Fan array fan section in air-handling systems

• US 7,137,775 B2
• Filed: 03/22/2004
• Issued: 11/21/2006
• Est. Priority Date: 03/20/2003
• Status: Expired due to Term

• Current Assignee: Nortek Air Solutions LLC (Melrose Industries Plc)
• Original Assignee: Huntair Incorporated (Melrose Industries Plc)
• Inventors: Hopkins, Lawrence G.
• Primary Examiner(s): Nguyen, Ninh H.
• Application Number:
  US10/806,775
• Publication Number:
  US 20040185771A1
• Time in Patent Office: 974 Days
• Field of Search: 415/60, 415/61, 415/108, 415/177, 415/119, 416/120, 417/3, 417/423.5, 417/426, 454/338
• US Class Current: 415/61
• CPC Class Codes: F04D 19/002 Axial flow fans
• CPC Class Codes: F04D 25/166 using fans
• CPC Class Codes: F04D 27/004 by varying driving speed
• CPC Class Codes: F04D 27/0261 by varying driving speed
• CPC Class Codes: F04D 29/522 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/644 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/664 by means of sound absorbing material
• CPC Class Codes: F05D 2270/023 of different spools or shafts
• CPC Class Codes: F05D 2270/03 in variable speed operation
• CPC Class Codes: F05D 2270/3061 of the working fluid
• CPC Class Codes: F24F 11/74 for controlling air flow rate or air velocity
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 7/007 with forced flow using ducting systems F24F7/06
• CPC Class Codes: F24F 7/06 with forced air circulation, e.g. by fan positioning of a ventilator in or against a conduit
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A fan array fan section in an air-handling system includes a plurality of fan units arranged in a fan array and positioned within an air-handling compartment. One preferred embodiment may include an array controller programmed to operate the plurality of fan units at peak efficiency. The plurality of fan units may be arranged in a true array configuration, a spaced pattern array configuration, a checker board array configuration, rows slightly offset array configuration, columns slightly offset array configuration, or a staggered array configuration.

Claims

1. A fan array fan section in an air-handling system comprising:

(a) at least six fan units;

(b) said at least six fan units arranged in a fan array;

(c) an air-handling compartment within which said fan array of fan units is positioned; and

(d) an array controller for controlling said at least six fan units to run at substantially peak efficiency by strategically turning selective ones of said at least six fan units on and off, wherein each fan unit has a peak efficiency operating range outside of which it operates at a reduced efficiency, and wherein said array controller is programmed to operate said at least six fan units at substantially peak efficiency by strategically turning off at least one fan unit operating at reduced efficiency and running the remaining fan units within said peak efficiency operating range.

2. The fan array fan section in an air-handling system of claim 1, wherein said at least six fan units are plenum fans.

4. The fan array fan section in an air-handling system of claim 1, wherein said at least six fan units are a plurality of fan units arranged in a fan array configuration selected from the group consisting of:

(a) a true array configuration;

(b) a spaced pattern array configuration;

(c) a checker board array configuration;

(d) rows slightly offset array configuration;

(e) columns slightly offset array configuration; and

(f) a staggered array configuration.

5. The fan array fan section in an air-handling system of claim 1, wherein said at least six fan units include at least two vertically arranged fan units.

6. The fan array fan section in an air-handling system of claim 1, wherein each of said at least six fan units is positioned within a fan unit chamber.

7. The fan array fan section in an air-handling system of claim 1, wherein each of said at least six fan units is suspended within a respective said fan unit chamber such that there is an air relief passage there below.

8. The fan array fan section in an air-handling system of claim 1, wherein each of said at least six fan units is positioned within a fan unit chamber having at least one acoustically absorptive insulation surface.

9. The fan array fan section in an air-handling system of claim 1, wherein each of said at least six fan units are mounted in a grid system.

10. The fan array fan section in an air-handling system of claim 1, wherein each of said at least six fan units has a fan wheel diameter, wherein spacing between said at least six fan units is less than 60% of said fan wheel diameter.

11. The fan array fan section in an air-handling system of claim 1, further comprising an array of backdraft dampeners, each backdraft dampener in line with a respective fan unit.

12. The fan array fan section in an air-handling system of claim 1, said array controller is programmed to operate said at least six fan units at peak efficiency for a performance level based on a criteria selected from the following group of criteria:

(a) air volume;

(b) level of air flow;

(c) pattern of air flow; and

(d) number of fan units to operate.

13. The fan array fan section in an air-handling system of claim 1, said array controller is programmed to operate said at least six fan units to produce a stable operating point and eliminate the surge effects.

14. The fan array fan section in an air-handling system of claim 1, said array controller is programmed to selectively control the speed of each of said at least six fan units to run at substantially peak efficiency.

15. The fan array fan section in an air-handling system of claim 1, said air-handling compartment positionable within a structure such that said air-handling system conditions the air of said structure.

3. The fan array fan section in an air-handling system of 1, wherein said air-handling compartment has an airway path, said airway path being less than 72 inches.

16. A fan array fan section in an air-handling system comprising:

(a) a plurality of independently controllable fan units, each fan unit comprising an inlet cone, a fan, and a motor;

(b) said plurality of fan units arranged in a fan array;

(c) an air-handling compartment within which said fan array of fan units is positioned;

(d) an array controller for controlling said plurality of fan units to run at substantially peak efficiency by strategically turning selective ones of said plurality of fan units on and off;

wherein

(e) each of said plurality of fan units has a fan wheel diameter, wherein spacing between said pluality of fan units is less than 60% of said fan wheel diameter.

17. The fan array fan section in an air-handling system of claim 16, wherein said plurality of fan units are plenum fans.

18. The fan array fan section in an air-handling system of claim 16, wherein said air-handling compartment has an airway path, said airway path being less than 72 inches.

19. The fan array fan section in an air-handling system of claim 16, wherein said plurality of fan units are a plurality of fan units arranged in a fan array configuration selected from the group consisting of:

(a) a true array configuration;

(b) a spaced pattern array configuration;

(c) a checker board array configuration;

(d) rows slightly offset array configuration;

(e) columns slightly offset array configuration; and

(f) a staggered array configuration.

20. The fan array fan section in an air-handling system of claim 16, wherein said plurality of fan units include at least two vertically arranged fan units.

21. The fan array fan section in an air-handling system of claim 16, wherein each of said plurality of fan units is positioned within a fan unit chamber.

22. The fan array fan section in an air-handling system of claim 16, wherein each of said plurality of fan units is suspended within a respective said fan unit chamber such that there is an air relief passage therebelow.

23. The fan array fan section in an air-handling system of claim 16, wherein each of said plurality of fan units is positioned within a fan unit chamber having at least one acoustically absorptive insulation surface.

24. The fan array fan section in an air-handling system of claim 16, wherein each of said plurality of fan units is mounted in a grid system.

25. The fan array fan section in an air-handling system of claim 16, further comprising an array of backdraft dampeners, each backdraft dampener in line with a respective fan unit.

26. The fan array fan section in an air-handling system of claim 16, wherein each fan unit has a peak efficiency operating range outside of which it operates at a reduced efficiency, wherein said array controller is programmed to operate said plurality of fan units at substantially peak efficiency by strategically turning off at least one fan unit operating at reduced efficiency and running the remaining fan units within said peak efficiency operating range.

27. The fan array fan section in an air-handling system of claim 16, said array controller is programmed to operate said plurality of fan units at peak efficiency for a performance level based on a criteria selected from the following group of criteria:

(a) air volume;

(b) level of air flow;

(c) pattern of air flow; and

(d) number of fan units to operate.

28. The fan array fan section in an air-handling system of claim 16, said array controller is programmed to operate said plurality of fan units to produce a stable operating point and eliminate the surge effects.

29. The fan array fan section in an air-handling system of claim 16, said array controller is programmed to selectively control the speed of each of said plurality of fan units to run at substantially peak efficiency.

30. The fan array fan section in an air-handling system of claim 16, said air-handling compartment positionable within a structure such that said air-handling system conditions the air of said structure.