Modular fan units with sound attenuation layers for an air handling system

• US 8,398,365 B2
• Filed: 11/10/2011
• Issued: 03/19/2013
• Est. Priority Date: 03/20/2003
• Status: Active Grant

• 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:
  US13/293,301
• Publication Number:
  US 20120057962A1
• Time in Patent Office: 495 Days
• Field of Search: 415/119, 415/213.1, 415/60, 415/61, 415/30
• US Class Current: 415/119
• CPC Class Codes: F04D 13/06 the pump being electrically driven
• CPC Class Codes: F04D 13/12 Combinations of two or more pumps combinations with priming pumps or booster pumps to counteract vapour-lock F04D9/04
• CPC Class Codes: F04D 15/00 Control, e.g. regulation, of pumps, pumping installations or systems
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 25/166 using fans
• CPC Class Codes: F04D 29/664 by means of sound absorbing material
• CPC Class Codes: F05D 2250/511 augmenting, i.e. with intercepting fluid flow cross sectional area greater than the rest of the machine behind the inlet
• CPC Class Codes: F05D 2260/96 Preventing, counteracting or reducing vibration or noise
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 13/24 Means for preventing or suppressing noise
• CPC Class Codes: F24F 2013/242 Sound-absorbing material
• CPC Class Codes: F24F 3/044 Systems in which all treatment is given in the central station, i.e. all-air systems
• 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: F24F 7/065 fan combined with single duct; mounting arrangements of a fan in a duct
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating
• CPC Class Codes: Y10T 29/49245 Vane type or other rotary, e.g., fan
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A modular fan array is provided that is configured for use in an air-handling system and configured to deliver air to a ventilation system for at least a portion of a building. The modular fan array comprises a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array. The modular units each include at least an interior surface, a front end and a back end that define a chamber. The modular fan array includes motors and fans positioned in the chambers of the modular units. The fans are located proximate to the front ends of the corresponding chambers. The fans direct air to discharge from the back ends of the chambers. Sound attenuation layers extend along at least a portion of the interior surface of the chambers. The sound attenuation layers are positioned between at least some of the adjacent chambers.

Claims

1. A modular fan system configured for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the fan system comprising:

a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular units each including a chamber having a front end and a back end;

motors and fans positioned in the chambers of the modular units, the fans located to take in air from the front ends of the corresponding chambers and to discharge air from the back ends of the corresponding chambers; and

sound attenuation layers that extend along at least a portion of the corresponding chambers such that the sound attenuation layers are positioned between at least some of the fans when the modular units are stacked adjacent to one another in the array, such that, when the modular units are stacked, the chambers open at the back ends into a common discharge plenum where the air mixes to provide substantially uniform airflow for the air-handling system.

2. The fan system of claim 1, further comprising inlet cones mounted at the front ends of the chambers, the inlet cones located upstream of the fans.

3. The fan system of claim 1, wherein the modular units are structured in a plug and play configuration.

4. The fan system of claim 1, further comprising a grid system into which the modular units are placed.

5. The fan system of claim 1, wherein the modular units have interlocking structures to facilitate locking the modular units together.

6. The fan system of claim 1, wherein the modular units include top, bottom and sides, the sound attenuation layers extending along at least one of the top, bottom and sides.

7. The fan system of claim 1, further comprising an array controller for controlling said motors and fans to run substantially at or above a selected performance level, wherein the motors and fans have a preferred operating range, wherein said array controller is configured to operate the motors and fans substantially at or above the selected performance level when at least one motor and fan is OFF by controlling a speed of the remaining motors and fans to run within said preferred operating range while still meeting the selected performance level.

8. The fan system of claim 1, further comprising an array controller for controlling said motors and fans to run substantially at or above a selected performance level, wherein the selected performance level is based on a criterion selected from the following group of criteria:

(a) air flow volume;

(b) air pressure; and

(c) pattern of air flow.

9. The fan system of claim 1, wherein the motors have a corresponding first speed when driven at a first frequency, wherein the first speed constitutes a nameplate rated speed for the corresponding motor.

10. The fan system of claim 1, wherein the motors have a corresponding first speed when driven at a first frequency, wherein the first speed constitutes synchronous speed for the corresponding motor.

11. The fan system of claim 1, wherein the modular units are stacked in a vertical column.

12. The fan system of claim 1, further comprising motor mounts that mount the motors suspended within the corresponding chambers such that air relief passages are provided below the motors.

13. The fan system of claim 1, further comprising an array controller configured to operate at least one of the motors at a speed that is greater than a first speed to deliver an associated air flow amount from the corresponding one of the fans, wherein the first speed constitutes a nameplate rated speed for the corresponding motor.

14. The fan system of claim 1, further comprising an array controller configured to operate at least one of the motors at a speed that is greater than a first speed to deliver an associated air flow amount from the corresponding one of the fans, wherein the first speed constitutes synchronous speed for the corresponding motor.

15. The fan system of claim 1, further comprising an array controller configured to operate at least one of the motors at a speed that is greater than a first speed to deliver an associated air flow amount from the corresponding one of the fans, wherein the first speed is associated with a first frequency that constitutes 60 Hertz.

16. The fan system of claim 1, wherein the back ends of the chambers are substantially open to provide a minimum restriction to air flow.

17. The fan system of claim 1, wherein the modular units are configured to be spaced apart when stacked.

18. The fan system of claim 1, wherein the modular units are configured to be stacked in a 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.

19. The fan system of claim 1, wherein the chambers are rectangular.

20. The fan system of claim 1, wherein the modular units are located directly against one another.

21. The fan system of claim 1, wherein the modular units are spaced apart from one another.

22. The fan system of claim 1, wherein the motors and fans are positioned entirely within the corresponding chambers.

23. The fan system of claim 1, wherein the motors and fans extend at least partially beyond back ends of the corresponding chambers.

24. The fan system of claim 1, wherein at least one of the modular units includes at least two chambers, each of the chambers including the corresponding motor and fan.

25. A modular fan system configured for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the fan system comprising:

a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular units each including a chamber having a front end and a back end;

motors and fans positioned in the chambers of the modular units, the fans located to take in air from the front ends of the corresponding chambers and to discharge air from the back ends of the corresponding chambers, wherein the motors have a corresponding first speed when driven at a first frequency, the fans being configured to deliver an air flow amount based on a speed of the corresponding motor;

sound attenuation layers that extend along at least a portion of the corresponding chambers such that the sound attenuation layers are positioned between at least some of the fans when the modular units are stacked adjacent to one another in the array; and

an array controller for controlling said motors, the array controller to operate at least one of the motors at a speed that is greater than the first speed to deliver an associated air flow amount from the corresponding one of the fans.

26. The system of claim 25, further comprising inlet cones mounted at the front ends of the chambers, the inlet cones located upstream of the fans.

27. The system of claim 25, wherein the modular units are structured in a plug and play configuration.

28. The system of claim 25, further comprising a grid system into which the modular units are placed.

29. The system of claim 25, wherein the modular units have interlocking structures to facilitate locking the modular units together.

30. The system of claim 25, wherein the modular units include top, bottom and sides.

31. The system of claim 25, wherein the array controller is configured to control the motors and fans to run substantially at or above a selected performance level, wherein the motors and fans have a preferred operating range, wherein said array controller is configured to operate the motors and fans substantially at or above the selected performance level when at least one motor and fan is OFF by controlling a speed of the remaining motors and fans to run within said preferred operating range while still meeting the selected performance level.

32. The system of claim 25, wherein the array controller is configured to control the motors and fans to run substantially at or above a selected performance level, wherein the selected performance level is based on a criterion selected from the following group of criteria:

(a) air flow volume;

(b) air pressure; and

(c) pattern of air flow.

33. The system of claim 25, further comprising motor mounts that mount the motors suspended within the corresponding chambers such that air relief passages are provided below the motors.

34. The system of claim 25, wherein the first speed constitutes a nameplate rated speed for the corresponding motor.

35. The system of claim 25, wherein the first speed constitutes synchronous speed for the corresponding motor.

36. The system of claim 25, wherein the first frequency constitutes 60 Hertz.

37. The system of claim 25, wherein the back ends of the chambers are substantially open to provide a minimum restriction to air flow.

38. The system of claim 25, wherein the modular units are configured to be stacked in at least a vertical column.

39. The system of claim 25, wherein the modular units are configured to be stacked in a 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.

40. A method for providing a modular fan system configured for use in an air-handling system that is configured to deliver air to a ventilation system for at least a portion of a building, the method comprising:

providing a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular units each including a chamber having a front end and a back end;

positioning motors and fans in the chambers of the modular units, the fans located to take in air from the front ends of the corresponding chambers and to discharge air from the back ends of the corresponding chambers; and

including, in at least a portion of the chambers, sound attenuation layers along at least a portion of the corresponding chambers such that the sound attenuation layers are positioned between at least some of the fans when the modular units are stacked adjacent to one another in the array, such that, when the modular units are stacked, the chambers open at the back ends into a common discharge plenum where the air mixes to provide substantially uniform airflow for the air-handling system.

41. The method of claim 40, further comprising mounting inlet cones at the front ends of the chambers, the inlet cones located upstream of the fans.

42. The method of claim 40, wherein the modular units are structured in a plug and play configuration.

43. The method of claim 40, wherein the modular units are joined to one another with separate interlocking structures.

44. The method of claim 40, further comprising a grid system into which the modular units are placed.

45. The method of claim 40, wherein the modular units include top, bottom and sides, the sound attenuation layers extending along at least one of the top, bottom and sides.

46. The method of claim 40, further comprising mounting the motors suspended within the corresponding chambers such that air relief passages are provided below the motors.

47. The method of claim 40, wherein the motors have a corresponding first speed when driven at a first frequency, the method further comprising:

configuring the fans to deliver an air flow amount based on a speed of the corresponding motor; and

configuring an array controller to control said motors, the array controller configured to operate at least one of the motors at a speed that is greater than the first speed to deliver an associated air flow amount from the corresponding one of the fans.

48. The method of claim 40, wherein the motors have a corresponding first speed when driven at a first frequency wherein the first speed constitutes a nameplate rated speed for the corresponding motor.

49. The method of claim 40, wherein the motors have a corresponding first speed when driven at a first frequency wherein the first speed constitutes synchronous speed for the corresponding motor.

50. The method of claim 40, wherein the motors have a corresponding first speed when driven at a first frequency wherein the first frequency constitutes 60 Hertz.

51. The method of claim 40, wherein the back ends of the chambers are substantially open to provide a minimum restriction to air flow.

52. The method of claim 40, further comprising configuring the modular units to be stacked in at least a vertical column.

53. The method of claim 40, further comprising configuring the modular units to be stacked in a 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.

54. A method for providing a modular fan system configured for use in an air-handling system that is configured to deliver air to a ventilation system for at least a portion of a building, the method comprising:

providing a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular units each including a chamber having a front end and a back end;

positioning motors and fans in the chambers of the modular units, the fans located to take in air from the front ends of the corresponding chambers and to discharge air from the back ends of the corresponding chambers, wherein the motors have a corresponding first speed when driven at a first frequency, the fans being configured to deliver an air flow amount based on a speed of the corresponding motor; and

including, in at least a portion of the chambers, sound attenuation layers along at least a portion of the corresponding chambers such that the sound attenuation layers are positioned between at least some of the fans when the modular units are stacked adjacent to one another in the array; and

configuring an array controller to operate at least one of the motors at a speed that is greater than the first speed to deliver an associated air flow amount from the corresponding one of the fans.

55. The method of claim 54, further comprising mounting inlet cones at the front ends of the chambers, the inlet cones located upstream of the fans.

56. The method of claim 54, wherein the modular units are structured in a plug and play configuration.

57. The method of claim 54, further comprising providing a grid system into which the modular units are placed.

58. The method of claim 54, further comprising providing interlocking structures to facilitate locking the modular units together.

59. The method of claim 54, further comprising shaping the modular units to include top, bottom and sides.

60. The method of claim 54, further comprising configuring the array controller to control the motors and fans to run substantially at or above a selected performance level, wherein the motors and fans have a preferred operating range, wherein said array controller is configured to operate the motors and fans substantially at or above the selected performance level when at least one motor and fan is OFF by controlling a speed of the remaining motors and fans to run within said preferred operating range while still meeting the selected performance level.

61. The method of claim 54, further comprising configuring the array controller to control the motors and fans to run substantially at or above a selected performance level, wherein the selected performance level is based on a criterion selected from the following group of criteria:

(a) air flow volume;

(b) air pressure; and

(c) pattern of air flow.

62. The method of claim 54, further comprising providing motor mounts that mount the motors suspended within the corresponding chambers such that air relief passages are provided below the motors.

63. The method of claim 54, wherein the first speed constitutes a nameplate rated speed for the corresponding motor.

64. The method of claim 54, wherein the first speed constitutes synchronous speed for the corresponding motor.

65. The method of claim 54, wherein the first frequency constitutes 60 Hertz.

66. The method of claim 54, wherein the back ends of the chambers are substantially open to provide a minimum restriction to air flow.