Modular air handling systems
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Solution Overview
Problem
Conventional air handling systems face challenges in efficiently managing airflow demands without significant increases in power consumption or acoustic noise, particularly when varying airflow requirements necessitate changes in fan configurations.
Innovation Solution
Modular air handling systems with independently controlled low velocity axial fans, sensors, and a centralized control system that allow for flexible configurations of fans in series or parallel, enabling closed-loop control and redundancy to maintain system performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fan speed is increased to meet airflow demand, then airflow is improved, but power consumption increases by the cube of the speed
Solution Approach 1:
The system divides the fan assembly into multiple independent fan modules (first fan module, second fan module, etc.), each capable of operating independently. This segmentation allows the system to meet airflow demands by activating multiple lower-power fans rather than overloading a single high-speed fan, thereby avoiding the cubic power increase associated with high-speed operation.
Solution Approach 2:
The control system dynamically adjusts the operational state of individual fan modules based on real-time airflow demands. Fans can be selectively activated or deactivated, and their speeds can be independently controlled, allowing the system to optimize power consumption by matching fan output precisely to demand rather than operating at constant high speed.
2Productivity
If fan speed is increased to meet airflow demand, then airflow is improved, but acoustic noise increases
Solution Approach 1:
By segmenting the fan system into multiple independent modules, the design enables multiple fans to operate at lower speeds rather than a single fan operating at high speed. Since acoustic noise increases with fan speed, this segmentation strategy reduces overall noise levels while maintaining the required airflow capacity.
Solution Approach 2:
The system combines multiple low-speed fan modules to achieve the same airflow output that would require a single high-speed fan. This merging approach leverages the fact that multiple fans operating in parallel at lower speeds generate less acoustic noise than one fan operating at high speed, thus resolving the noise-airflow trade-off.
3Device complexity
If single fan configuration is used, then device complexity is reduced, but system reliability decreases when high airflow or pressure is required
Solution Approach 1:
The system is divided into multiple independent fan modules, each with its own control capabilities. This segmentation provides redundancy and flexibility: if one fan module fails or requires maintenance, others can continue operating, and the control system can dynamically adjust to maintain required airflow or pressure levels, thereby enhancing reliability without excessive complexity.
Solution Approach 2:
The control system can change operational parameters (such as the number of active fans and their individual speeds) to adapt to varying airflow and pressure demands. This parameter flexibility allows the system to maintain reliable performance across different operating conditions while keeping the physical configuration relatively simple and modular.
4Productivity
If multiple fans are operated in parallel, then maximum airflow is increased, but maximum pressure remains unchanged
Solution Approach 1:
The control system dynamically adjusts the operational configuration of fan modules based on real-time system demands. When high airflow is required, fans operate in parallel mode. When high pressure is needed, the control system can reconfigure fans to operate in series or adjust individual fan speeds to optimize pressure generation, providing adaptive response to varying operational requirements.
Solution Approach 2:
The system can change the operational parameters of fan modules, including their configuration (parallel or series) and rotational speeds, to match demand conditions. This parameter flexibility allows the system to optimize for either airflow or pressure as needed, rather than being locked into a fixed configuration that excels at only one parameter.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently manages airflow demands with reduced power consumption and acoustic noise, allowing for seamless operation even when individual components fail, through independent fan control and modular design.
Implementation Method 1
at least one low velocity axial fan
Implementation Method 2
an isolation damper
Implementation Method 3
a number of sensors for receiving process data, discharge data, and environmental data
Implementation Method 4
a control system for processing data from the number of sensors to provide a closed loop control of the modular air handling system
Implementation Method 5
the head portion is manufactured from an acoustical energy absorbing material
Implementation Method 6
a number of inlet airflow guides for providing acoustic attenuation and flow straightening
Data Source
AI summary
Modular air handling systems are presented including: at least one blade, where the at least one blade includes: an intake section for receiving an airflow including: an intake air portion, a filter portion, a coil portion, and a head portion; a removable fan module, where the removable fan module includes: at least one low velocity axial fan; and an isolation damper; a discharge section for discharging the airflow including: a discharge air portion; and a number of sensors for receiving process data, discharge data, and environmental data; and a control system for processing data from the number of sensors to provide a closed loop control of the modular air handling system, where each blade operates independently, and where the at least one low velocity axial fan for each removable fan module are controlled by a single control signal.