Toroidal Heating Element Assembly for Axial Fan Air Handling Units
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Solution Overview
Problem
Traditional heating element assemblies for air handling units with axial fans are ineffective in transferring heat to the air due to gaps and improper positioning, leading to inefficiencies in energy consumption.
Innovation Solution
The proposed solution involves a heating element assembly with a toroidal shape, positioned downstream of the stator in the airflow path, and supported by central and lateral supports to ensure effective heat transfer. This assembly includes multiple heating elements that are coaxial and coplanar, and can be integrated into the stator vanes or outlet nozzle to enhance heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rectangular heating element assembly is used in an axial fan air handling unit, then the heating elements can be positioned to extend across the outlet, but gaps appear where air escapes without sufficient heating and corners have reduced airflow
Solution Approach 1:
The heating element assembly is configured in a circular pattern rather than rectangular, matching the circular airflow pattern from the axial fan. This circular configuration eliminates the corner gaps and edge effects present in rectangular designs, ensuring uniform heat distribution across the entire airflow path and preventing energy waste from unheated air leakage.
2Loss of energy
If heating elements are positioned close to the axial fan outlet, then heat transfer efficiency improves, but the heating elements may overheat due to high air velocity
Solution Approach 1:
A support structure with radial supports and a central hub is introduced as an intermediary component. This support structure positions the heating elements at an optimized distance from the fan outlet, maintaining sufficient air velocity for heat transfer while preventing direct contact and overheating. The support structure acts as a mediator between the high-velocity airflow and the heating elements.
3Volume of stationary object
If the heating element assembly is made compact to fit within the casing, then space is saved, but the heating surface area is reduced
Solution Approach 1:
The heating elements are arranged in a circular pattern with multiple radial positions, utilizing the radial dimension to maximize heating surface area within the confined cylindrical space. This two-dimensional circular arrangement allows the heating elements to extend outward from the center in multiple directions, effectively increasing the total heating surface area while maintaining a compact overall assembly volume that fits within the axial fan casing.
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 described configuration ensures that the heating elements are fully immersed in the high-velocity airflow, enhancing heat transfer efficiency and reducing energy consumption by minimizing gaps and optimizing the positioning of the heating elements.
Implementation Method 1
include one or more heating elements 116 (i.e., electrical resistive heating elements)
Data Source
AI summary
The disclosed technology includes an axial fan assembly for an air handling unit. The axial fan assembly can include an axial fan that is configured to direct a flow of air along an airflow path through the axial fan assembly and a stator that is disposed in the airflow path downstream of the axial fan to at least partially straighten the flow of the air. The axial fan assembly can include a heating element assembly disposed in the airflow path downstream of the stator. The heating element assembly can include a heating element having a generally toroidal shape having an outer diameter less than an inner diameter of a casing disposed around the axial fan. The heating element assembly can have one or more supports configured to space the heating element a distance downstream from the stator to form a gap between the stator and the heating element.