Fan Array Control System for Peak Efficiency and Space Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional air-handling systems face challenges such as large size, high costs, inefficiency, and vibration due to single large fan units, which occupy valuable space, are expensive to produce and operate, and lack redundancy, leading to uneven airflow and noise issues.
Innovation Solution
A fan array system with multiple small fan units arranged in configurations like true arrays, spaced patterns, or staggered arrays, controlled by an array controller to optimize efficiency and airflow, reducing the need for large structures and enabling modular, efficient, and redundant operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large fan unit is used, then high air flow and pressure are achieved, but the system occupies large space and incurs high costs
Solution Approach 1:
The patent divides a single large fan unit into multiple smaller fan units arranged in an array configuration. This segmentation allows the system to achieve the same or greater air flow capacity while occupying less space, as the multiple small fans can be arranged more compactly than one large fan unit.
Solution Approach 2:
The patent transitions from a single-point fan arrangement to a distributed array arrangement across multiple dimensions. By spreading fan units across an array grid, the system achieves better space utilization and airflow distribution without requiring a single large footprint.
2Productivity
If a single large fan unit is used, then high air flow is achieved, but production and operating costs increase
Solution Approach 1:
The system segments the air handling function into multiple identical or similar fan units, which can be manufactured using standardized processes. This reduces production costs through economies of scale and modular manufacturing, eliminating the need for custom-built large fan units.
Solution Approach 2:
The patent uses multiple copies of identical or similar fan units in an array configuration. This copying approach allows for standardized manufacturing of each unit, reducing overall production costs while maintaining the required air flow capacity through the combined output of multiple units.
3Productivity
If a single large fan unit is used, then high air flow is achieved, but system efficiency decreases
Solution Approach 1:
The patent implements dynamic control of individual fan units within the array, allowing each fan to be independently adjusted based on system requirements. This dynamic operation optimizes energy efficiency by running only the necessary number of fans at appropriate speeds, rather than operating a single large fan at suboptimal conditions.
Solution Approach 2:
The system changes operational parameters by distributing air flow management across multiple fan units with variable speed control. This allows optimization of each fan's operating point for maximum efficiency, unlike a single large fan that must operate across a wide range of inefficient conditions.
4Productivity
If a single large fan unit is used, then high air flow is achieved, but vibration and noise increase
Solution Approach 1:
The patent segments the air moving function into multiple smaller fan units, which inherently generate less vibration and noise each. The distributed arrangement also prevents vibration resonance that would occur with a single large fan, while the combined output achieves the required air flow capacity.
Data Source
AI summary
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 by computing the power consumed in various configurations and selecting the configuration requiring minimum power to operate.