Description:METHOD OF MANUFACTURING OF STATOR AND ROTOR OF A TWP FAN USING UNUTILIZED MATERIAL OF CEILING FAN STATOR

TECHNICAL FIELD
[0001] The present disclosure relates to a method of manufacturing stator and rotor of a table wall pedestal (TWP) fan using unutilized material of a ceiling fan. Further, the present method relates to manufacturing of a stator and a rotor of a ceiling fan and a table wall pedestal (TWP) fan. In particular, the present disclosure relates to the method, where both the rotor and the stator of the ceiling fan and the table wall pedestal (TWP) fan, respectively, are manufactured from a single metal sheet by maintaining high yield percentage of material usage. Therefore, the method disclosed herein is not only cost effective in nature but also prevents undue wastage of the metal sheet.
BACKGROUND
[0002] Figure 1 depicts an existing arrangement of a ceiling fan. Typically, in the ceiling fan, a rotor (104) is an outermost ring shaped structure which allows fitment of a stator (102) inside it. The ceiling fan stator (102) is supported with the ceiling fan rotor (104) through a rod shaped spindle (106). The spindle (106) also enables the ceiling fan to be hooked onto ceiling.
[0003] The table wall pedestal (TWP) fan, on the other hand, comprises of a rotor and a stator, where the table wall pedestal (TWP) fan stator is the outermost part supporting the table wall pedestal (TWP) fan rotor inside it.
[0004] In an existing method of manufacturing of the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan as discussed above, separate metal sheets are used by the manufacturers in order to fabricate the same. Consequently, this results into a maximum percentage yield of around 55 percent for the ceiling fan and around 52 percent for the table wall pedestal (TWP) fan. Thus, a considerable portion of the sheet metal gets wasted thereby having an impact on the overall cost of production, particularly of the table wall pedestal (TWP) fan.
[0005] Further, in order to reduce weight of the stator of the ceiling fan, multiple holes are provided which also add another step of stamping process resultantly increasing cost and manufacturing time. Further, the multiple holes are provided for better heat dissipation. The material received after stamping the small holes are complete scrap material and have no use which increases pressure on environment and natural resources.
[0006] Towards, this direction, the present disclosure intends to mitigate the above mentioned challenges in order to ease the process of with a view to prevent wastage of metal sheet.
OBJECTS OF THE INVENTION
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0008] It is an object of the present subject matter to overcome the aforementioned and other drawbacks existing in the prior art systems and methods.
[0009] It is a significant object of the present disclosure to provide a method utilizing a single sheet of metal for manufacturing stator and rotor for both the ceiling fan and the table wall pedestal (TWP) fan.
[0010] It is another significant object of the present disclosure to provide a method for using the unutilized material of the ceiling fan stator to prepare the stator and the rotor of the table wall pedestal (TWP) fan.
[0011] It is another principal object of the present disclosure to provide the method for manufacture of the stator and rotor for both the ceiling fan and the table wall pedestal (TWP) fan such that overall weight of the ceiling fan and the table wall pedestal (TWP) fan is reduced than the existing arrangement.
[0012] It is another object of the present disclosure to provide the method that is simple and easy to implement.
[0013] It is yet another object of the present disclosure to provide the method that is cost effective in nature.
[0014] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taking into consideration with accompanied drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION
[0015] This summary is provided to introduce concepts related to a method of manufacturing/preparing stator and rotor of a table wall pedestal (TWP) fan using unutilized material of ceiling fan stator. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0016] According to an embodiment of a present disclosure, there is provided a method of manufacturing an assembly of stator and rotor of a ceiling fan and a table wall pedestal (TWP) fan, respectively, from a single metal sheet.
[0017] In an aspect, the method comprises cutting a circular sheet (C1) with a radius (R1) from the single metal sheet, obtaining a ceiling fan rotor by cutting a circular sheet (C2) with a radius (R2) from the cut circular sheet (C1), obtaining a ceiling fan stator by cutting a circular sheet (C3) with a radius (R3) from the cut circular sheet (C2), and obtaining a stator and a rotor for a TWP fan by cutting a circular sheet (C4) with a radius (R4) from the cut circular sheet (C3).
[0018] In an aspect, herein the circular sheets (C1, C2, C3, C4) are concentric circulate plates.
[0019] In an aspect, the method includes cutting of the single sheet in a manner to define the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan respectively, such that difference in width of outer periphery and inner periphery of the plurality of concentric circular sheets, is greater than or equal to distance between two consecutive teeth of the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan, respectively.
[0020] In an aspect, the method includes production of the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan by a single punching machine.
[0021] In an aspect, the method facilitates yield of the single sheet metal ranging from 62 percent to 70 percent.
[0022] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0023] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which numerals represent like components.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING(S)
[0024] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which
[0025] Figure 1 represents an existing arrangement for a stator and a rotor of a ceiling fan and a table wall pedestal (TWP) fan, respectively;
[0026] Figure 2 represents manufacturing of the stator and the rotor of both the ceiling fan and the table wall pedestal (TWP) fan from a single sheet metal in accordance with an embodiment of the present disclosure; and
[0027] Figure 3 represents an example method of manufacturing of the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan, respectively, from a single sheet in accordance with an embodiment of the present disclosure.
[0028] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0029] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0030] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
[0031] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.
Exemplary implementations/embodiments
[0032] The present disclosure relates to a method of manufacturing an assembly of a stator and a rotor of a ceiling fan and a table wall pedestal (TWP) fan from a single sheet, particularly of a metal. Therefore, in this manner the method disclosed herein prevents wastage of the metal sheet after the ceiling fan stator and the rotor is developed and utilizes the same in obtaining the stator and the rotor, respectively, of the table wall pedestal (TWP) fan as well. The detailed methodology is disclosed in the subsequent sections.
[0033] Figure 2 represents manufacturing of the stator and the rotor of both the ceiling fan and the table wall pedestal (TWP) fan from a single sheet metal in accordance with an embodiment of the present disclosure. Herein, as can be observed from the figure, a plurality of concentric circular plates viz., C1, C2, C3 and C4 is cut from a single metal sheet.
[0034] In an aspect, the concentric circular plates C1, C2, C3 and C4 are having radius of R1, R2, R3 and R4, respectively, where R1, R2, R3, R4 follow the relation R1>R2>R3>R4.
[0035] In an aspect, the single sheet is cut in a manner such that a first circular plate C1 represents a ceiling fan rotor (202) and a second circular plate C2 represents a ceiling fan stator (204).
[0036] In an aspect, a third circular plate C3 is extracted from central portion of the ceiling fan stator (204), where the third circular plate C3 represents a table wall pedestal (TWP) fan stator (206).
[0037] In an aspect, a fourth circular plate C4 is extracted from central portion of the table wall pedestal (TWP) fan stator (206), where the fourth circular plate C4 represents a table wall pedestal (TWP) fan rotor (208).
[0038] Therefore, the single sheet is utilized in manufacturing the ceiling fan rotor (202), the ceiling fan stator (204), the table wall pedestal (TWP) fan stator (206) and the table wall pedestal (TWP) fan rotor (208), respectively thereby preventing wastage and reducing cost of the overall production process.
[0039] Therefore, it is evident that the method disclosed in the present disclosure is not only helping in utilization of the single sheet to a maximum possible extent but also is ensuring that the resultant ceiling fan and the table wall pedestal (TWP) fan are light weight in nature.
[0040] Figure 3 illustrates an example method for manufacturing the assembly of the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan, respectively from a single metal sheet where the ceiling fan rotor (202), the ceiling fan stator (204), the table wall pedestal (TWP) fan stator (206), the table wall pedestal (TWP) fan rotor (208) are designed by a single punching machine. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the methods, or an alternative method.
[0041] At block (302), the method includes cutting the circular sheet (C1) with the radius (R1) from the single metal sheet.
[0042] At block (304), the method includes obtaining (504) the ceiling fan rotor (202) by cutting the circular sheet (C2) with the radius (R2) from the cut circular sheet (C1).
[0043] At block (306), the method includes obtaining (506) the ceiling fan stator (204) by cutting the circular sheet (C3) with the radius (R3) from the cut circular sheet (C2).
[0044] At block (308), the method includes obtaining (508) the stator (206) and the rotor (208) for the table wall pedestal (TWP) fan by cutting a circular sheet (C4) with the radius (R4) from the cut circular sheet (C3).
[0045] Additionally, in an aspect, the single sheet is cut into concentric circular sheets C1, C2, C3 and C4, to define the stator (204, 206) and the rotor (202, 208) of the ceiling fan and the table wall pedestal (TWP) fan respectively, in a manner such that difference in width of outer periphery and inner periphery of the concentric circular sheets C1, C2, C3 and C4 is greater than or equal to distance between two consecutive teeth of the stator (204, 206) and the rotor (202, 208) of the ceiling fan and the table wall pedestal (TWP) fan, respectively.
[0046] Technical Advantages
[0047] All in all, the invention described in the present disclosure is having the following advantages:
a) The method facilitates utilization of a single sheet to a maximum extent thereby reducing wastage. The stator yield of material with the utilization of unused area of ceiling fan as disclosed in the present subject matter becomes around 66 percent; significantly higher than that of the existing arrangements.
b) Both the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan can be made at single line which saves cost and time.
c) The method involves production of the stator and the rotor of the table wall pedestal (TWP) fan from raw material of the ceiling fan without hampering the performance and safety of the ceiling fan.
d) The method facilitates the stator of the ceiling fan to become lighter in weight which in turn enhances mounting of fan and simultaneously decreases the load of hook of ceiling on which the ceiling fan is supposed to be hinged.
e) The method helps in enhancement of efficiency of motor of the ceiling fan and the table wall pedestal (TWP) fan by controlling rise in temperature of the motor, due to involvement of the stator with less material.
f) The method facilitates substantial increase in productivity of stator and rotor lamination as these are produced simultaneously by a single punching machine.
g) The method is simple and easy to implement.
h) The method is cost effective and reduces overall production cost of the ceiling fan and the table wall pedestal (TWP) fan.
Equivalents
[0048] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various systems that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0049] Although embodiments for the present subject matter have been described in language specific to package features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/device of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.
[0050] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0051] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
, Claims:We Claim:

1. A method of manufacturing a stator and a rotor of a table wall pedestal (TWP) fan using unutilized material of a ceiling fan stator, the method comprising:
- cutting (302) a circular sheet (C1) with a radius (R1) from the single metal sheet;
- obtaining (304) a ceiling fan rotor (202) by cutting a circular sheet (C2) with a radius (R2) from the cut circular sheet (C1);
- obtaining (306) the ceiling fan stator (204) by cutting a circular sheet (C3) with a radius (R3) from the cut circular sheet (C2); and
- obtaining (308) the stator (206) and the rotor (208) for a TWP fan by cutting a circular sheet (C4) with a radius (R4) from the cut circular sheet (C3),
- wherein the circular sheets (C1, C2, C3, C4) are concentric circular plates derived from the single metal sheet.

2. The method as claimed in claim 1, wherein the method includes cutting of the single sheet in a manner to define the stator (204, 206) and the rotor (202, 208) of the ceiling fan and the table wall pedestal (TWP) fan respectively, such that difference in width of outer periphery and inner periphery of the plurality of concentric circular sheets, is greater than or equal to distance between two consecutive teeth of the stator (204, 206) and the rotor (202, 208) of the ceiling fan and the table wall pedestal (TWP) fan, respectively.
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3. The method as claimed in claim 1, wherein the radius (R1, R2, R3, R4) follow relation R1>R2>R3>R4.

4. The method as claimed in claim 1, wherein the stator and the rotor of the ceiling fan and the table wall pedestal (TWP) fan are produced by a single punching machine.

5. The method as claimed in claim 1, wherein the method facilitates yield of the single sheet metal ranging from 62 percent to 70 percent.