Fan Array with Coplanar Silencers to Reduce Noise and Vibration
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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 are expensive to produce and operate, and suffer from non-uniform airflow and noise issues.
Innovation Solution
The implementation of a fan array system using multiple small fan units arranged in a compact array configuration, supported by a minimal frame to reduce airflow interference, with an array controller to optimize efficiency and power usage by turning off unnecessary units, and incorporating sound attenuation materials for improved noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large fan unit is used, then air handling capacity is sufficient, but system size and real estate requirements increase
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 maintain the required air handling capacity through collective operation of multiple fans while significantly reducing the space required per fan unit and allowing for more compact system installation.
2Productivity
If a single large fan unit is used, then air handling capacity is met, but production and operating costs increase
Solution Approach 1:
By segmenting the air handling system into multiple smaller fan units, the patent enables standardized mass production of identical modular components, reducing per-unit manufacturing costs compared to custom-building a single large fan unit. The modular approach also simplifies assembly and maintenance operations.
Solution Approach 2:
The patent changes the operational parameters by running multiple fans at lower individual capacities rather than one fan at high capacity, which can improve overall system efficiency and reduce energy consumption, thereby lowering operating costs.
3Productivity
If a single large fan unit is used, then air handling capacity is sufficient, but airflow uniformity deteriorates
Solution Approach 1:
The patent segments the air handling function across multiple fan units that can be distributed throughout the system, allowing for more uniform air distribution patterns. Each fan serves a localized area, creating overlapping airflow zones that result in improved overall uniformity compared to a single centralized fan.
4Productivity
If a single large fan unit is used, then air handling capacity is met, but vibration and noise increase
Solution Approach 1:
The patent divides the air handling load across multiple smaller fan units, which generate less vibration and noise individually. The distributed configuration allows vibration isolation and reduces the propagation of harmful factors compared to a single large fan operating at high capacity.
Solution Approach 2:
The patent changes the operational parameters by operating multiple fans at lower speeds and capacities rather than one fan at high speed, which inherently reduces vibration generation, noise levels, and associated harmful effects while maintaining the required air handling capacity.
5Area of stationary object
If multiple small fan units are used, then real estate requirements and costs are reduced, but system complexity increases
Solution Approach 1:
The patent employs identical modular fan units that serve multiple purposes: air moving, vibration isolation, and redundancy. This universality simplifies the overall system design despite the increased number of components, as each module is standardized and can be independently installed, maintained, and replaced.
6Object-generated harmful factors
If multiple small fan units are used, then vibration and noise are minimized, but control complexity increases
Solution Approach 1:
The patent combines the control of multiple fan units into a unified control system that manages all fans collectively. This merging of control functions simplifies operation compared to managing each fan independently, while still allowing the system to leverage the vibration and noise reduction benefits of multiple units operating in coordination.
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
A fan array (230) of an air handling system, the fan array comprising a plurality of fan cells. Each fan cell comprises a fan (200), a motor (208) coupled to the fan to drive the fan to rotate and a coplanar silencer at least partially surrounding the fan (200) and the motor (208). The coplanar silencer is configured to attenuate sound produced by the fan (200) and the motor (208). The coplanar silencer comprises a fan frame (250) and an insulation surface (248).