Modular Fan Array With Angled Mounting Bracket
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Solution Overview
Problem
Existing air-handling systems require heavy, large fan assemblies that necessitate structural redesigns and significant space, leading to increased costs and reduced flexibility in installation and maintenance.
Innovation Solution
A modular fan array system comprising a fan assembly with a fan wheel, motor, and mounting bracket, where the fan assembly is designed with a frame and housing that allows for easy assembly and replacement, featuring a mounting bracket with angled legs for secure attachment and a housing with removable fan assemblies, enabling flexible configurations and reduced footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional large metal fan assemblies are used, then structural strength and stability are improved, but weight and footprint area increase significantly
Solution Approach 1:
The fan assembly is divided into separate modular components including the fan motor, fan wheel, mounting bracket, and housing. These segments can be individually manufactured with optimized materials and assembled on-site, reducing the weight of each component while maintaining overall structural strength through the modular configuration.
Solution Approach 2:
The mounting bracket is formed from composite materials that provide high strength-to-weight ratio. The bracket includes a motor mount portion and rearwardly extending legs that can be securely attached to the frame while significantly reducing the overall weight compared to traditional solid metal constructions.
2Stability of the object's composition
If traditional large fan assemblies are used, then structural stability is improved, but footprint area and installation space increase
Solution Approach 1:
The fan assembly is segmented into compact modular components that can be vertically stacked or arranged in space-efficient configurations. The mounting bracket with rearwardly extending legs allows for compact attachment to the frame, reducing the horizontal footprint while maintaining structural stability through proper load distribution.
Solution Approach 2:
The mounting bracket extends rearwardly from the motor mount portion, utilizing the depth dimension rather than horizontal spread. This allows the fan assembly to be securely mounted within a compact footprint by distributing loads in the vertical and depth directions rather than requiring large horizontal mounting surfaces.
3Strength
If traditional fan assemblies are used, then structural integrity is improved, but assembly time and material usage increase
Solution Approach 1:
The fan assembly is pre-assembled in segments (motor, wheel, bracket, housing) that can be manufactured independently and then quickly assembled on-site using standardized connection methods. The mounting bracket is designed as a separate component that can be easily attached to the frame with minimal fastening operations, significantly reducing assembly time while maintaining structural integrity.
Solution Approach 2:
The mounting bracket serves multiple functions: it mounts the motor, positions the fan wheel, attaches to the frame, and provides structural support. This multi-functionality reduces the number of separate components needed, simplifying assembly while maintaining structural integrity through the bracket's integrated design.
4Strength
If traditional fan assemblies are used, then structural support is improved, but ease of repair and maintenance deteriorate
Solution Approach 1:
The fan assembly is divided into separable segments including the motor, fan wheel, mounting bracket, and housing. This segmentation allows individual components to be easily removed and replaced during maintenance without requiring disassembly of the entire assembly. The mounting bracket is designed to be easily detached from the frame, facilitating quick component replacement while maintaining structural support when assembled.
Data Source
AI summary
A modular fan array includes a fan assembly having a fan wheel, a fan motor, and a mounting bracket. The fan wheel has a diameter. The assembly includes a frame having at least a pair of vertical members having a spacing therebetween. The spacing is greater than the fan wheel diameter. The mounting bracket includes a motor mount portion and a pair of rearwardly and outwardly extending legs. The motor mount portion includes an opening in which the motor is mounted. The rearwardly and outwardly extending legs each have a first angled section angled relative to the motor mount portion and second frame mount portion. The frame mount portions extend outwardly from the angled portions and parallel to the motor mount portion. The frame mount portions are removably secured to the frame.