberglass or resin reinforced with glass fibers.

Accordingly, both extruded and pultruded profiles extend over a length that is a priori indefinite and have a fixed cross-section all along the main axis.

A further preferred embodiment foresees an adequate attachment to the hub, which has been identified as a rectangular shape attachment because laser, plasma, oxy cutting systems could be used to cut any type of shape in a metal sheet and then the optimized position of the blade with respect to the fan radius can be obtained at low cost.

A second mode vibration attachment as sketched in the FIG. 9 would be ideal for this type of blade, not only because it is lowering the loads but also because if the bade is not too long this attachment could enter the blade for an extension that it would give the possibility to reach the outer profile part so that it could be directly fixed on it. However, fixing the two blade parts together is very simple in this case and numerous solutions could be used. Within the meaning of the present invention, the blade 1 can be provided both by joining together the inner portion 1a and the outer portion 1b (prepared in advance) or even by forming the blade 1, comprising inner portion 1a and outer portion 1b as a single one piece blade, casting aluminum, steel or plastic to get the shapes for small and medium size blades. For large blades instead it could be used any of the fiberglass construction systems actually used for the common large blades.

Of course, this construction system could be also used for the small blades.

A combination of different embodiments for inner and outer part of blade could also be a good solution.

The extraordinary results achieved by means of the blade according to the present invention can be fully understood when noise and aerodynamic efficiency are considered.

In the following, as anticipated, the blade according to the present invention (FIG. 6) will be compared with blades according to the prior art (FIGS. 7a and 7b).

As to the noise level, the following has to be considered.

The forward sweep angle that the leading edge is forming at the tip with the air relative velocity direction as indicated by the arrows (see also FIG. 8a), is comparable to that of the low noise fan 30 of FIG. 6 and much larger than that of FIGS. 7a and 7b, taking the maximum advantage derived by the noise attenuation related to the forward swept leading edge blade technique;

The forward sweep angle that the trailing edge is forming at the tip with the air relative velocity direction (FIG. 8b) is smaller than that of any of the low noise fan shown in FIGS. 7a and 7b, taking the maximum advantage derived by the noise attenuation related to the forward swept trailing edge blade technique.

The leading edge extension is wider than that of FIGS. 7a and 7b, in a range from 1.05 to 1.46 times, desirably, though not necessarily, 1.2 times. Therefore, the noise benefit will be larger than the prior art.

The trailing edge extension is much larger than prior art by a unique very large amount, in a range from 1.1 to 3 times, desirably, though not necessarily, 1.5 times. Therefore, the noise benefit will be much larger. Additionally, the relevant extension of the trailing edge allows to utilize in a much more efficient way the several well-known techniques to reduce the sound emission to be applied on the trailing edge, for example a serrated system.

The average tip clearance on the tip will be greatly smaller because the chord is smaller and the noise originated by the tip vortices will be reduced.

The relatively small size of tip chord is allowing to still apply as a standard the tip winglets 34 which, as it is well known, can further reduce the noise. The tip winglet 34 cannot be applied on large chord blades because at high pitch angle has a negative effect.

With reference to the aerodynamic efficiency, the following has to be considered. The described geometry or design is realized stacking in blade span direction wing profile having very high aerodynamic efficiency.

The blade span is increased maintaining the same chord width, allowing to increase the ratio length/width and consequently, as well known from whom is skilled in the aerodynamics, the blade efficiency.

The blade 1 can be not only twisted but also tapered from root to tip the get the best efficiency as a common fan of noise level 1. At the contrary the fan blades according to the prior art are tapered from tip to root decreasing the blade efficiency.

Furthermore, the blade airfoil sections are disposed in the optimal direction with respect to the incident air stream, optimizing the air circulation around the section itself, particularly on the outer part of the bade where the most part of the flow passes through.

The winglet 34 at the tip will also improve the efficiency, allowing less backflow to pass. With reference to the manufacturing costs, the following should be considered.

The reduced chord width distribution all along the radial span makes the fan blade lighter than the known solutions, consequently the bending and axial loads at the radial sections are reduced, particularly at the root.

The reduced chord width, particularly at the outer part of the blade, contributes to reduce the inertial torsional moment at the root section.

The higher efficiency of the blade 1 means lower drag force at the same lift, with a consequent reduction of shear loads at the radial sections, particularly at the root. The load reduction all along the blade radial span and particularly at the root section allows to design reduced sections to resist to them with a significant reduction in material cost.

In the following, with reference to FIG. 12, a further embodiment of a blade 1 according to the present invention will be described.

In FIG. 12, the blade 1 according to the embodiment of the present invention as depicted therein is still identified by the reference numeral 1. The blade 1 still comprises a root portion 1r provided for the purpose of fixing the blade 1 to an axial rotor 32 (not depicted in FIG. 12); again, the blade may be fixed to the axial fan 30 at different orientation angles (pitch angles) with respect to the axis X-X as identified by the dashed line in FIG. 12. The rotor 32 is supposed to be rotated, during operation of the fan, in the clockwise direction as depicted by the arrow, the axis of rotation R-R of the fan 30 corresponding to the axis of rotation R-R of the rotor 32. With respect to FIG. 12, the axis of rotation is perpendicular to plane of the figure; the smallest pitch angle is the angle at which the projection of the blade on a plane perpendicular to the axis of rotation occupies the largest area or surface. Pitch angles of larger amounts result in the projections of the blade on the plane perpendicular to the axis of rotation (also referred to, in the following, as the plane of rotation π) occupying corresponding smaller areas or surfaces. As depicted, with the blade 1 oriented at the smallest pitch angle, in particular at zero pitch angle, the projection of the blade on the rotation plane π, is such that a V shape is formed along the span of the blade (see FIG. 12). In particular, the blade 1 comprises a first, inner, portion 1a close to the rotational axis R-R (to the root portion 1r) and extending from the root portion 1r, along with a second, outer, portion 1b, and extending from the first portion 1a. With respect to the axis X-X, the first portion 1a extends along a first direction substantially parallel to the axis X-X, whilst, still with respect to the axis X-X, the second portion 1b extends along a second direction other than the first direction (forming an angle V with the axis X-X).

Moreover, with respect to the direction of rotation of the blade 1 (identified by the arrow in FIG. 12), in the blade 1 two edges can still be identified, namely the leading edge 1l impinging against the air during rotation of the blade 1), and the trailing edge 1t (opposite to the leading edge 1l).

Still as depicted, the first portion 1a and the second portion 1b are oriented one with respect to the other so that an obtuse angle V (more than 90° and less than 180°) is still defined by the leading edge 1l, whilst a bigger angle V′ (more than 180°) is defined by the trailing edge 1t. Such angles V and V′, as can be seen in the attached FIG. 12, are considered outside the blade 1.

Aa apparent, the main difference between the embodiment of FIG. 5 and the embodiment of FIG. 12 relates to the fact that, in the embodiment of FIG. 12, with reference to the axis X-X which, as depicted, crosses both the blade portion 1a and the blade portion 1b, the vertex Vv of the angle V defined by the leading edge 1l and the opposite tips (points B and C) of the leading edge 1l are located on the same side with respect to the axis X-X.

Moreover, a further difference with respect to the embodiment of FIG. 5 may relate to the length of the bade portions 1a and 1b which, in the embodiment of FIG. 12, have different lengths.

However, even in the embodiment of FIG. 12 the blade portions 1a and 1b may have substantially the same length. In the same way, as anticipated, the blade portions in the embodiment of FIG. 5 may have different lengths.

In the following, some preferred embodiments of the invention are disclosed with specific reference to FIGS. 13 to 27. In particular, FIGS. 13, 19, and 25 show plan views of blades 1 similar to the one of FIG. 12.

In FIGS. 13, 19, and 25, the blades 1 according to the embodiments of the present invention as depicted therein are still identified by the reference numeral 1. Each one of such blades 1 still comprises a root portion 1r provided for the purpose of fixing the blade 1 to an axial rotor 32; again, the blade may be fixed to the axial fan 30 at different pitch angles with respect to the axis X-X as identified by the dashed lines in FIGS. 13, 19, and 25. The rotor 32 is supposed to be rotated, during operation of the fan, in the clockwise direction as depicted by the arrow, the axis of rotation R-R of the fan 30 corresponding to the axis of rotation R-R of the rotor 32. With respect to FIGS. 13, 19, and 25, the axis of rotation R-R is perpendicular to the plane of the figure or plane of rotation π. The projection of the blade on the rotation plane π, is such that a V shape is formed along the span of the blade (FIGS. 13, 19, and 25). In particular, the blade 1 comprises a first, inner, portion 1a close to the rotational axis R-R (to the root portion 1r) and extending from the root portion 1r, along with a second, outer, portion 1b, and extending from the first portion 1a. With respect to the axis X-X, the first portion 1a extends along a first direction substantially parallel to the axis X-X, whilst, still with respect to the axis X-X, the second portion 1b extends along a second direction other than the first direction (forming an angle V with the axis X-X).

Moreover, with respect to the direction of rotation of the blade 1 (identified by the arrow in FIGS. 13, 19, and 25), in the blade 1 two edges can still be identified, namely the leading edge 1l impinging against the air during rotation of the blade 1), and the trailing edge 1t (opposite to the leading edge 1l).

Still as depicted, the first portion 1a and the second portion 1b are oriented one with respect to the other so that an obtuse angle V (more than 90° and less than 180°) is still defined by the leading edge 1l. Such angle V, as can be seen in the attached FIGS. 13 and 19, is considered outside the blade 1.

Moreover, according to such embodiments, the trailing edge 1t of the whole blade 1 is defined by the first portion 1a only (see in particular FIGS. 13, 16, 18, 19, 22, 24, and 25). In such embodiments, the portion of the leading edge 1I defined by the first portion 1a and the portion of the leading edge defined by the second portion 1b extend along different directions and define an obtuse angle V, so that the projection of the blade on the rotation plane π is V-shaped. In particular, the angle V is obtuse when considered outside the blade (see FIGS. 13, 19, and 25), such that the portion of the leading edge 1l defined by the second portion 1b extends along a direction inclined forward with respect to the rotation direction.

The whole trailing edge 1t is entirely defined by the first portion 1a of the blade, while the second portion 1b defines a portion of the leading edge 1l only. According to some embodiments (see FIGS. 13 and 19), the second portion 1b extends from the trailing edge 1t forward, toward the rotation direction. According to some embodiments (see FIG. 25), the second portion starts further forward than the trailing edge and extends toward the rotation direction. In all these embodiments, the first portion 1a of the blade is longer than the second portion 1b. The embodiments of FIGS. 13 to 26 permit to obtain a particularly stiff and strong structure of the blade 1.

Preferably, the first portion 1a of the blade extends in a substantially radial direction. In other words, the leading edge 1l defined by the first portion 1a is substantially parallel to axis X-X. Preferably, the blade 1 comprises the so-called “trimmed flap”, already described with reference to FIG. 2c. The trimmed flap is a technical solution, known per se, which is advantageously adopted with extruded and pultruded profiles. As a matter of fact, the extruded/pultruded profiles have constant cross section all along their longitudinal extension. However, in the fan blades (and in many other applications of such profiles) remarkable advantages can derive form slight changes of the airfoil 36 along the longitudinal extension of the blade 1. In this respect it is known to provide the basic airfoil 36 with a shape similar to the ones shown in FIGS. 14 and 20: in the rear region (the region near the trailing edge) of such airfoils 36, the upper wall and the lower wall merge and extend in a monolithic rear appendix 38 (also called “flap”). The flap 38 can be cut (or “trimmed”) according to the design needs. For example, the flap 38 can be trimmed to progressively reduce the chord extension and/or the curvature of the airfoil 36 towards the radially outer tip. FIGS. 14 and 20 show the intact airfoils 36, having the same shape defined by the dye during the extrusion/pultrusion process. FIGS. 15 and 21 show the same airfoils 36, respectively, after their flap 38 has been trimmed.

As briefly reported above, the blades 1 of the invention can be easily manufactured starting from extruded or pultruded profiles. Many types of blades (differing with respect to span, angles, proportions, etc.) can be obtained just by cutting and joining the extruded/pultruded profiles in different ways.

In order to better explain this aspect of the invention, a brief description of the manufacturing method is provided, with reference to FIGS. 28 to 33. FIG. 28 schematically shows a plan view of an extruded/pultruded profile, having constant cross section all along its longitudinal extension. The cross section in schematically shown in FIG. 29. FIG. 28 also shows, in dotted lines, the cuts which are needed for obtaining the first portion 1a and the second portion 1b of a blade 1 according to the invention. Both the straight cuts form an angle ±V/2 with the longitudinal direction of the profile in a plan view.

If the design of the blade 1 comprises a dihedral angle α, then the cuts form an angle with the longitudinal direction of the profile also in a front view. In this case, as shown in FIG. 30, the cuts must be inclined of an angle 90°−α/2 with respect to the longitudinal direction of the profile in a front view.

Preferably, the flap 38 of the first portion 1a can be trimmed, in a manner know per se. FIG. 31 schematically shows, in a dotted line, the cut for trimming the flap 38.

Once the first portion 1a and the second portion 1b are ready, they have to be joined together. FIGS. 32 and 33 schematically show the second portion 1b juxtaposed to the first portion 1a before being joined.

Once the first portion 1a and the second portion 1b are joined, the root portion 1r has to be added for obtaining the blade 1. Preferably, other elements can be added, like for example a tip winglet 34.

The size and proportions of the first and second portions 1a, 1b of FIGS. 28 to 32 are intended to obtain a blade 1 similar to the one of FIG. 19. However, as the skilled person can easily understand, with the same manufacturing method many different blades 1 can easily be obtained, starting from few different types of basic extruded/pultruded profiles. According to some embodiments of the invention, the blades 1 of the fan 30 define a so-called precone, i.e., the blades 1 are inclined with respect to the plane of rotation π towards the low-pressure region. More precisely, as shown in FIGS. 26 and 27, the axis X-X of the blade 1 defines a precone angle β with the plane of rotation π. Preferably, the precone angle β, as defined in FIG. 27, is comprised between 0° and 5°. The precone allows to obtain some mechanical and aeraulic advantages.

A blade 1 according to the invention defining both a dihedral angle α and a precone angle β is shown in FIG. 26. FIG. 27 shows the same geometric characteristics where the blade 1 itself has been removed for clarity.

Some exemplary embodiments of fans 30 according to the invention, i.e., low noise industrial axial fans 30 having large diameter and adjustable pitch angle, are shown in the attached figures. FIGS. 16 to 18 show a fan 30 comprising three blades 1 similar to the one of FIG. 13. FIGS. 22 to 24 show a fan 30 comprising four blades 1 similar to the one of FIG. 19. As the skilled person can easily understand, the number of the blades 1, as well as their shape, span, can be changed in accordance with the specific design needs, while remaining within the scope of the invention.

Preferably, the root portion 1r (see FIG. 34) comprises the seats for two different fasteners, e.g., two bolts or screws, for joining the blade to the hub or rotor 32. Preferably, a first seat is a simple hole, while the second seat is a curved slot defining an arch around the first seat. In such a manner, the fastener received in the first seat physically defines the pitch adjustment axis X-X, while the other fastener can fix the blade 1 with respect to the rotor once the pitch angle is defined.

It has therefore been demonstrated, by means of the above description of the embodiments of the present invention depicted in the drawings that the present invention allows to overcome the drawbacks affecting the solutions according to the prior art.

Although the present invention has been clarified by means of the above description of the embodiment thereof as depicted in the drawings, the present invention is not limited to the embodiments as disclosed above and depicted in the drawings.

As an example, within the meaning of the present invention, the blade can be manufactured according to different methods among those known in the art, for instance extruding and/or pressing and/or forging one or both of the two blade portions and joining them by welding, screwing, gluing, or the like.

Moreover, one or both of the blade portions may be hollow or not.

Finally, it is pointed out that even if the blade according to the present invention (to each embodiment thereof) has been disclosed as being particularly adapted to the used in combination with large diameter axial fans, the possible applications of the blade according to the present invention are not limited to large diameter axial fans but comprise fans of any size and/or diameter.

Moreover, the blade according to the present invention may be used in combination with fans provided for purposes other than cooling such as in fans of helicopters and/or airplanes or the like.

The scope of the present invention is rather defined by the appended claims.

Claims

1. An axial fan, having a large diameter and an adjustable pitch angle, comprising:

at least one blade comprising a front edge and a rear edge, the front edge being a leading edge of the at least one blade facing a direction of rotation of the axial fan in an operative condition, and the rear edge being a trailing edge of the at least one blade,

the at least one blade further comprising: a root portion configured to fix the blade to a rotor of the axial fan; a first blade portion extending from the root portion; and a second blade portion extending from the first portion,

wherein a portion of the leading edge defined by the first portion and a portion of the leading edge defined by the second portion extend along different directions and define an obtuse angle so that the projection of the at least one blade on a plane of rotation of the axial fan is V-shaped, and

the trailing edge of the at least one blade is defined by the first portion only.

2. The axial fan according to claim 1, wherein the root portion is shaped so as to define a pitch adjustment axis X-X, and with reference to the pitch adjustment axis X-X, a vertex of an angle defined by the portion of the leading edge defined by the first portion and the portion of the leading edge defined by the second portion lies on one side along with opposite tips of the leading edge.

3. The axial fan according to claim 1, wherein the obtuse angle is in a range between 90° and 170° when considered outside the at least one blade.

4. The axial fan according to claim 3, wherein the obtuse angle is in a range between 100° and 120° when considered outside the at least one blade.

5. The axial fan according to claim 1, wherein at a portion of the at least one blade where the first part and the second part join, a dihedral angle is defined between the first portion and the second portion of the at least one blade.

6. The axial fan according to claim 5, wherein the dihedral angle is in a range between 0° and 20°.

7. The axial fan according to claim 1, wherein the axis X-X of the at least one blade is inclined towards a low-pressure region with respect to the plane of rotation of the axial fan and defines a precone angle.

8. The axial fan according to claim 7, wherein the precone angle is in a range between 0° and 5°.

9. The axial fan according to claim 1, wherein the at least one blade further comprises a tip winglet.

10. An axial fan, having a large diameter and an adjustable pitch angle, comprising:

at least one blade comprising a front edge and a rear edge, the front edge being a leading edge of the at least one blade facing a direction of rotation of the axial fan in an operative condition, and the rear edge being a trailing edge of the at least one blade,

the at least one blade further comprising: a root portion configured to fix the blade to a rotor of the axial fan; a first blade portion extending from the root portion; and a second blade portion extending from the first portion, wherein a portion of the leading edge defined by the first portion and a portion of the leading edge defined by the second portion extend along different directions and define an obtuse angle so that the projection of the at least one blade on a plane of rotation of the axial fan is V-shaped, and the trailing edge of the at least one blade is defined by the first portion only, and the at least one blade is produced by a process of manufacturing that starts from at least one of extruded or pultruded semifinished products, the process further comprising: cutting the extruded or pultruded semifinished products to obtain at least one of the first blade portion and the second blade portion; joining together the first blade portion and second blade portion; and adding the root portion so as to obtain the at least one blade.