Fan array fan section in air-handling systems

• US 10,641,271 B2
• Filed: 03/21/2017
• Issued: 05/05/2020
• Est. Priority Date: 03/20/2003
• Status: Active Grant

• Current Assignee: Nortek Air Solutions LLC (Melrose Industries Plc)
• Original Assignee: Nortek Air Solutions LLC (Melrose Industries Plc)
• Inventors: Hopkins, Lawrence G.
• Primary Examiner(s): Nguyen, Ninh H.
• Application Number:
  US15/464,948
• Publication Number:
  US 20170306969A1
• Time in Patent Office: 1,141 Days
• 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 system comprising:

an air handling compartment having a discharge plenum configured to deliver air to a ventilation system for at least a portion of a building;

a fan array of fan units positioned in the air handling compartment;

the fan units configured to be ON and OFF, the fan array having redundant air flow capacity such that, when at least one of the fan units is removed or OFF;

the fan units that are ON have sufficient air flow capacity to meet a specified air capacity;

a sound attenuation layer positioned between two of the fan units, the two of the fan units being adjacent to one another;

at least three fan units; and

a control system for controlling the at least three fan units to run substantially at or above a selected performance level, wherein the fan units have a preferred operating range, wherein the control system is configured to operate the at least three fan units substantially at or above the selected performance level when at least one fan unit is OFF by controlling a speed of the remaining fan units to run within the preferred operating range while still meeting the selected performance level;

wherein the array controller is programmed to operate the at least three fan units to produce a stable operating point and eliminate surge effects.

2. The system of claim 1, further comprising an array controller programmed to control a speed of the fan units to at least meet a current air demand of at least the portion of the building.

3. The system of claim 2, wherein the control system comprises the programmable array controller.

4. The system of claim 1, wherein the selected performance level is based on a criterion selected from the following group of criteria:

air flow volume;

air pressure; and

pattern of air flow.

5. The system of claim 1, wherein the specified air capacity corresponds to a total air handling requirement specified for at least the portion of the building.

6. The system of claim 1, wherein the fan array comprises a first group of fan units sufficient in number to at least meet the specified air capacity;

and at least one redundant fan unit in addition to the first group of fan units.

7. The system of claim 1, wherein the fan array includes at least six fan units.

8. The system of claim 1, wherein the fan units are positioned adjacent to one another in a common plane, wherein the sound attenuation layer positioned between two of the fan units comprises:

a sound attenuation layer arranged between every pair of adjacent fan units of the fan units, the sound attenuation layers, each one of which is arranged between every pair of adjacent fan units of the fan units, being arranged in at least one of rows and columns.

9. The system of claim 1, wherein the sound attenuation layer is provided along at least one of a top, bottom, and side of the fan units.

10. The system of claim 1, wherein the sound attenuation layer includes a perforated facing and at least one layer of insulation material.

11. The system of claim 1, wherein the fan array is arranged in a 2-dimensional pattern.

12. The system of claim 1, wherein the control system controls the fan units by at least one of taking fan units on-line, taking fan units off-line, and changing a speed of fan units that are on-line.

13. The system of claim 1, wherein the control system is configured to automatically turn ON and turn OFF individual fan units.

14. The system of claim 1, wherein the control system is configured to permit a user to manually turn ON and turn OFF the individual fan units.

15. The system of claim 1, wherein the control system is configured to be programmed with at least one of a desired air flow volume, air pressure, and a pattern of fan units to operate.

16. The system of claim 1, further comprising one or more air handling components located downstream of at least one of the fan array and the discharge plenum, the air handling components include at least one of a cooling coil, a heating coil, a filter, a humidifier and a damper.

17. The system of claim 1, wherein the fan units direct air into a common area of the discharge plenum where the air combines before exiting the discharge plenum.

18. The system of claim 1, wherein the fan array is configured to meet a current air demand by operating all of the fan units at a first fan speed and wherein the fan array is configured to meet the current air demand by operating a subset of the fan units at a second fan speed faster than the first fan speed.