Ceiling-mounted air conditioning unit

Abstract

An object of the present application is to provide a method for manufacturing a ceiling-mounted air conditioning unit in which air conditioning equipment intended for installation in a suspended state is attached to a frame. [Solution] The present invention is a method for manufacturing a ceiling-mounted air conditioning unit, comprising an equipment assembly process in which multiple ceiling-mounted air conditioning devices are assembled together; an upper frame attachment process in which an upper frame that forms the upper part of the frame that holds the multiple air conditioning devices together is attached from above to the assembled multiple air conditioning devices; and a lower frame attachment process in which the upper frame with the multiple air conditioning devices attached is raised and a lower frame that forms the lower part of the frame is attached from below the multiple air conditioning devices.

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing a ceiling mounted air conditioning unit. [Background technology]

[0002] In recent years, various techniques have been proposed to facilitate the installation of air conditioning equipment such as concealed air conditioners and chambers that are installed above the ceiling (see, for example, Patent Documents 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5208841 [Patent Document 2] JP 2019-207092 A [Patent Document 3] JP 2019-207095 A Summary of the Invention [Problem to be solved by the invention]

[0004] Concealed air conditioners that are installed in the ceiling are usually attached to a bar screw (sometimes called a "full screw") that is fixed to the structural material of the building, and are installed in a suspended state by the bar screw. Therefore, the mounting parts of commercially available concealed air conditioners are structured on the premise that they will be installed in this suspended state. Therefore, even in cases where, for example, auxiliary parts such as a chamber are integrated with the air conditioner body and the like in advance by a frame in a factory in order to facilitate the installation of the air conditioner at the site, and the air conditioner is transported from the factory to a remote construction site by a vehicle or the like, in order to install an air conditioner that is structured to be installed in a suspended state on the frame at the factory, it is necessary to handle the air conditioner in a proper posture in order to prevent damage to the mounting parts provided on the air conditioner.

[0005] The present invention has been made in consideration of the above circumstances, and has an object to provide a method of manufacturing a ceiling-mounted air conditioning unit in which air conditioning equipment intended for installation in a suspended state is attached to a frame. [Means for solving the problem]

[0006] In order to solve the above problem, in the present invention, an upper frame is attached from above to multiple air conditioning devices that are assembled together, then the upper frame is raised and a lower frame is attached from below the multiple air conditioning devices.

[0007] In detail, the present invention is a method for manufacturing a ceiling-mounted air conditioning unit, comprising an equipment assembly process for assembling multiple ceiling-mounted air conditioning devices together, an upper frame attachment process for attaching an upper frame that forms the upper part of a frame that holds the multiple air conditioning devices together from above to the multiple air conditioning devices that have been assembled together, and a lower frame attachment process for lifting the upper frame to which the multiple air conditioning devices are attached and attaching a lower frame that forms the lower part of the frame from below the multiple air conditioning devices.

[0008] In the above manufacturing method, the upper frame is attached from above to the multiple air conditioners that are assembled together, then the upper frame is raised and the lower frame is attached from below the multiple air conditioners, so when attaching an air conditioner that is designed to be installed with its mounting parts suspended to the frame, the manufacturing work can be easily performed while keeping the air conditioner in the correct position. Therefore, no damage will occur to the mounting parts of the air conditioner. Therefore, it is possible to efficiently manufacture a ceiling-mounted air conditioning unit.

[0009] The above manufacturing method may further include a preparation step of preparing frame members that integrally hold multiple ceiling-mounted air conditioners, an upper frame assembly step of assembling an upper frame that forms the upper part of the frame, and a lower frame assembly step of assembling a lower frame that forms the lower part of the frame. According to this, since the upper frame and the lower frame are assembled, the assembly of the ceiling-mounted air conditioner unit can be started without the upper frame or the lower frame.

[0010] In the upper frame assembly process, the upper frame may be assembled upside down and then turned upside down, which allows the upper frame to be assembled in a stable position even if the upper frame has a configuration in which the member for attaching the lower frame protrudes downward.

[0011] The above-mentioned manufacturing method further includes a frame transport step of transporting the upper frame assembled in the upper frame assembly step and the lower frame assembled in the lower frame assembly step, and the equipment installation step, the upper frame attachment step, and the lower frame attachment step may use the upper frame and the lower frame transported from another location in the frame transport step. In this way, each step can be performed at an appropriate location.

[0012] The above manufacturing method may further include a restricting means attachment step of attaching restricting means to a mounting portion of the air conditioner for ceiling suspension, the restricting means being used to restrict relative movement of the air conditioner with respect to the frame when the frame and the air conditioner are tilted from the suspended position of the air conditioner. This allows the manufactured ceiling-suspended air conditioning unit to be transported in a laid-down position.

[0013] In addition, in the lower frame installation step, the upper frame to which the multiple air conditioners are attached may be hoisted by a hoist and the lower frame may be installed from below the multiple air conditioners. This makes it possible to easily lift the upper frame to which the multiple air conditioners are attached.

[0014] The above manufacturing method may further include an auxiliary frame attachment step of attaching an auxiliary frame supporting piping provided in the air conditioner to the upper frame, whereby the piping provided in the air conditioner can be protected by the auxiliary frame during the manufacturing process of the ceiling-mounted air conditioning unit. Effect of the Invention

[0015] The above-described method for manufacturing a ceiling-mounted air conditioning unit makes it possible to easily attach air conditioning equipment, which is intended to be installed in a suspended state, to a frame while maintaining the equipment in the correct posture. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 shows a ceiling-mounted air conditioning unit as viewed obliquely from above. [Diagram 2] FIG. 2 shows the ceiling-mounted air conditioning unit as viewed from the side. [Diagram 3] FIG. 3 shows the frame of the ceiling-mounted air-conditioning unit in a completed state. [Figure 4] FIG. 4 is a diagram showing an example of an assembly process for the upper frame. [Diagram 5] FIG. 5 is a diagram showing an example of the operation of turning the upper frame upside down. [Figure 6] FIG. 6 is a first diagram showing an example of an assembly process for the lower frame. [Figure 7] FIG. 7 is a second view showing an example of the assembly process for the lower frame. [Figure 8] FIG. 8 is a first diagram showing an example of a process for assembling an air conditioner. [Figure 9] FIG. 9 is a second diagram showing an example of a process for assembling an air conditioner. [Figure 10] FIG. 10 is a diagram showing a method of mounting the air conditioner body to a ceiling-hanging mounting portion. [Figure 11] FIG. 11 is a diagram showing an example of a process for attaching a lower frame to an air conditioner. [Figure 12]FIG. 12 shows the lower frame after installation is completed. [Figure 13] FIG. 13 is a diagram showing how the auxiliary frame is attached. [Figure 14] FIG. 14 is a diagram showing a method for mounting a ceiling-mounted air conditioning unit on a vehicle. [Figure 15] FIG. 15 is a diagram showing components provided in the ceiling-mounted air-conditioning unit. [Figure 16] FIG. 16 is a diagram showing temporary fastening. [Figure 17] FIG. 17 shows the temporarily attached state. [Figure 18] FIG. 18 is a diagram showing an example of a cart on which a ceiling-mounted air-conditioning unit is placed. [Figure 19] FIG. 19 is a diagram showing how to use the dolly. [Figure 20] FIG. 20 shows a first modified example of a ceiling-mounted air conditioning unit. [Figure 21] FIG. 21 is a diagram comparing the external dimensions of the ceiling-mounted air-conditioning units of the embodiment and the modified example. [Figure 22] FIG. 22 is a diagram showing an example of an obstacle prevention means provided on the auxiliary frame. [Diagram 23] FIG. 23 is a diagram showing an example of an obstacle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The following describes an embodiment of the present invention. The embodiment described below is an example of the present invention, and the technical scope of the present invention is not limited to the following aspect.

[0018] FIG. 1 is a diagram showing the ceiling-mounted air-conditioning unit 1 as viewed obliquely from above. FIG. 2 is a diagram showing the ceiling-mounted air-conditioning unit 1 as viewed from the side. FIG. 1 shows the ceiling-mounted air-conditioning unit 1 suspended from the ceiling by a suspension bolt K. For convenience of explanation, in this embodiment, the Z-axis direction in FIG. 1 and FIG. 2 is defined as the upward direction of the ceiling-mounted air-conditioning unit 1, and the direction along the XY plane determined by the X-axis and the Y-axis is defined as the lateral direction of the ceiling-mounted air-conditioning unit 1. In addition, the suspension bolt K that suspends the ceiling-mounted air-conditioning unit 1 from the ceiling of the building is usually provided with a vibration stopper F as shown in FIG. 1, but the vibration stopper provided on the suspension bolt K is not limited to this form. The vibration stopper provided on the vibration stopper F may be, for example, a cross-type form that crosses diagonally when viewed from above. The vibration stopper may be omitted, for example, when the ceiling-mounted air-conditioning unit 1 is directly attached to the ceiling, when the hanging bolts K for hanging the ceiling-mounted air-conditioning unit 1 are extremely short, or when the ceiling-mounted air-conditioning unit 1 is rigidly connected to the ceiling with metal fittings stronger than the hanging bolts K. The vibration stopper is not limited to being attached to the top and bottom of the hanging bolts K, and may be, for example, one in which the top end is embedded in the ceiling and the bottom end is connected to the ceiling-mounted air-conditioning unit 1.

[0019] As shown in Fig. 1 and Fig. 2, the ceiling-mounted air conditioning unit 1 is an air conditioning unit in which an air conditioner main body 3, an air supply chamber 4, and a return air chamber 5 are assembled and integrated into a frame 2. In addition to the air supply chamber 4 and the return air chamber 5, the ceiling-mounted air conditioning unit 1 has refrigerant piping, water piping, drain piping, a drain pump, a damper, an intake and exhaust grill, a filter, and various other air conditioning devices. The ceiling-mounted air conditioning unit 1 is installed in a narrow ceiling space between the floor that constitutes the floor surface of the upper floor or roof of a building and the decorative ceiling panel that constitutes the ceiling surface of the floor on which the ceiling-mounted air conditioning unit 1 is installed. Therefore, as shown in Fig. 1, the ceiling-mounted air conditioning unit 1 basically has a horizontally elongated external shape in which the horizontal dimension is longer than the vertical dimension.

[0020] Furthermore, when the ceiling-mounted air conditioning unit 1 is installed behind a ceiling panel, the ceiling-mounted air conditioning unit 1 is in a concealed state. However, the ceiling-mounted air conditioning unit 1 is not limited to being installed in such a concealed state. For example, when a decorative ceiling panel is not installed on the ceiling, In this case, the ceiling-mounted air-conditioning unit 1 becomes visible to people in the room.

[0021] In addition, the hanging bolt K may be screwed into a nut for supporting the hanging bolt embedded in the floor concrete that constitutes the floor, or alternatively, it may be screwed into various components such as hangers attached to structural materials such as H-shaped steel that constitutes the beam.

[0022] As shown in Figs. 1 and 2, the ceiling-mounted air-conditioning unit 1 has an air supply chamber 4 connected to the exhaust port side of the air conditioner body 3, and a return air chamber 5 connected to the intake port side of the air conditioner body 3. Thus, the ceiling-mounted air-conditioning unit 1 has an air conditioner body 3 disposed at the center of the frame 2, and the air conditioner body 3 is sandwiched between the air supply chamber 4 and the return air chamber 5. The connection part between the air conditioner body 3 and the air supply chamber 4, and the connection part between the return air chamber 5 and the air conditioner body 3 are connected with screws. The connection part between the air conditioner body 3 and the air supply chamber 4, and the connection part between the return air chamber 5 and the air supply chamber 4 may be loosely connected so that some relative movement is possible. In this case, the opening to be fitted into one opening is made slightly smaller, and the gap between the openings is filled with a sealant such as a flexible sponge packing for airtightness, resulting in a flexible connection structure that allows some relative movement.

[0023] First, the air conditioner main body 3 will be described. The air conditioner main body 3 is a package unit that incorporates a coil through which a heat medium for temperature adjustment flows inside a rectangular housing 31 and an electric fan for blowing air, and is also provided with auxiliary equipment 32 and auxiliary piping 33 outside the housing 31. Examples of the auxiliary equipment 32 include a valve that switches the flow path of the heat medium piping through which the heat medium flows in the coil, and a drainage pump that drains a drain pan that receives water condensed on the coil. The air conditioner main body 3 may be an air conditioner in which a refrigerant for a refrigeration cycle that repeats evaporation and condensation is supplied through the auxiliary piping 33 and the coil inside the machine functions as a condenser or evaporator, or it may be an air conditioner in which cold water or hot water supplied through the auxiliary piping 33 is passed through the coil inside the machine to cool or heat the air. The air conditioner main body 3 may also be one in which the auxiliary equipment 32 is omitted.

[0024] The air conditioner body 3 is supported by attaching the ceiling-hanging mounting part 34 provided on the outer surface of the housing 31 to the hanging bracket 26 provided on the frame 2. The air conditioner body 3 is a ready-made device that is intended to be used in a suspended state by a hanging bracket such as a hanging bolt K provided on a building, so the ceiling-hanging mounting part 34 is also designed to be attached to a hanging bracket such as a hanging bolt K. Therefore, in the ceiling-hanging air-conditioning unit 1 of this embodiment, the hanging bracket 26 provided on the frame 2 is designed to be in a form similar to such a hanging bracket, so that the air conditioner body 3 is designed to be suspended within the frame 2. In addition, since the air conditioner body 3 has a built-in electric fan, the ceiling-hanging mounting part 34 is provided with a vibration-proof rubber 35, which blocks vibrations transmitted from the air conditioner body 3 to the frame 2. This minimizes the generation of abnormal noises caused by the frame 2 resonating with vibrations generated by the air conditioner body 3. Since the vibration-proof rubber 35 is designed to have a vibration-proof allowable direction that allows movement for vibration prevention, it is desirable that the vibration-proof allowable direction and the direction of the load (direction of gravity) generally coincide when the air conditioner is transported under a load. The means for isolating the vibration of the air conditioner body 3 is not limited to the form in which the vibration-proof rubber 35 is interposed between the frame 2 and the air conditioner body 3. For example, a spring or rubber may be provided at the connection portion between the frame 2 and the hanging bolt K. However, in this case, the frame 2 is movable relative to the hanging bolt K, so that the frame 2 itself does not have earthquake resistance. Therefore, from the viewpoint of ensuring the earthquake resistance of the entire ceiling-mounted air-conditioning unit 1, in this embodiment, the connection portion between the frame 2 and the hanging bolt K is rigidly connected to make the frame 2 itself an earthquake-proof structure, and instead, the vibration-proof rubber 35 is interposed between the frame 2 and the air conditioner body 3.

[0025] Next, the air supply chamber 4 will be described. The air supply chamber 4 is a chamber for distributing the conditioned air blown out from the air conditioner main body 3 to a plurality of air supply ducts arranged throughout the building. Therefore, a rectangular housing 41 forming the internal space of the chamber is provided with a plurality of connection openings 42 for connecting the air supply ducts. In Figs. 1 and 2, six connection openings 42 are provided in the housing 41, but the number of connection openings 42 is appropriately changed depending on the size of the housing 41, the diameter of the connection openings 42, etc. In addition, the air supply chamber 4 is not limited to a form in which the air supply ducts are connected to all six connection openings 42. The number of air supply ducts actually connected to the air supply chamber 4 depends on the number of air supply ducts provided at the location where the ceiling-mounted air-conditioning unit 1 is installed. Therefore, if there are two air intake ducts provided at the location where the ceiling-mounted air conditioning unit 1 is installed, four of the six connection openings 42 in the air intake chamber 4 are used with the openings closed. Therefore, it is possible to omit the connection openings 42 whose openings are closed in advance and manufacture an air intake chamber 4 with only the required number of connection openings 42 and incorporate it into the ceiling-mounted air conditioning unit 1, but in this embodiment, in order to improve construction efficiency and shorten the manufacturing period of the components, it is proposed to prepare a large number of common ceiling-mounted air conditioning units 1 that can be applied to various installation locations. However, the ceiling-mounted air conditioning unit 1 disclosed in this application is not limited to a form that can be commonly applied to various locations. The ceiling-mounted air conditioning unit 1 may be equipped with an air intake chamber 4 having the number of connection openings 42 according to the installation location.

[0026] Next, the return air chamber 5 will be described. The return air chamber 5 is a chamber for joining air flowing from a plurality of return air ducts installed throughout the building. Thus, like the supply air chamber 4, the return air chamber 5 is provided with a plurality of connection openings for connecting the return air ducts. Like the supply air chamber 4, the return air chamber 5 also has a form provided with a number of connection openings so that it can be applied to various installation locations, but the ceiling-mounted air-conditioning unit 1 may also be provided with a return air chamber 5 having a number of connection openings according to the installation location, as described above. The return air chamber 5 may be omitted depending on the building.

[0027] The supply air chamber 4 and the return air chamber 5 do not have built-in driving units such as electric fans, unlike the air conditioner main body 3, and therefore do not generate vibrations. Therefore, in this embodiment, the supply air chamber 4 and the return air chamber 5 are attached to the frame 2 without using any parts such as vibration-proof rubber to block vibration transmission. However, the ceiling-mounted air-conditioning unit 1 is not limited to this form. The ceiling-mounted air-conditioning unit 1 may be, for example, one in which the supply air chamber 4 and the return air chamber 5 are attached to the frame 2 via vibration-proof rubber. The ceiling-mounted air-conditioning unit 1 may be, for example, one in which the supply air chamber 4 and the return air chamber 5 are attached to the frame 2 by members with a hanging structure similar to the air conditioner main body 3.

[0028] Thus, the ceiling-mounted air conditioning unit 1 in which the air conditioner main body 3, the supply air chamber 4, and the return air chamber 5 are integrated is naturally heavier than each of the air conditioner main body 3, the supply air chamber 4, and the return air chamber 5 individually. Therefore, weight reduction is required in order to be able to lift it with an indoor aerial work vehicle and install it near the ceiling of a building. Therefore, in the ceiling-mounted air conditioning unit 1 of this embodiment, the frame 2 is made of aluminum members. Therefore, even in the part where the angle irons 21 constituting the frame 2 are fastened to each other, by fastening them to the rib plates 22 and 23 with bolts, sufficient strength is exerted compared to when the angle irons 21 are welded to each other. Also, in order to increase the strength near the end of the frame 2, a bar screw 25 is provided to fasten the ends of the angle irons 21 to each other at the parts corresponding to the corners of the frame 2. Also, among the fastening parts between the multiple angle irons 21 on the frame 2, one rib plate 23 is provided at each part (parts indicated by reference numeral 23) where a load is applied in the direction along the plate surface of the rib plate (surface direction), while the rib plate is bent. For the portion (portion indicated by reference numeral 22) to which the load in the direction is applied, the number of rib plates 22 that can satisfy the thickness required to ensure the strength is provided. If the number of plates that can satisfy the thickness required to ensure the strength is, for example, two, the angle iron 21 is fastened to each other in a state in which the angle iron 21 is sandwiched between the two rib plates 22, thereby preventing the rib plate 22 from being deformed or damaged by the load. For example, as can be seen from FIG. 1, the hanging portion 24 provided on the frame 2 to attach to the hanging bolt K that hangs the ceiling-mounted air-conditioning unit 1 is provided in the middle of the angle iron 21 extending in the horizontal direction, so that when the ceiling-mounted air-conditioning unit 1 is hung by the hanging bolt K, the load of the entire ceiling-mounted air-conditioning unit 1 is applied to the end of the angle iron 21. Therefore, providing multiple rib plates 22 at such a portion is effective in ensuring the strength of the frame 2.

[0029] The above-mentioned ceiling-mounted air-conditioning unit 1 is manufactured in a factory and then transported to a construction site using a transport vehicle such as a truck. A method for manufacturing the ceiling-mounted air-conditioning unit 1 will be described below.

[0030] Fig. 3 is a diagram showing the frame 2 of the completed ceiling-mounted air-conditioning unit 1. In Fig. 3, for ease of understanding, a diagram showing only the frame 2 is shown alongside a diagram showing the completed ceiling-mounted air-conditioning unit 1.

[0031] 3, the frame 2 has a three-dimensional structure, and has a portion that forms the upper part of the ceiling-suspended air-conditioning unit 1 and a portion that forms the lower part of the ceiling-suspended air-conditioning unit 1. The manufacturing method of the ceiling-suspended air-conditioning unit 1 in this embodiment includes several steps, such as a process of manufacturing the portion of the frame 2 that forms the upper part of the ceiling-suspended air-conditioning unit 1 and a process of manufacturing the portion of the frame 2 that forms the lower part of the ceiling-suspended air-conditioning unit 1. Therefore, for ease of explanation, hereinafter, the portion of the frame 2 that forms the upper part of the ceiling-suspended air-conditioning unit 1 will be referred to as the upper frame 2U, and the portion of the frame 2 that forms the lower part of the ceiling-suspended air-conditioning unit 1 will be referred to as the lower frame 2B.

[0032] In the manufacturing method of the ceiling-mounted air-conditioning unit 1 in this embodiment, the upper frame 2U and the lower frame 2B are assembled separately. FIG. 4 is a diagram showing an example of the assembly process of the upper frame 2U. As shown in FIG. 4, the upper frame 2U is a structure in which a plurality of angle bars 21 are fastened together with bolts and nuts. In the manufacturing process of the upper frame 2U, a plurality of angle bars 21 prepared using a material processing machine or the like are butted together, and in this state, fastened together with bolts and nuts to form a structure. In the portion where the angle bars 21 are fastened together at right angles, a rib plate 22 is appropriately used in combination. This ensures the overall strength of the upper frame 2U that is completed by fastening the angle bars 21 together.

[0033] As described above, the strength of the frame 2 is ensured by providing a number of rib plates 22 that can satisfy the thickness required to ensure the strength at the locations of the frame 2 where the load of the entire ceiling-mounted air-conditioning unit 1 is applied. When providing two rib plates 22 at such locations, the two rib plates 22 are arranged so as to sandwich the fastening portion of the angle material 21 from both sides. Then, a bolt is inserted into a screw hole in one of the two rib plates 22. The bolt inserted into the screw hole passes through the screw hole of the first rib plate 22, the screw hole of the angle material 21, and the screw hole of the second rib plate 22. Then, the tip of the bolt protrudes from the screw hole of the second rib plate 22. By screwing a nut onto the tip of the bolt, the fastening portion of the angle material 21 is sandwiched between the two rib plates 22 from both sides.

[0034] Of the upper frame 2U shown in FIG. 4, a rectangular frame (a central frame among three frames formed in the upper frame 2U) whose four sides are all surrounded by angle members 21 is a frame for the air conditioner main body 3. The upper frame 2U corresponds to the hanging position. The two rectangular frames (the outer two frames of the three frames formed in the upper frame 2U) whose four sides are surrounded by three angle bars 21 and one bar screw 25 correspond to the supply air chamber 4 and the return air chamber 5. Therefore, the outer rectangular frame formed by the entire upper frame 2U forms the exoskeleton of the frame 2. The same is true for the lower frame 2B. Therefore, the air conditioner main body 3, the supply air chamber 4, and the return air chamber 5 are contained inside the exoskeleton of the frame 2 formed by the rectangular frame forming the outermost part of the upper frame 2U and the rectangular frame forming the outermost part of the lower frame 2B, and are protected by the exoskeleton even during transportation of the ceiling-mounted air-conditioning unit 1. The bar screw 25 is not particularly necessary for holding the air conditioner main body 3, the supply air chamber 4, and the return air chamber 5 to the frame 2, but functions as a necessary component for enduring the impact force of an object colliding with the end of the angle bar 21 and for the frame 2 to exhibit structural strength as an exoskeleton.

[0035] During the manufacture of the upper frame 2U, the work is performed with the upper frame 2U upside down. Then, when the manufacture of the upper frame 2U is completed, the work of turning the upper frame 2U upside down is performed so that the top and bottom of the upper frame 2U face in the correct direction. Figure 5 is a diagram showing an example of the work of turning the upper frame 2U upside down. When the manufacture of the upper frame 2U is completed, for example, as shown in Figure 5, the work of turning the upper frame 2U upside down is performed.

[0036] FIG. 6 is a first diagram showing an example of an assembly process of the lower frame 2B. FIG. 7 is a second diagram showing an example of an assembly process of the lower frame 2B. As shown in FIG. 6 and FIG. 7, the lower frame 2B is a structure in which a plurality of angle members 21 are fastened together with bolts and nuts, similar to the upper frame 2U. In the manufacturing process of the lower frame 2B, a plurality of angle members 21 prepared using a material processing machine or the like are butted together, and in this state, fastened together with bolts and nuts to form a structure. In addition, the angle members 21 and the rib plate 23 are fastened so that the rib plate 23 for connecting the upper frame 2U protrudes upward. In the lower frame 2B, not only the rib plate 22 and the rib plate 23 but also an L-shaped metal fitting 29 is used in the fastening portion between the angle members 21. In addition, as shown in FIG. 7, the lower frame 2B is also equipped with a support member 27 described later and an earthquake-resistant vibration stopper 2A for preventing air conditioning equipment attached to the frame 2 from swinging relative to the frame 2.

[0037] After assembling the upper frame 2U and the lower frame 2B, the air conditioner is assembled. FIG. 8 is a first diagram showing an example of the process of assembling the air conditioner. FIG. 9 is a second diagram showing an example of the process of assembling the air conditioner. At the site where the ceiling-mounted air conditioning unit 1 is manufactured, the air conditioner body 3, the supply air chamber 4, and the return air chamber 5 are prepared. The air conditioner body 3 is placed on a workbench or the like with the top and bottom facing in the correct direction. Therefore, when assembling the air conditioner, first, as shown in FIG. 8, the upper frame 2U with the top and bottom facing in the correct direction is placed so as to cover the upper side of the air conditioner body 3, and the mounting part of the air conditioner body 3 is attached to the upper frame 2U. Next, as shown in FIG. 9, the supply air chamber 4 and the return air chamber 5 are assembled. The supply air chamber 4 is connected to the air outlet of the air conditioner body 3. The return air chamber 5 is connected to the air intake of the air conditioner body 3. The air conditioner main body 3, the supply air chamber 4, and the return air chamber 5 are connected to each other with screws, with the top and bottom all facing in the correct direction.

[0038] As described above, the air conditioner main body 3, the supply air chamber 4, and the return air chamber 5 are designed on the assumption that they will be suspended from a ceiling. For example, the air conditioner main body 3 is supported by attaching the ceiling-suspended mounting part 34 provided on the outer surface of the housing 31 to the suspension bracket 26 of the frame 2. A partially enlarged view of FIG. 9 shows the ceiling-suspended mounting part 34 provided on the air conditioner main body 3 and its surroundings. FIG. 10 is a diagram showing a method of mounting the ceiling-suspended mounting part 34 of the air conditioner main body 3. The ceiling-suspended mounting part 34 is, as shown in FIG. 10, The screw holes are inserted into the angle members 21 of the upper frame 2U and secured with nuts. The fixed rod-threaded hanging bracket 26 is inserted and fixed in a state where it is sandwiched by a nut screwed onto the hanging bracket 26 via the vibration-isolating rubber 35 and temporary fasteners 6. The temporary fasteners 6 are removed after the ceiling-mounted air-conditioning unit 1 is transported to the installation site. The air conditioner main body 3 was connected to the supply air chamber 4 and return air chamber 5 with screws, and was in a state of being temporarily fastened, but by fixing it to the hanging bracket 26 at the ceiling-mounting mounting parts 34 in this way, the air conditioners attached to the frame 2 are firmly fixed to each other.

[0039] FIG. 11 is a diagram showing an example of a process for attaching the lower frame 2B to an air conditioner. As described above, the air conditioner body 3, the supply air chamber 4, and the return air chamber 5 are attached to the upper frame 2U. Therefore, when attaching the lower frame 2B to the upper frame 2U to complete the frame 2, the upper frame 2U is lifted up by a hoist (also called a "hoist") as shown in FIG. 11. As described above, the air conditioner body 3, the supply air chamber 4, and the return air chamber 5 are attached to the upper frame 2U using mounting parts provided on each air conditioner for hanging from the ceiling. Therefore, when the upper frame 2U is lifted up by the hoist, the air conditioner body 3, the supply air chamber 4, and the return air chamber 5 are lifted up together with the upper frame 2U while hanging from the upper frame 2U. After the upper frame 2U is lifted up by the hoist, the lower frame 2B is attached to the upper frame 2U from below the air conditioner body 3, the air supply chamber 4, and the return air chamber 5 that are suspended from the upper frame 2U. When arranging the lower frame 2B below the air conditioner body 3, the air supply chamber 4, and the return air chamber 5, the hoist suspending the upper frame 2U is moved onto the lower frame 2B, or the lower frame 2B is moved below the air conditioner body 3, the air supply chamber 4, and the return air chamber 5 that are suspended from the upper frame 2U. When moving, the moving work is performed so that the air conditioner body 3, the air supply chamber 4, and the return air chamber 5 that are suspended from the upper frame 2U are positioned so as not to interfere with the support member 27 and the vibration brace 2A provided on the lower frame 2B, for example, so that the air conditioner body 3 is positioned between the two support members 27. Then, the rib plates 23 of the lower frame 2B are fastened to the angle members 21 of the upper frame 2U with bolts and nuts, whereby the lower frame 2B is attached to the upper frame 2U, and the frame 2 is formed.

[0040] 12 is a diagram showing the state where the installation of the lower frame 2B is completed. After the lower frame 2B is attached to the upper frame 2U, the hoisting machine suspending the upper frame 2U is lowered, and the lifting wire attached to the upper frame 2U is removed from the upper frame 2U. Then, any parts that remain to be installed are installed and the ceiling-mounted air-conditioning unit 1 is made ready for transport to the construction site.

[0041] 13 is a diagram showing how the auxiliary frame 103 is attached. As described above, various pipes are provided in the air conditioner main body 3. Therefore, when assembling the ceiling-mounted air-conditioning unit 1, the auxiliary frame 103 for supporting these pipes is attached to the upper frame 2U. The auxiliary frame 103 may be attached after the lower frame 2B is attached to the upper frame 2U, but in order to protect the pipes of the air conditioner main body 3 while assembling the ceiling-mounted air-conditioning unit 1, it may also be attached to the upper frame 2U when assembling the upper frame 2U, for example.

[0042] The above manufacturing method completes the ceiling-mounted air conditioning unit 1. With the above manufacturing method, when mounting an air conditioning unit that is designed to be installed with its mounting parts suspended, such as commercially available concealed air conditioning units, to the frame 2 in a factory, the air conditioning unit can be easily mounted while being kept in the correct position, so that the mounting parts of the air conditioning unit are not damaged. This makes it possible to efficiently manufacture the ceiling-mounted air conditioning unit 1.

[0043] The ceiling-suspended air-conditioning unit 1 can be transported from a factory to a construction site, for example, in the following manner. FIG. 14 is a diagram showing a method of mounting the ceiling-suspended air-conditioning unit 1 on a vehicle. As described above, the ceiling-suspended air-conditioning unit 1 has a horizontally elongated external shape in which the horizontal dimension is longer than the vertical dimension in order to be installed in a narrow ceiling space between the floor and the ceiling panel. The air-conditioning unit body 3 is suspended within the frame 2 by a hanging bracket 26 provided on the frame 2. For this reason, for example, when the ceiling-suspended air-conditioning unit 1 assembled in a factory is transported to a construction site, the ceiling-suspended air-conditioning unit 1 is normally stacked flat on the loading platform of the vehicle V without being turned over, as shown in FIG. 14(A). However, in this case, the space above the loading platform of the ceiling-suspended air-conditioning unit 1 is not effectively utilized, and the ceiling-suspended air-conditioning unit 1 cannot be transported efficiently. 14(B), it is possible to load the ceiling-mounted air-conditioning unit 1 on its side on the cargo bed of the vehicle V. If the ceiling-mounted air-conditioning unit 1 is loaded on its side on the cargo bed of the ceiling-mounted air-conditioning unit 1, the space above the cargo bed of the vehicle V can be effectively utilized.

[0044] However, when the ceiling-mounted air-conditioning unit 1 is transported on its side as described above, there is a possibility that the air-conditioning body 3 moves relative to the frame 2 in a direction horizontal to the hanging direction of the hanging bracket 26. If the air-conditioning body 3 moves relative to the frame 2 in a direction horizontal to the hanging direction of the hanging bracket 26, there is a possibility that the hanging bracket 26 connecting the frame 2 and the air-conditioning body 3 will be deformed, and the vibration-proof rubber 35 between the ceiling-mounting attachment part 34 and the hanging bracket 26 will be damaged.

[0045] Therefore, when transporting the ceiling-suspended air-conditioning unit 1 of this embodiment, the following measures are taken to prevent such a problem. FIG. 15 is a diagram showing the members provided on the ceiling-suspended air-conditioning unit 1. As shown in FIG. 15, the ceiling-suspended air-conditioning unit 1 of this embodiment is provided with temporary fasteners 6 on the ceiling-suspended mounting portion 34. In addition, the frame 2 is provided with a support member 27 that limits the relative movement of the air-conditioning body 3 with respect to the frame 2 to a predetermined range. Since the support member 27 limits the relative movement of the air-conditioning body 3 with respect to the frame 2 to a predetermined range, when the ceiling-suspended air-conditioning unit 1 is in a normal position, the support member 27 does not come into contact with the frame 2. Then, when the ceiling-suspended air-conditioning unit 1 is turned over on its side and the air-conditioning body 3 moves in the direction of gravity under its own weight, the air-conditioning body 3 comes into contact with the support member 27 provided on the frame 2, and the air-conditioning body 3 is in a state of being supported from below by the support member 27. Furthermore, for the vibration-isolating rubber 35, the temporary fasteners 6 restrict the relative movement between the hanging brackets 26 and the ceiling-hanging mounting parts 34 so that a lateral load is not applied to the air conditioner body 3 relative to the frame 2. The temporary fasteners 6 and support members 27 are attached to the frame 2 at an appropriate timing during the manufacturing process of the ceiling-hanging air-conditioning unit 1 described above. Then, the temporary fasteners 6 are removed after transportation of the ceiling-hanging air-conditioning unit 1 is completed.

[0046] 16 is a diagram showing the temporary fastener 6. The temporary fastener 6 is a metal piece that is U-shaped in cross section and has a flat, rectangular top plate portion 61 and side wall portions 62 provided along each of the two long sides of the top plate portion 61. The top plate portion 61 is provided with a cutout portion 63 that is slightly larger than the outer diameter of the hanging bracket 26. The temporary fastener 6 is a temporary fastener for transportation that is attached when the ceiling-mounted air-conditioning unit 1 is transported. Such a temporary fastener 6 is attached to the ceiling-mounting attachment portion 34 in the following state.

[0047] 17 is a diagram showing the attached state of the temporary fastener 6. The upper surface of the top plate portion 61 of the temporary fastener 6 is pressed by a nut screwed onto the hanging bracket 26. The lower ends of the two side wall portions 62 along the long sides of the top plate portion 61 press the ceiling-hanging mounting portion 34 with the pressing force of the nuts pressing the upper surface of the top plate portion 61, thereby preventing the hanging bracket 26 and the ceiling-hanging mounting portion 34 from moving relative to each other due to deformation of the vibration-proof rubber 35. Also, the pressing force that the side wall portions 62 of the temporary fastener 6 apply to the ceiling-hanging mounting portion 34 is in the direction of the load assumed in the design of the vibration-proof rubber 35. Therefore, unless the nut pressing against the upper surface of the top plate portion 61 is excessively tightened, the pressing force is unlikely to damage the vibration-proof rubber 35.

[0048] As described above, since the ceiling-mounted air-conditioning unit 1 is provided with the temporary fasteners 6 and the support members 27, even if the ceiling-mounted air-conditioning unit 1 is turned sideways to be placed on the loading platform of the vehicle V, the relative movement of the air-conditioning unit body 3 with respect to the frame 2 is restricted. Therefore, even if the air-conditioning unit body 3 is attached in a suspended state to the frame 2, the hanging brackets 26, the ceiling-mounting mounting parts 34, and the vibration-proof rubber 35 are not damaged by the weight of the air-conditioning unit body 3. Therefore, the ceiling-mounted air-conditioning unit 1 of this embodiment can be efficiently mounted in the limited space of the loading platform of the vehicle V. It should be noted that, of course, the restricting means such as the temporary fasteners 6 and the support members 27 may be omitted if the ceiling-mounted air-conditioning unit 1 is not transported in a sideways position. In addition, although FIG. 14(A) illustrates the ceiling-mounted air-conditioning unit 1 in a form that does not stack, the ceiling-mounted air-conditioning unit 1 of this embodiment is not limited to a non-stackable one. The ceiling-mounted air-conditioning units 1 of this embodiment may be stacked flat in multiple stages.

[0049] Fig. 18 is a diagram showing an example of a dolly on which the ceiling-suspended air-conditioning unit 1 is placed. The ceiling-suspended air-conditioning unit 1 can be transported, for example, by a dolly 112 as shown in Fig. 18. The dolly 112 includes a bottom 112A forming the bottom of the dolly 112, a side 112B surrounding the ceiling-suspended air-conditioning unit 1 from the sides, a hinge 112C connecting the side 112B to the bottom 112A so as to be rotatable in the lateral direction, and wheels 112D provided on the underside of the bottom 112A. Since the side 112B supporting the ceiling-suspended air-conditioning unit 1 from the sides can be rotated in the lateral direction relative to the bottom 112A, the dolly 112 can be transported, for example, as follows.

[0050] FIG. 19 is a diagram showing how to use the dolly 112. For example, as shown in FIG. 19(A), the dolly 112 can mount a plurality of ceiling-suspended air-conditioning units 1. In addition, the side portion 112B that supports the ceiling-suspended air-conditioning unit 1 from the side can rotate in a direction to lie sideways relative to the bottom portion 112A. Therefore, for example, in a factory where the ceiling-suspended air-conditioning unit 1 is manufactured, the dolly 112 carrying the ceiling-suspended air-conditioning unit 1 can be transported to the vicinity of the installation location of the ceiling-suspended air-conditioning unit 1 using a transportation truck or a temporary or permanent elevator at a construction site, and then the ceiling-suspended air-conditioning unit 1 can be removed from the dolly 112 as follows. That is, after the dolly 112 carrying the ceiling-suspended air-conditioning unit 1 is transported to the vicinity of the installation location of the ceiling-suspended air-conditioning unit 1, the side portion 112B is placed sideways together with the ceiling-suspended air-conditioning unit 1 as shown in FIG. 19(B). When mounting the ceiling-suspended air-conditioning unit 1 on the cart 112, if the ceiling-suspended air-conditioning unit 1 is mounted so that the ceiling-suspended air-conditioning unit 1 is correctly positioned in the up-down direction when the ceiling-suspended air-conditioning unit 1 is laid down on its side together with the side portion 112B, the upper surface of the ceiling-suspended air-conditioning unit 1 faces upward in the state shown in FIG. 19(B). Therefore, the worker can easily install the ceiling-suspended air-conditioning unit 1 on the ceiling by lifting the ceiling-suspended air-conditioning unit 1 while it is still placed on a part of the frame constituting the side portion 112B and fixing it to the hanging bolt K, or by directly lifting the ceiling-suspended air-conditioning unit 1 placed on the side portion 112B to the ceiling using an elevator or the like equipped with a fork-shaped lifting part. After the ceiling-suspended air-conditioning unit 1 is attached to the ceiling, the part of the frame constituting the side portion 112B is removed from the ceiling-suspended air-conditioning unit 1 and reassembled to the cart 112.

[0051] The ceiling-mounted air-conditioning unit 1 can be transported in this manner. Compared to the case where the air conditioner main body 3, the air supply chamber 4, and the return air chamber 5 are brought separately to the construction site and assembled, the ceiling-mounted air-conditioning unit 1 can complete on-site work in an extremely short time, significantly shortening the construction period at the construction site. Also, the ceiling-mounted air-conditioning unit 1 can be assembled in a factory, allowing efficient assembly in an environment suitable for assembling the ceiling-mounted air-conditioning unit 1. Therefore, the air conditioner main body 3 and the air supply chamber 4 and the return air chamber 5 are brought separately to the construction site and assembled, allowing the construction period at the construction site to be completed in an extremely short time. This makes it possible to reduce the overall man-hours compared to when the frame 4 and the return air chamber 5 are brought in separately and assembled. However, the ceiling-mounted air-conditioning unit 1 is not limited to being completed in a factory. For example, the frame 2 may be manufactured as a semi-finished product, which is then transported to a location other than the manufacturing site of the frame 2, after which air-conditioning equipment such as the air-conditioning unit body 3 is attached to the frame 2, and then the frame 2 is installed at the construction site.

[0052] Furthermore, the ceiling-suspended air-conditioning unit 1 of the above embodiment may be modified as follows. Fig. 20 shows a first modified example of the ceiling-suspended air-conditioning unit 1. In the ceiling-suspended air-conditioning unit 1 of this first modified example, a duct connection part 101 is provided in place of the connection opening 42 provided in the air supply chamber 4. Also, an auxiliary frame 103 is provided on the frame 2 to support a hot and cold water piping connection part 102 attached to the air conditioner main body 3.

[0053] The duct connection part 101 hardly protrudes from the outer surface of the air supply chamber 4. The hot and cold water pipe connection part 102 is a part for connecting the hot and cold water pipes to the coil provided inside the air conditioner main body 3, and is composed of a coupler for pipe connection that can be connected with one touch without using pipes, solenoid valves, or tools. The pipes are appropriately provided with heat insulating material. Since the hot and cold water pipe connection part 102 is a part that protrudes from the housing of the air conditioner main body 3, if various external forces such as the load of the pipes are applied to the hot and cold water pipe connection part 102, the root part of the hot and cold water pipe connection part 102 may be damaged. Therefore, when such a hot and cold water pipe connection part 102 is provided in the ceiling-mounted air conditioning unit 1, it is preferable to provide an auxiliary frame 103 that supports the hot and cold water pipe connection part 102 on the frame 2. The auxiliary frame 103 is formed of angle members 104 similar to the angle members 21 of the frame 2, bolts, nuts, and various other structural members.

[0054] Since the air supply chamber 4 of the first modified example is provided with such a duct connection part 101, the ceiling-suspended air-conditioning unit 1 can be made smaller than the case where the connection opening 42 is provided. FIG. 21 is a diagram comparing the outer dimensions of the ceiling-suspended air-conditioning unit 1 of the above embodiment and this modified example. Compared with the connection opening 42, the duct connection part 101 hardly protrudes from the outer surface of the air supply chamber 4, so as can be seen from FIG. 21, the outer dimensions of the ceiling-suspended air-conditioning unit 1 of the modified example can be made smaller by a distance L1 than the ceiling-suspended air-conditioning unit 1 of the embodiment. The protruding amount of the connection opening 42 is the length of the connection part of a general duct (approximately 5 to 15 cm), so the distance L1 is approximately equivalent to this length. Therefore, the ceiling-suspended air-conditioning unit 1 of this modified example, which uses the duct connection part 101 instead of the connection opening 42, makes it easier to transport and install at the site, and furthermore, the risk of damage such as deformation of the connection opening 42 due to contact with an object can be suppressed as much as possible. For this reason, this modified example using the duct connecting portion 101 is extremely easy to install.

[0055] As described above, the auxiliary frame 103 plays a role in protecting the piping provided in the air conditioner main body 3 during assembly and transportation of the ceiling-suspended air-conditioning unit 1. The auxiliary frame 103 can also be used for the purpose of preventing objects that may hinder the maintenance of the ceiling-suspended air-conditioning unit 1 from being mistakenly installed around the ceiling on which the ceiling-suspended air-conditioning unit 1 is installed. FIG. 22 is a diagram showing an example of an obstacle prevention means provided on the auxiliary frame 103. For example, an obstacle prevention means such as a plate-shaped member such as an obstacle prevention cover 107 or a box can be installed on the auxiliary frame 103. The obstacle prevention cover 107 may be completely fixed to the auxiliary frame 103 by a fixing means such as a bolt, or may be fixed in a movable state by a fixing means having a movable part such as a hinge, or may be provided in a removable state. The obstacle prevention cover 107 can be attached at any timing during the manufacturing process of the ceiling-suspended air-conditioning unit 1. If the obstacle prevention cover 107 is removable or movable using a hinge or the like, it is possible to prevent the obstacle prevention cover 107 from interfering with transportation of the ceiling-mounted air-conditioning unit 1.

[0056] Usually, the air conditioner body 3 is equipped with a built-in filter to prevent the coils and the like from becoming dirty due to suspended matter in the air. The filter requires periodic maintenance such as replacement. For this reason, the air conditioner body 3 is provided with a filter replacement port 108 for inserting and removing the filter, for example, as shown in FIG. 22(A). In a ceiling-embedded type air conditioner, when the filter replacement port 108 is provided on the side of the housing of the air conditioner body 3 as in the air conditioner body 3 shown in FIG. 22(A), the filter replacement work is usually performed through an inspection port provided in the ceiling panel that forms the ceiling of the room. Then, as shown in FIG. 22(B), the filter 109 is pulled out from the filter replacement port 108. Then, as shown in FIG. 22(C), the filter 109 is removed from the air conditioner body 3. Then, when the replacement work is completed, the inspection port is closed, and the area around the filter replacement port 108 is hidden by the ceiling panel.

[0057] In the ceiling space formed by the ceiling panel and hidden from the occupants in the room, for example, lighting fixtures, communication devices, and various other devices are installed in addition to the ceiling-suspended air-conditioning unit 1. The devices installed in the ceiling space are basically suspended by suspension bolts suspended from the ceiling slab. Therefore, by providing an obstacle prevention means such as the obstacle prevention cover 107 that interferes with the installation of the suspension bolts suspended from the ceiling slab so as to cover at least from above the vicinity of the filter replacement port 108 and other locations where a work space needs to be secured during maintenance work on the ceiling-suspended air-conditioning unit 1, it is possible to prevent such various devices from being installed in locations that interfere with the maintenance work on the ceiling-suspended air-conditioning unit 1.

[0058] FIG. 23 is a diagram showing an example of an obstacle. In the absence of the obstacle prevention cover 107, for example, a structure such as the obstacle 110 may be installed near the filter replacement opening 108. A contractor who installs various devices in the ceiling space may not be aware that the ceiling-mounted air-conditioning unit 1 requires a work space for maintenance, and may install the obstacle 110. In this regard, if the obstacle prevention cover 107 for preventing the installation of the obstacle 110 is installed near the filter replacement opening 108, the obstacle prevention cover 107 prevents the hanging bolt for installing the obstacle 110 from being hung from the ceiling slab, so that the possibility of the obstacle 110 being installed erroneously can be suppressed as much as possible. [Explanation of symbols]

[0059] K·· Hanging bolt F··Sway rest V·Vehicle 1. Ceiling-mounted air conditioning unit 2. Frame 3. Air conditioner unit 4. Air supply chamber 5. Return air chamber 6. Temporary fastening 2U Upper Frame 2B Lower Frame 21. Angle iron 22 Rib plate 23 Rib plate 24 Hanging part 25··Bar screw 26··Hanging bracket 27, 28 Support member 29··L-shaped bracket 2A··Sway stopper 31. Housing 32. Auxiliary equipment 33. Auxiliary piping 34··Ceiling mounting part 35 Anti-vibration rubber 41··Case 42... Connection opening 61··Top plate 62 Side wall 63 Cutout 101··Duct connection part 102 Cold and hot water piping connection 103 Auxiliary frame 104··Angle iron 107··Obstacle prevention cover 108··Filter replacement port 109··Filter 110 Obstacles 112··Trolley 112A...Bottom 112B Side 112C··Hinge 112D·Wheel

Claims

1. Multiple air conditioners, a frame that holds the plurality of air conditioners in an assembled state with each other, At least one predetermined air conditioning device among the plurality of air conditioning devices has a predetermined part that is opened, closed, or attached and detached during maintenance, the frame is formed so that the predetermined part of the predetermined air-conditioning device it holds can be opened, closed or attached / detached, and has an obstacle prevention means for preventing an obstacle from being erroneously installed in a working space where the predetermined part is opened, closed or attached / detached, The frame is a three-dimensional structure formed by fastening frame members together, The obstacle prevention means is formed using the frame member. Ceiling mounted air conditioning unit.

2. The obstacle prevention means is provided so as to protrude from the predetermined air conditioning equipment in a direction in which the predetermined component is opened / closed or in a direction in which the predetermined component is attached / detached. The ceiling-mounted air conditioning unit according to claim 1.

3. The obstacle prevention means is formed by an angle bar provided so as to protrude from the predetermined air conditioning equipment in the opening / closing direction or the attachment / detachment direction of the predetermined part. The ceiling-mounted air conditioning unit according to claim 2.

4. The obstacle prevention means includes an obstacle prevention cover fixed to the frame. The ceiling-mounted air conditioning unit according to any one of claims 1 to 3.

Images