FAN FOR REGENERATIVE AIR VACUUM STREET SWEEPER, AND METHOD OF FAN MANUFACTURE AND ASSEMBLY

Abstract

A fan with airfoil blades is provided for a regenerative air vacuum street sweeper. The blades are formed using cut and pressed upper and lower panels which are welded at a forward edge to a rod to form the airfoil leading edge and welded at the rear edges to form the airfoil trailing edge. Pins extend laterally outwardly from the rod for mounting each blade in corresponding holes in the front and rear plates of the fan housing. The side edges of the blade are welded to the plates at a 9-11° angle of attack. The airfoil blades allow for reduced size, horse power, noise, and manufacturing and shipping costs.

Claims

1. A regenerative street sweeper having a pick-up head residing close to a street surface, a hopper to receive debris-laden air from the pick-up head, a dust separator, and a fan to receive air from the dust separator and direct air to the pick-up head, the fan comprising: a cylindrical housing having opposite sides and a curved wall extending between the opposite sides; an axial air inlet downstream of the dust separator; a radial air outlet to direct clean air to the pick-up head; and a plurality of rotatable airfoil blades mounting in the housing to direct air from the air inlet to the air outlet.

2. The regenerative street sweeper of claim 1 wherein each air foil blade includes a leading-edge rod.

3. The regenerative street sweeper of claim 2 wherein the rod has opposite ends with pins for mounting the rod in holes in the opposite sides of the housing.

4. The regenerative street sweeper of claim 1 wherein each of the blades has opposite lateral sides welded to the opposite sides of the housing.

5. The regenerative street sweeper of claim 1 wherein the fan has a rotational axis and each of the blades has an angle of attack of 9-11°.

6. The regenerative street sweeper of claim 1 wherein the blades each have curved upper and lower surfaces.

7. The regenerative street sweeper of claim 6 wherein the upper and lower surfaces are formed from rectangular panels.

8. The regenerative street sweeper of claim 7 wherein forward ends of the panels are attached to the rod, and rearward ends of the panels are attached to one another.

9. The regenerative street sweeper of claim 8 wherein the upper and lower panels are cut and bent before being attached to the rod and to one another.

10. A method of manufacturing an airfoil fan blade, comprising: cutting a first sheet of metal into a first rectangular panel with a leading edge and a trailing edge and then bending the first rectangular panel into a curved profile; cutting a second sheet of metal into a second rectangular panel having a leading edge and a trailing edge; the first rectangular panel having a distance between its leading and trailing edges which is greater than the distance between the leading and trailing edges of the second rectangular panel; connecting an elongated rod to the leading edges of the first and second rectangular panels; and securing the trailing edges of the first and second rectangular panels together; whereby the rod and first and second rectangular panels form a blade with an airfoil profile.

11. The method of claim 10 further comprising providing pins on the ends of the rod.

12. The method of claim 11 wherein the rod has a longitudinal axis and the pins extend coaxially with the longitudinal axis.

13. The method of claim 11 wherein the pins extend laterally outwardly from the ends of the rod.

14. The method of claim 11 wherein the pins extend beyond lateral edges of the first and second panels.

15. A method of assembling a fan having a housing with a plurality of internal airfoil blades each having leading and trailing edges, comprising: inserting pins on opposite sides of the leading edge of each blade into mating holes in opposite sides of the housing; and fixing the trailing edges of each blade to the housing.

16. The method of claim 15 further comprising welding opposite lateral sides of each blade to opposite sides of the fan housing.

17. The method of claim 15 further comprising orienting each blade at an angle of attack of 9-11°.

18. The method of claim 15 wherein the blades are arranged in a circular pattern.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a perspective view illustrating a regenerative air vacuum street sweeper having the fan assembly of the present invention.

[0012] FIG. 2 is a perspective view of the fan assembly of the present invention.

[0013] FIG. 3 is a sectional view of the fan assembly showing the arrangement of airfoil blades for the fan of the present invention.

[0014] FIG. 4 is a front perspective view of one of the airfoil blades according to the present invention.

[0015] FIG. 5 is a rear perspective view of one of the airfoil blades of the invention.

[0016] FIG. 6 is a side elevation view of one of the airfoil blades.

[0017] FIG. 7 is a top plane view of one of the airfoil blades.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] A regenerative air street sweeper 10 is shown in FIG. 1. The sweeper 10 is normally mounted on the chassis of a truck. The sweeper 10 includes a pickup head 12 adapted to be positioned closely above the street or road surface. A first tube 14 directs high velocity air to the pickup head 12, such that the air dislodges and suspends dust, particles, and other debris on the road surface for suspension and vacuuming into a second tube 16 which leads to an enlarged hopper 18 on the rear of the sweeper 10. The air velocity is substantially reduced in the hopper 18, such that the particles and dust fall into the bottom of the hopper. The dust-carrying air is then directed to a dust separator 20 having filters for removing the dust. The clean air is then recycled to the air outlet tube 14 to continue the vacuum process.

[0019] The above description of the sweeper 10 is conventional and does not constitute a part of the present convention.

[0020] The invention is directed toward the air circulation fan 22 which directs the air to the outlet tube 14 and draws the air into the inlet tube 16 of the pickup head 12. In a conventional sweeper, the fan blades are flat. In the present invention, the fan blades 24 have a profile of an airfoil, with a curved upper surface 26, a curved lower surface 28, a leading edge 30, and a trailing edge 32.

[0021] Airfoil blades used in other industries are normally cast, stamped, or extruded, each of which requires specialized equipment, and involves relatively costly manufacturing. For these reasons, airfoil blades have not been used in the vacuum street sweeping industry. The airfoil blades 24 of the street sweeper fan 22 are manufactured with different methodology, at a substantially reduced cost.

[0022] More particularly, in the present invention, and the preferred embodiment, the upper surface 26 and the lower surfaced 28 of each blade 24 are cut from sheet-metal, or similar material, using a cutting machine, and then bent into their respective curved profiles using a brake press. Thus, the rectangular panels which form the upper and lower surfaced 26, 28 are first cut and then bent using relatively simple equipment and at substantial cost savings compared to conventional manufacturing of airfoil blades.

[0023] The forward edges of the upper and lower panels are welded or otherwise fixed to an elongated, tubular rod 34, so as to form the leading edge 30 of the blade 24. The rear edges of the upper and lower panels 26, 28 are welded together to form the trailing edge 32. This process of forming the airfoil profile of the blades 24 is substantially less expensive than the methodology used for conventional airfoil blades in other industries.

[0024] The assembly of the fan 22 is also simplified, as compared to conventional fans. More particularly, the fan 22 includes opposite plates 36, 38. In the orientation shown in FIG. 1, the front plate 36 includes a hub 40 to which the rotational drive mechanism (not shown) is attached. The rear plate 38 has an enlarged, central opening for introduction of air into the fan 22, as indicated by the inlet arrow in FIG. 2. A curved wall extends around the perimeter edge of the plates 36, 38 such that the plates and the wall form a fan housing.

[0025] Each airfoil blade 24 has a pin 42 extending outwardly from the opposite ends of the rod 34. The pins 42 may be machined on the ends of the rod 34 or may be attached in a convenient manner to the ends of the rod 34. For example, the ends of the rod 34 may have recesses into which the pins 42 are press fit. The pins 42 of each blade 24 are adapted to be received within corresponding holes 44 in the plates 36, 38 so as to position the leading edge 30 of the blade 24 in the fan housing. Then the lateral edges of the upper and lower panels 26, 28 are welded to the inside surfaces of the plates 36, 38, such that the blade is oriented at a preferred angle of attack of approximately 9-11° relative to the rotational axis of the fan 22.

[0026] Testing of the new airfoil fan blade compared to Applicant's conventional Sentry street sweeper with straight fan blades is set forth in the following table, wherein:

[0027] PH=pickup head height above the street surface;

[0028] GB=gutter broom rotational speed

TABLE-US-00001 Horsepower Torque Engine Tolerance (Nm) RPM Horsepower Max Min 11 Degree Airfoil Fan 39.0 2500 10.2 12.8 7.7 Head down 47.0 2500 12.3 15.4 9.2 Head down + GB Down 62.0 2500 16.2 20.3 12.2 Head down + GB 79.0 2500 20.7 25.9 15.5 spinning (sweep mode) 11 Degree Road Test 74.8 2382 18.7 23.3 14.0 (PH 4, GB Sp 10) Sweep Mode 68.0 2718 19.4 24.2 14.5 (PH 3, GB Sp 8) Sweep Mode 77.0 2717 21.9 27.4 16.4 (PH 2, GB Sp 10) Sweep mode 81.2 2715 23.1 28.9 17.3 (PH 3, GB Sp 10) 11 Degree Road Test 44.8 2700 12.7 15.8 9.5 (PH 10, GB Sp 10) Head down + GB Down 46.0 2700 13.0 16.3 9.8 Sweep mode (PH 86.0 2700 24.3 30.4 18.2 10, GB Sp 10 DP 7) Sweep mode (PH 84.0 2700 23.7 29.7 17.8 10, GB Sp 10 DP 7) Sweep mode (PH 62.0 2714 17.6 22.0 13.2 10, GB Sp 6 DP 7) Sweep mode (PH 77.0 2701 21.8 27.2 16.3 10, GB Sp 6 DP 7) Sweep mode (PH 85.8 2633 23.7 29.6 17.7 10, GB Sp 9 DP 7) Sweep mode (PH 8, 83.0 2700 23.5 29.3 17.6 GB Sp 9 DP 7) Fan Starting Up 141.9 1400 20.8 26.0 15.6 Sweep mode (PH 5, 88.0 2700 24.9 31.1 18.7 GB Sp7 DP 7) Start up Sweep mode (PH 5, 81.0 2700 22.9 28.6 17.2 GB Sp 7 DP 7) Constant

TABLE-US-00002 % Change Current Sentry 70.0 2540 18.6 23.3 14.0 82% Head down 72.0 2540 19.1 23.9 14.4 56% Head down + GB 118.2 2528 31.3 39.1 23.5 93% Down Head down + GB 126.5 2500 33.1 41.4 24.8 60% spinning (sweep mode) 11 Degree Road Test 127.2 2753 36.7 45.8 27.5 97% (PH 4, GB Sp 10) Sweep Mode 117.5 2701 33.2 41.5 24.9 72% (PH 3, GB Sp 8) Sweep Mode 115.8 2680 32.5 40.6 24.4 48% (PH 2, GB Sp 10) Sweep mode 127.0 2703 35.9 44.9 27.0 56% (PH 3, GB Sp 10) Average 70%

[0029] From these tests, the airfoil blades reduced power consumption by 60%, compared to the straight Sentry blade. Also, the airfoil blades allow the size of the fan to be reduced, for decreased weight, easier packaging, and less expensive shipping. The airfoil blade design also reduces the noise level to a maximum of 87 dB at full speed, which is beneath the OSHA threshold for ear protection. Isolation of the fan and inclusion of dampening mechanisms can further reduce the noise level.

[0030] The fan 22 with the airfoil blades 24 can be original equipment on the street sweeper 10 or may be retrofit onto existing street sweepers.

[0031] Thus, the fan assembly, and the blade manufacturing and assembly processes described above accomplish at least all of the stated objectives.

[0032] The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.