Modular Bulkhead Panel System for Crane-Free HVAC Fan Retrofitting
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Solution Overview
Problem
The existing HVAC systems require the entire air handling unit to be replaced when a fan system malfunctions, which is costly and often necessitates the use of a crane, due to the weight and size constraints of the units, making retrofitting difficult and expensive.
Innovation Solution
A modular bulkhead system comprising interlocking vertical panels that can be hand-carried and installed within an existing air handling unit cabinet, allowing for the support and attachment of new fans without the need for a crane, enabling cost-effective retrofitting of fan systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire air handling unit is replaced when a fan system malfunctions, then the fan system can be renewed, but the cost increases substantially and crane equipment is required
Solution Approach 1:
The bulkhead is divided into multiple removable panels that can be individually accessed and installed. This segmentation allows the fan system to be replaced without removing the entire air handling unit, as each panel can be separately removed and reinstalled, eliminating the need for crane equipment and reducing retrofitting costs.
Solution Approach 2:
The fan system is extracted as a separate replaceable component from the bulkhead structure. By designing the bulkhead with removable panels, the fan system can be taken out and replaced independently without affecting the rest of the air handling unit, enabling cost-effective maintenance while maintaining system reliability.
2Ease of repair
If the air handling unit cabinet is deconstructed to facilitate removal, then the fan system can be accessed, but the weight and size constraints still require crane usage
Solution Approach 1:
The bulkhead is segmented into multiple panels that can be individually removed. This allows technicians to access the fan system by removing only the necessary panels rather than deconstructing the entire cabinet, making the repair process easier while avoiding the need to handle heavy cabinet components that would require crane equipment.
Solution Approach 2:
The bulkhead panels are pre-designed with removable features that facilitate easy access to the fan system. This preliminary design consideration allows for straightforward panel removal and reinstallation during maintenance, improving ease of repair without requiring heavy equipment to handle the cabinet structure.
3Adaptability or versatility
If new equipment is retrofitted within the existing cabinet, then the cabinet structure is utilized, but the cabinet doors and confined space limit the retrofitting options
Solution Approach 1:
The bulkhead is divided into multiple panels that can be removed and reinstalled, creating temporary openings large enough to accommodate new fan equipment. This segmentation approach provides retrofitting flexibility by allowing the cabinet structure to be partially opened without removing the entire cabinet or doors, enabling adaptation while utilizing the existing cabinet framework.
Solution Approach 2:
The removable panel design creates additional access dimensions by allowing panels to be taken off and reinstalled. This provides a third dimension of access (panel removal state) beyond the fixed cabinet door opening, enabling retrofitting of equipment that might not fit through the normal door opening while still utilizing the existing cabinet structure.
Data Source
AI summary
A structural support system for a fan array system. The system allows for a modular bulkhead wall to be customized and installed within a cabinet of an air handling unit. The modular bulkhead wall comprises one or more intermediate bulkhead stiffening elements that enable the modular bulkhead wall to support the fan array system.