Modular Fan Box Framework for Simplified Air Handler Assembly
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Solution Overview
Problem
Existing air handling units face challenges with complex assembly processes, excessive number of components, and high logistics and transportation costs due to the need for on-site assembly and sealing of multiple panels, which increases installation time and costs.
Innovation Solution
The air handler is designed with modular components, including air suction, mixing, and discharge modules, using sliding coupling and sealing structures to reduce assembly operations and eliminate the need for extensive screw fastening and secondary sealing, allowing for simplified assembly and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple panels are coupled to frames using screws to achieve high coupling strength, then air leakage is prevented, but the number of assembly operations increases excessively
Solution Approach 1:
The air handling unit is divided into modular sections where panels are pre-assembled with frames as integrated units. Each module can be independently manufactured and then quickly connected to other modules, reducing the total number of assembly operations while maintaining coupling strength through optimized connection points.
Solution Approach 2:
The panel and frame are combined into an integrated modular assembly that is pre-assembled during manufacturing. This merging of components into a single transportable module eliminates the need for extensive on-site assembly operations, as entire sections are installed as complete units rather than individual components.
2Reliability
If electrical insulating tape and sealant are applied to prevent air leakage, then hermetic sealing is achieved, but the assembly process becomes more complicated and time-consuming
Solution Approach 1:
Sealing structures are pre-integrated into the panel-frame assemblies during manufacturing, with sealing surfaces and gaskets positioned in advance. This preliminary preparation eliminates the need for secondary sealing operations like applying sealant on-site, as the hermetic sealing is already built into the modular components before installation.
3Adaptability or versatility
If all component elements are transported to installation site for complete assembly, then the air handler can be customized on-site, but logistics and transportation costs increase
Solution Approach 1:
The air handling unit is segmented into standardized modular sections that can be manufactured and pre-assembled at the production site. These modules are designed with universal connection interfaces, allowing them to be transported efficiently and then configured in different arrangements on-site to meet specific installation requirements, reducing both transportation costs and maintaining adaptability.
Solution Approach 2:
The modular panels and frames are designed with universal connection features and standardized dimensions that allow the same components to be used in various configurations. This universality enables on-site customization without requiring unique components for each installation, reducing the total number of different parts that need to be transported while maintaining flexibility in assembly.
Data Source
AI summary
An air handler and a fan module for an air handier are provided. The fan module may include a plurality of box frames that form a framework of at least one fan box; a plurality of safety nets coupled to the framework of the at least one fan box formed by the plurality of box frames to form surfaces of the at least one fan box; and at least one box frame connector that interconnects neighboring one of the plurality of box frames to form the framework of the at least one fan box, wherein the at least one box frame connector has a fan box connection end configured to assist connection of the neighboring one of the plurality of fan boxes. As such, manufacturing costs may be reduced due to reduction in a number of components, and assembly time may be remarkably reduced due to a reduced number of assembly operations. This advantageously results in reduced labor cost and enhanced air conditioning efficiency.