Fan Array Control for Peak Efficiency and Uniform Airflow
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Solution Overview
Problem
Traditional air-handling systems face issues such as large size, high production and operating costs, inefficiency, uneven airflow, vibration, and space constraints due to the use of single large fan units, which are expensive, inefficient, and prone to failure, with no redundancy and significant space requirements.
Innovation Solution
A fan array system comprising multiple small fan units arranged in a configuration such as a true array, spaced pattern, or staggered array, controlled by a controller to optimize efficiency and power usage by turning units on or off to achieve peak efficiency, reducing the need for large structures and enhancing airflow uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large fan unit is used, then the air-handling system can handle large air volumes, but the system size and space requirements increase significantly
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 volume handling capacity while reducing the overall size of the air-handling compartment, as multiple small fans can be arranged more compactly than one large fan requiring the same total airflow.
2Productivity
If a single large fan unit is used, then the system can provide high airflow, but production and operating costs increase
Solution Approach 1:
The patent segments the airflow generation function across multiple smaller fan units. These smaller fans are less expensive to manufacture individually and can be produced using standardized components, reducing overall production costs while maintaining the required total airflow capacity.
Solution Approach 2:
The patent employs multiple smaller, less expensive fan units that can be more easily replaced if needed. These smaller fans use less expensive motors and components compared to a single large fan, reducing both initial production costs and long-term operating expenses.
3Productivity
If a single large fan unit is used, then the system can move large air volumes, but efficiency decreases
Solution Approach 1:
The patent divides the air moving function among multiple smaller fan units, each operating within its optimal efficiency range. Smaller fans typically operate more efficiently at their design point compared to oversized large fans operating at partial load, reducing overall energy consumption while maintaining the required air volume movement.
4Productivity
If a single large fan unit is used, then the system provides high airflow, but vibration and turbulence increase
Solution Approach 1:
The patent segments the airflow generation across multiple smaller fan units spaced apart in an array. This distribution reduces the intensity of turbulence and vibration from each individual fan, and the spatial separation allows these disturbances to dissipate before combining, resulting in lower overall vibration and more uniform airflow compared to a single large fan.
5Productivity
If a single large fan unit is used, then the system can handle high airflow, but reliability decreases due to no redundancy
Solution Approach 1:
The patent segments the airflow function across multiple independent fan units. If one fan fails, the remaining fans can continue to operate, providing natural redundancy and maintaining partial airflow capacity. This modular architecture inherently improves system reliability without requiring additional backup components.
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.