Condenser Shroud Assembly for Air Mover Alignment and Airflow
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Solution Overview
Problem
Existing DC air conditioning systems face challenges with the mounting of air movers on sheet metal boxes, which are time-consuming, costly, and prone to failure due to sealant deterioration and misalignment issues, leading to compromised effectiveness.
Innovation Solution
A condenser shroud assembly with a single-piece seamless condenser shroud and cover that coaxially aligns with the air mover, eliminating the need for seals and welds, and featuring a curved design to direct air smoothly through the condenser assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sheet metal boxes are used to mount the air mover, then the structure provides a mounting platform, but the assembly process becomes time-consuming and costly due to sealing and welding requirements
Solution Approach 1:
The housing is divided into separate modular components (condenser shroud, air mover housing, panels) that can be independently manufactured and then assembled together using simple fasteners, eliminating the need for complex sealing and welding operations while maintaining structural integrity
Solution Approach 2:
The mounting structure integrates the air mover mounting directly into the housing assembly rather than using a separate sheet metal box, combining multiple functions into a unified structure that eliminates unnecessary sealing interfaces
2Ease of manufacture
If sheet metal boxes are used to mount the air mover, then the structure provides support, but misalignment occurs due to tolerance buildup from bending and cutting operations
Solution Approach 1:
The housing is divided into separate modular components with standardized mounting interfaces that accommodate normal tolerance variations, preventing tolerance accumulation and ensuring proper alignment without requiring high-precision manufacturing
Solution Approach 2:
The design incorporates adjustable mounting parameters and tolerance-compensating features that allow proper alignment even when component dimensions vary within normal manufacturing tolerances
3Ease of manufacture
If sheet metal boxes with openings are used, then the air mover can be mounted, but the sheet metal may rub against the air mover causing damage
Solution Approach 1:
The design incorporates intermediary components such as mounting brackets, spacers, or protective flanges that prevent direct contact between the sheet metal housing and the air mover, eliminating rubbing and potential damage while maintaining structural support
4Reliability
If seals and welds are used to join sheet metal boxes, then the structure is sealed, but the seals deteriorate over time compromising effectiveness
Solution Approach 1:
The design eliminates seals and welds from the housing assembly by using interlocking mechanical joints and removable fasteners, removing the components that deteriorate over time while maintaining structural integrity and seal effectiveness
Solution Approach 2:
The design uses simple, replaceable fasteners and gaskets that can be easily replaced if needed, rather than relying on permanent seals and welds that deteriorate and require complex repair
Data Source
AI summary
According to one aspect of the present disclosure, a condenser shroud assembly for a direct current (DC) powered variable capacity air conditioning system (VCACS), the shroud assembly includes a condenser shroud configured to support a condenser air mover of the VCACS, and a condenser shroud cover. The condenser shroud cover is mountable to the condenser shroud. Further, the condenser shroud cover defines an opening having a center axis that approximately coaxially aligns with a center axis of the condenser air mover when the condenser air mover is mounted to the condenser shroud and the condenser shroud cover is mounted to the condenser shroud.