Fan Array Control for Efficient Airflow and Redundant Cooling
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Solution Overview
Problem
Traditional air-handling systems face issues such as large size leading to high real estate costs, expensive and inefficient single fan units, limited redundancy, noise, vibration, and uneven airflow due to the use of a single large fan unit.
Innovation Solution
A fan array system with multiple small fan units arranged in various configurations, controlled by an array controller to optimize efficiency and airflow, allowing for peak performance and reduced power consumption by turning off non-essential units, and utilizing modular and acoustically absorptive materials for sound attenuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large fan unit is used to meet high air volume requirements, then the air flow capacity is sufficient, but the system occupies more space and increases real estate 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 total air flow capacity (e.g., 50,000 CFM) while occupying less space, as the multiple small fans can be arranged more compactly than one large fan unit.
2Productivity
If a single large fan unit is used, then the air flow capacity is sufficient, but the production and operational costs increase
Solution Approach 1:
The system uses multiple identical small fan units instead of one custom-large fan unit. This allows for standardized manufacturing of the small units, which reduces production costs through economies of scale and modular assembly, while still achieving the required 50,000 CFM capacity.
Solution Approach 2:
The patent changes the operational parameters by allowing individual fan units to be turned on or off based on demand. This enables the system to operate at optimal efficiency points for each small fan rather than forcing one large fan to operate inefficiently at partial load, reducing operational costs.
3Productivity
If a single large fan unit is used, then the air flow capacity is sufficient, but the system lacks redundancy
Solution Approach 1:
By segmenting the system into multiple independent fan units, the patent inherently creates redundancy. If one or more small fan units fail, the remaining units can continue to operate and maintain the required air flow capacity, ensuring system reliability and continuous cooling.
4Productivity
If a single large fan unit is used, then the air flow capacity is sufficient, but noise and vibration increase
Solution Approach 1:
The patent segments the air flow generation into multiple small fan units, which produces less noise and vibration per unit compared to one large fan. The distributed configuration allows sound and vibration to disperse rather than concentrate, reducing the overall harmful effects while maintaining the required 50,000 CFM capacity.
Solution Approach 2:
The system applies local quality by positioning fan units with different operational characteristics in different locations within the array. This allows optimization of noise and vibration distribution, with some units potentially operating at lower speeds or being positioned to minimize their acoustic impact on surrounding areas.
5Productivity
If a single large fan unit is used, then the air flow capacity is sufficient, but airflow uniformity decreases
Solution Approach 1:
The patent segments the air flow output into multiple discrete streams from different fan units, which can be individually optimized and controlled. This segmentation allows for more uniform distribution of air flow across the discharge area, as each small fan creates a more localized and consistent flow pattern compared to the large variations produced by a single large fan.
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.