CA3050302C - Sensor assembly for monitored heat exchanger system and related - Google Patents

Abstract

A sensor assembly that includes a mounting frame; and a support platform coupled with the mounting frame. The support platform has a top platform surface with a circuit board disposed thereon. The circuit board is operably configured with a secondary microcontroller and a Hall effect sensor. There is an inner sensor housing configured to extend out and around the circuit board and the support platform. There is a first magnet coupled to an underside of the inner sensor housing. There is a rotating member configured with a plurality of blades and a rotating member mounting ring, the rotating member is proximately disposed on top of the inner sensor housing.

Description

SENSOR ASSEMBLY FOR MONITORED HEAT EXCHANGER SYSTEM AND
RELATED
This application is a divisional of Canadian Patent Application Serial No.
3,030,718, which itself is a divisional of Canadian Patent Application Serial No. 2,979,845 filed on September 20, 2017.
BACKGROUND
Field of the Disclosure 100011 This disclosure generally relates to a heat exchanger unit with characteristics of improved: airflow, noise reduction, cooling efficiency, and/or structural integrity. In some embodiments, the disclosure relates to a heat exchanger unit used in connection with equipment found in an industrial setting. Other aspects relate to a system for monitoring airflow through a heat exchanger unit, or fouling related thereto. In particular embodiments, a monitoring module is mounted externally to the heat exchanger unit of a monitored system, the system being usable to monitor fouling of the unit, and provide an associated warning. The monitoring module may be operably associated with a durable, rugged airflow sensor assembly. The heat exchanger unit may be used for cooling various utility fluids used with a heat generating device, such as an engine, a pump, or a genset.
Other embodiments pertain to a method of monitoring fouling, a method for using a monitoring system, and a method of doing business.
Background of the Disclosure 100021 Whether its refrigeration, hot showers, air conditioning, and so on, the function of heating and cooling is prevalent in today's residential and industrial settings. One area of relevance is the oil and gas industry, including exploration, upstream, and downstream operations where the ability to heat and/or cool is critical. Upstream operations can include drilling, completion, and production, whereas downstream operations can include refining and other related hydrocarbon processing, all of which utilize a vast amount of process equipment including that which provide heat transfer. To be sure, the background of the disclosure is relevant elsewhere, but for brevity discussion is focused on O&G.
100031 As the modern world continues to experience growth in population, it similarly continues to experience an increase in energy demand and consumption, and the oil and gas industry needs to respond accordingly. Although 'green' energy has experienced a gain in popularity, the dominant source of energy remains fossil fuels. Driven by demand and high prices for fossil fuels, the U.S. energy sector experienced a boom in the late 2000's and into the early 2010's, contributing to expansion in exploration and production across the country.
100041 Quite unexpectedly various global economic factors resulted in a rapid turnaround in demand and a decrease in profit margin that left many industry related companies vying to remain in business. This has resulted in consolidation and innovation, as the reality of likely never again seeing the record highs associated with the price of oil sets in.
To remain competitive, companies have begun looking at how they can be successful and profitable with a margin based on an oil price in a range of about $30-$50 per barrel.
100051 A particular segment in the upstream area of oil and gas production pertains to fracing.
Now prevalent, fracing includes the use of a plug set in a wellbore below or beyond a respective target zone, followed by pumping or injecting high pressure frac fluid into the zone. The frac operation results in fractures or "cracks" in the formation that allow valuable hydrocarbons to be more readily extracted and produced by an operator, and may be repeated as desired or necessary until all target zones are fractured.
100061 The injection fluid, which may be mixed with chemicals, sand, acid, etc., may be pressurized and transported at high rate via one or more high pressure frac pumps, typically driven by diesel combustion engines.
100071 Figures 1A and 1B together illustrate a conventional land-based fracturing operation and frac pump trailer unit. The operation 101 may include multiple frac pump units 105. Each unit 105 is typically operable with a pump 1 1 3 and engine 103 mounted or otherwise disposed thereon, and is capable of producing upwards of 15,000 psi. Suitable units 105 include those manufactured or provided by NOV, Haliburton, Magnum, Weatherford, and the like.
100081 The necessity of fracturing, has progressively increased as production rates on new wells continue to decline. It is believed by some that at least 90 percent of all future wells in North America will require some degree of fracturing to increase production results, with a majority of these operations occuiTing in shale gas formations.
100091 As demand continues to rise, producers have moved to unconventional sources such as the Barnett Shale, which for the first time resulted in wide reliance on horizontal drilling, leading

2 to an increase on pumping pressures and operating times. Horizontal drilling and its associated multistage fracturing techniques are now the norm as shale formations have become the leading source of natural gas in North America. This harsher pumping environment demands stronger pumps capable of operating at extreme pressures and extended pumping intervals.
100101 The frac pump is now part of a pumping system (or skid unit, etc.) that is typically self-contained on a transportable system, such as a trailer unit 105. The system components include the engine 103 and the frac pump 113, as well as a radiator (or cooler, heat exchanger, etc.) 100.
Today's pumps are capable of producing 2500 BHP @ 1900 rpm while operating in standard pressure pumping well service operations in ambient conditions of about 0 F to 125 F, and can provide upwards of 15,000 psi injection pressure at a working rate of 17 bpm.
The frac pump 113 provides pressurized fluid into well(s) 191 via transfer (injection) lines 190.
100111 But there are several drawbacks to this modem equipment. First, the operational requirements have driven the associated equipment to become massive in weight, and single trailer units sometimes exceed 80,000 lbs. Unfortunately the trailer unit 105 must comply with federal, state, and local regulation, where a number of regulators are starting to draw a line on weight limitations. Permits for a job site will only be issued when requirements are met.
100121 Similarly, the operational requirements have driven the associated equipment, such as the diesel engine or radiator fan, to become huge point sources of noise pollution. And again, regulators are starting to draw a line on noise. This is even more problematic as job sites start to encroach closer and closer to residential areas.
100131 Next, operational requirements have driven the associated equipment, for example the diesel engine, to become extreme generators of heat, thus requiring a larger cooling system. The typical radiator further adds significant weight to the trailer unit. And as a result of spatial constraints, the radiator 100 often lies horizontal on the bed of the trailer unit 105, as shown in Figure 1B. The problem with this arrangement is that as the radiator fan 108 blows in ambient air to cool various service fluids (F1, F,, F3, etc.), the air becomes progressively hot (e.g., cooling in series, where T)u, > > T, >
Tam). See Figure IC. This temperature gradient results in ineffective cooling as the air is moved through the radiator 100.
100141 The heat exchanger is typically used to cool by passing a hot service fluid through the heat exchanger along one path (or side), and passing a cooling medium through the heat exchanger along a second path (or side). In an air-cooled radiator, a fluid may circulate through

3 the equipment and pass through the first side, and air may be drawn through the second side to cool the fluid before it returns to the equipment.
100151 Operational requirements have further attributed to extreme conditions (e.g., temperature, pressure, vibration, etc.) that subject equipment to additional failure modes, for example, it has been found that leaks may occur at the joints of the equipment.
100161 One type of heat exchanger is one that may be formed from a series of header bars and face bars, with plates connected between the bars to form flow paths. One or more tanks may be connected in fluid communication with either or both of a first and a second path to direct fluid flow through the respective path. In one example, in which plates are brazed to the header and face bars, and tanks welded to the ends of the heat exchangers, it was found that leaks were occurring adjacent to the header and face bars.
100171 It was found that when the header bars and face bars were small, the heat affected zone related to a weld between the core and the tank extended past the header bars and face bars and into the brazed joint between the plates and the respective bar(s). When the weld temperature (i.e., melting point of weld material) was greater than the brazing temperature, the brazing material would melt and flow away, such that the connection at these points was either opened, or weakened, and resulted in greater likelihood of failure during operation.
100181 Figure 1E shows a close-up side view of part of a radiator core. A tank 177 is welded to the core 106 at the core end 1 0 6a (i.e., the weld point). The tank 177 has a tank end, which has an effective tank end mass. The mass of the tank (and its end) 177 is extensive (including as depending on tank wall thickness Wt), and a significant amount of heat must be applied in order to reach the weld temperature Tw at the weld point. The temperature of the melting point of the weld material Tw (typically about 1200 F) is greater than the melting point Tb (typically about 960 F) of the brazing material between the parting sheets 172 and respective bars 175 (e.g., header and face). As the tank end mass of the tank end (Mte) is larger than a core end mass of the core end (Mce), the presence of weld temperature at the weld point results in a heat profile P
into the core 106 (which the profile P may be parabolic).
100191 Heat at the weld point radiates along the easiest path. As the heat profile of temperature greater than Tb extends length 1, and is beyond the effective bar brazing length (or area A) 1 85 of the bar 175, the brazing material B (by having a melting temperature Tb less than weld temperature Tw) is heated and can freely flow or leach away from the area A
between the bar

4 175 and the parting sheet 172. This results in the core 106 being susceptible to failure because upon cooling the brazing is now incomplete.
100201 Another issue that reduces the structural integrity of the heat exchanger unit is the then-nal expansion of a radiator core, particularly those made of aluminum.
Typically a core is rigidly mounted without regard for how it might expand in application.
However, as the core experiences expansion, it becomes prone to leaking. It was determined that a cause of the leaks was the impact of thermal expansion, with some large heat exchangers expanding by almost 1/2".
As the cores are solidly brazed together and then hard mounted (welded or nut/bolt) to a frame, the stress from expansion caused cracking in some welds due to excessive load being applied to it.
100211 Thermal expansion occurs, for example, when the radiator core is manufactured at ambient temperature, but is generally exposed to temperatures well above ambient during use.
As a result, the material of the core will expand. As the core is normally rigidly mounted to a support structure, which resisted thermal expansion, it is believed that stresses are induced in the heat exchanger, and that failures can occur in the welds as a result.
100221 One or more of these concerns is just as valid to non-oilfield related heat exchangers.
Figure 1D illustrates a simple schematic overview of a heat generation device (HGD) 103a used in a general industrial operation or setting 101a. The operation or setting 101a may be a construction site, a building, a water treatment plant, a manufacturing facility, or any other setting whereby a heat exchanger 100a is used for heat transfer, such as to cool (or heat) a utility fluid F that is used with the HGD 103a. The operation of a fan 108 results in an undesirable noise characterized by an acoustic frequency f with amplitude Al, which his readily discernable to an operator.
100231 In an analogous manner HGD's associated with a residential setting may also have similar concerns. In other aspects, it is becoming more and more common that an industrial setting or operation is adjacent or proximate to a residential setting.
100241 Common settings are nothing short of challenging in the sense that in many instances operations and processes (and related equipment) are exposed to environmental conditions, such as extreme heat, cold, wind, and dust (including natural amounts of particulate, as well as that caused by the operation of equipment and vehicles).

100251 It is routine to have (indeed, need) some type of heat exchange ability in such settings.
As set forth in US S/N 15/477,097, an example operation in an industrial setting may include one or more frac pump units. Each unit is typically operable with a pump and engine mounted or otherwise disposed thereon, as well as a radiator (or analogously referred to as cooler, heat exchanger, etc.). As mentioned before, equipment like this must be rugged and durable in order to have long-term operational capacity and effectiveness.
100261 The radiator is configured for cooling one or more hot service fluids associated with the equipment of the frac pump unit, such as lube oil or jacket water. The radiator typically includes a 'core' of stacked fins, with one part of the core providing a flow are for the service fluid(s), while another part of the core provides a proximate, albeit separate, flow area for ambient air. A
fan is used to blow or pull air through the stacked fins, the air being a low or moderate enough temperature to cool the service fluid, which is then recirculated in a loop.
100271 The stacked fins often have a configuration that is tantamount to an extensive amount of small air passageways proximate to (albeit separate from) service fluid passageways, whereby the air and the service fluid can 'exchange heat' via the surface material of the stacked fins between the passageways (e.g., aluminum).
100281 Over time airborne dirt in and other particulate in the air will begin to deposit on the air intake side (and elsewhere), resulting in a fouled radiator. Fouling can seriously deteriorate the capacity of the surface of the fins to transfer heat under the conditions for which they were designed. Among other problems, the fouling layer has a low thermal conductivity which increases the resistance to heat transfer and reduces the effectiveness of heat exchangers. In addition, fouling reduces the cross-sectional area in the passageways, which causes an increase in pressure drop across a heat exchanger.
100291 Radiator fouling affects both capital and operating costs of heat exchangers (and overall processes). Higher capital expenditures include that for excess surface area (for heat transfer), extra space, and transport and installation costs. Operating expenditures include that for energy losses due to the decrease in thermal efficiency, increases in the pressure drop through process equipment, and production losses during planned and unplanned plant shutdowns for fouling cleaning.
100301 Moreover, government emissions regulations are forcing engine manufacturers and their customers to reduce emissions from reciprocating engines. Current solutions involve returning the exhaust through heat exchange, which elevates combustion temperature and puts significantly more heat into the cooling system. Tier 4 Final (US and CA) Emission regulations come into effect in 2017 & 2020 will force end users into significant equipment redesign industry wide.
100311 In summary, fouling of heat transfer surfaces is one of the most important problems in heat transfer equipment. Some have described fouling as the major unresolved problem in heat transfer. Equipment operators world-wide are also trying to reduce maintenance costs. One of the highest maintenance costs any piece of equipment has is cooling system maintenance.
100321 And yet despite these detriments, consideration of improved remediation or management techniques have been largely ignored and unchanged. Conventional techniques include mitigation (such as upstream filtering) and chemical treatment.
100331 Mechanical cleaning is also used, but only during predetermined periodic intervals, namely during a planned shutdown or when an exchanger reaches a point of failure and is no longer operable. This approach relies on extensive cost and resource being allocated toward the antiquated philosophy of operational redundancy.
100341 There is a need in the art to overcome deficiencies and defects identified herein. There is a need in the art to reliably monitor fouling of a radiator. There is a need in the art to provide a real-time warning indication about fouling conditions of a radiator.
100351 There is a need in the art for a monitoring system that is durable for use in outdoor and other difficult environmental conditions. There is a need in the art for a monitoring system capable of high degree of sensing accuracy, yet impervious to or otherwise able to withstand external conditions. There is a further need for an improved rugged sensor assembly suitable for ongoing and extended use in association with the monitoring system in extreme environmental conditions.
100361 There is a need in the art for a method of doing business that includes monitoring and servicing of radiators, especially when the radiator reaches various stages of fouling or provides other indication requiring attention. There is a need in the art to clean a fouled radiator with little or no downtime.

100371 There is a need in the art for a monitoring module that can be retrofitted to any existing heat exchanger, including of great importance to a heat exchanger that has one or more sides (or surfaces) exposed to ambient air.
100381 There is a particular need in the art for a monitoring system that is readily adaptable and compatible to radiators associated with different pieces of heat generating equipment, such as an engine, a motor, a pump, or a genset useable in a wide range of settings.
100391 There is a need in the art to overcome deficiencies and defects identified herein. There is a particular need in the art for a heat exchanger that is readily adaptable and compatible to different pieces of heat generating equipment, such as an engine, a motor, a pump, or a genset useable in a wide range of settings.
100401 There is a need in the art to be able to reduce pressure drop, whereby airflow through a heat exchanger can be streamlined and increased. There is a need to reduce sound emission from a heat exchanger so that it may satisfy regulatory limitations or be suitable for use in or proximate to a residential setting.
100411 There is a need in the art for a heat exchanger that can accommodate spatial constraints, and is lighter in weight. There is a need in the art for a heat exchanger that has improved or reduced sound emissions. There is a need in the art for a heat exchanger that improves cooling efficiency. There is a need in the art for a heat exchanger with improved structural integrity, including the ability to withstand or tolerate thermal expansion and hot welding temperatures.
SUMMARY
100421 Embodiments herein pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device, with an at least one service fluid being transferable thercbetween, the heat exchanger unit further having a frame.
There may be at least one cooler coupled with the frame, the at least one cooler having an airflow side and a service fluid side.
100431 Embodiments herein pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device, with an at least one service fluid being transferable thercbetween. The heat exchanger unit may further include: a frame; and an at least one cooler coupled with the frame, the at least one cooler having an airflow side and a service fluid side fluidly separated from each other. There may be a primary microcontroller operably associated with the heat exchanger unit. There may be an at least one sensor assembly in operable communication with the primary microcontroller.
100441 Embodiments of the disclosure pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device. There may be an at least one service fluid being transferable therebetween. The heat exchanger unit may include a frame; and an at least one cooler coupled with the frame. The at least one cooler may have an airflow side and a service fluid side fluidly separated from each other.
100451 Embodiments herein pertain to a monitoring module for monitoring operation of a heat exchanger unit that may include one or more sensor assemblies coupled therewith. At least one of the sensor assemblies may include a mounting frame configured for coupling to the heat exchanger unit. There may be a support platform connected with the mounting frame. The support platform may further include a platform hollow and a top platform surface. There may be a shaft rotatably disposed in the platform hollow.
100461 Yet other embodiments of the disclosure pertain to a method for monitoring a heat exchanger unit that may include one or more steps of coupling the heat exchanger unit in fluid communication with a heat generating device; associating a monitoring module with an airflow side of the heat exchanger unit; and based on an indication, performing a cleaning action on the heat exchanger unit.
100471 Still other embodiments pertain to a method of doing business that may in include the steps of entering into a transaction with a first recipient; per terms of the transaction, providing a monitoring module for a heat exchanger unit, operably associating the monitoring module with the heat exchanger unit, the monitoring module being operable to monitor a fouling condition of the heat exchanger unit, the monitoring module including a sensor assembly in operable communication with a primary microcontroller; receiving an indication from the monitoring module related to the fouling condition; and performing a cleaning action of the heat exchanger unit upon based on the indication. In aspects, the transaction may include terms pertaining to at least one of: equipment purchase, installation, software license, data sharing, cleaning service, and combinations thereof.
100481 Embodiments of the disclosure pertain to an airflow sensor assembly that may include: a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening; a mounting frame disposed proximate to the casing bottom side, the mounting frame further comprising a central segment; a guard disposed proximate to the casing topside; a support platform coupled with the central segment, and further comprising:
a platform hollow; and a top platform surface; a shaft centrally positioned within the casing opening and further disposed in the platform hollow; a plurality of assembly screws disposed through the casing, the mounting frame, and the guard; a plurality of fasteners configured for connecting with the plurality of assembly screws; a first bearing disposed around the shaft and proximate the support platform; a second bearing disposed around the shaft and on top of the first bearing, and proximate the support platform; a circuit board positioned onto the top platform surface, the circuit board being configured with an operable logic circuit further comprising a secondary microcontroller, a Hall effect sensor, and a transceiver; a first lock nut threadingly engaged around the shaft in an amount sufficient to engage the second bearing;
an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform; an at least one magnet coupled with the inner sensor housing; a rotating member comprising a plurality of blades, and the rotating member being disposed around the shaft; a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member.
100491 Embodiments herein pertain to an airflow sensor assembly for a monitored heat exchanger system that may include a mounting frame configured for coupling the assembly with the heat exchanger unit, the mounting frame further having a central segment.
There may be a support platform coupled with the central segment. The support platform may include a platfon-n hollow; and a top platform surface.
100501 Still other embodiments of the disclosure pertain to a sensor assembly comprising having a mounting frame further comprising a central segment; a support platform coupled with the central segment, and further comprising: a platform hollow; and a top platform surface; a shaft disposed in the platform hollow; a first bearing disposed around the shaft, and also disposed at least partially in the platform hollow.
100511 Yet other embodiments of the disclosure pertain to a sensor assembly that may include a mounting frame; and a cylindrical support platform coupled with the mounting frame. The support platform may include a platform hollow; and a top platform surface.
The assembly may include a circuit board positioned or otherwise mounted onto the top platform surface. The circuit board may be configured with a secondary microcontroller and a Hall effect sensor.
There may be an inner sensor housing configured to extend out and around the circuit board and the support platform. There may be a first magnet coupled to an underside of the inner sensor housing. There may be a rotating member configured with a plurality of blades and a rotating member mounting ring. The rotating member may be proximately disposed on top of the inner sensor housing.
100521 These and other embodiments, features and advantages will be apparent in the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
100531 A full understanding of embodiments disclosed herein is obtained from the detailed description of the disclosure presented herein below, and the accompanying drawings, which are given by way of illustration only and are not intended to be limitative of the present embodiments, and wherein:
100541 Figure lA shows an overview process diagram of a conventional land-based fracturing operation;
100551 Figure IB shows a side view of a frac pump truck;
100561 Figure IC shows a close-up profile view of a horizontal heat exchanger useable with the frac pump truck of Figure 1B;
100571 Figure ID shows a simple schematic view of a heat exchanger used with a heat generation device in a general industrial setting;
100581 Figure lE shows a close-up side view of a typical temperature profile when a tank is welded to a radiator core;
100591 Figure 2A shows a side view of a heat exchanger unit coupled with a heat generation device according to embodiments of the disclosure;
100601 Figure 2B shows an isometric view of a frame of the heat exchanger unit according to embodiments of the disclosure;
100611 Figure 2C shows a side cross-sectional view of an HX unit configured with a plurality of baffles according to embodiments of the disclosure;

100621 Figure 2D shows an isometric view of a set of a plurality of baffles according to embodiments of the disclosure;
100631 Figure 2E shows a close-up partial side view of a baffle coupled to a vertical member according to embodiments of the disclosure;
100641 Figure 3A shows an isometric view of a baffle according to embodiments of the disclosure;
100651 Figure 3B shows a lateral cross-sectional view of a baffle according to embodiments of the disclosure;
100661 Figure 4A shows an isometric partial view of a radiator core according to embodiments of the disclosure;
100671 Figure 4B shows a partial close-up downward view of an end of a radiator cooler having a tank and a core according to embodiments of the disclosure;
100681 Figure 4C shows a view of a tank welded to a core according to embodiments of the disclosure;
100691 Figure 5A shows a close-up view of a radiator core mounted to a frame of a heat exchanger unit according to embodiments of the disclosure;
100701 Figure 5B shows a component breakout view of a flexible mount assembly according to embodiments of the disclosure;
100711 Figure 5C shows a partial side cross-sectional view of a flexible mount assembly used with a bracket and a frame of a heat exchanger unit assembly according to embodiments of the disclosure;
100721 Figure 5D shows a component breakout view of another flexible mount assembly according to embodiments of the disclosure;
100731 Figure 5E shows a partial side cross-sectional view of the flexible mount assembly of Figure 5D used with a core a heat exchanger unit according to embodiments of the disclosure;
100741 Figure 5F shows a close-up view of a flex mount assembly used for coupling various components of a heat exchanger unit according to embodiments of the disclosure;
100751 Figure 6A shows a downward looking isometric view of a top region of a heat exchanger unit according to embodiments of the disclosure;
100761 Figure 6B shows an isometric view of a fan mount according to embodiments of the disclosure;

100771 Figure 7A shows an isometric view of a monitored heat exchanger system that includes a monitoring module, a heat exchanger unit, and a heat generation device operably coupled together according to embodiments of the disclosure;
100781 Figure 7B shows an isometric view of a frame of the heat exchanger unit according to embodiments of the disclosure;
100791 Figure 7C shows a component breakout view of a controller housing usable with a monitoring module, and having various internal components according to embodiments of the disclosure;
100801 Figure 8A shows a logic circuit process flow diagram according to embodiments of the disclosure;
100811 Figure 8B shows a logic circuit decision tree operable as part of a monitoring module according to embodiments of the disclosure; and 100821 Figure 9 shows a side view of a monitored heat exchanger system that includes a monitoring module, a four-sided heat exchanger, and a heat generating device coupled together according to embodiments of the disclosure;
100831 Figure 10A shows a component breakout view of a sensor assembly usable with a monitoring module, and having various internal components according to embodiments of the disclosure;
100841 Figure 10B shows a heat exchanger unit having a sensor assembly and a heat generation device operably coupled together according to embodiments of the disclosure;
100851 Figure 10C shows a longitudinal cross-sectional view of an airflow sensor assembly according to embodiments of the disclosure;
100861 Figure 1 lA shows a view of an airflow sensor assembly connected with a rock guard according to embodiments of the disclosure;
100871 Figure 11B shows a view of an airflow sensor assembly connected with another rock guard according to embodiments of the disclosure;
100881 Figure 1 1C shows a view of a circuit board with circuitry and circuit components according to embodiments of the disclosure;
100891 Figure 11D shows a view of a circuit board with circuitry and circuit components according to embodiments of the disclosure; and 100901 Figure 12 shows an alternative sensor assembly configuration according to embodiments of the disclosure.
DETAILED DESCRIPTION
. 100911 Herein disclosed are novel apparatuses, systems, and methods that pertain to an improved heat exchanger and aspects related thereto, details of which are described herein.
100921 Embodiments of the present disclosure are described in detail with reference to the accompanying Figures. In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, such as to mean, for example, "including, but not limited to...... While the disclosure may be described with reference to relevant apparatuses, systems, and methods, it should be understood that the disclosure is not limited to the specific embodiments shown or described. Rather, one skilled in the art will appreciate that a variety of configurations may be implemented in accordance with embodiments herein.
100931 Although not necessary, like elements in the various figures may be denoted by like reference numerals for consistency and ease of understanding. Numerous specific details are set forth in order to provide a more thorough understanding of the disclosure;
however, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
Directional terms, such as "above," "below," "upper," "lower," "front," "back," "right", "left", "down", etc., are used for convenience and to refer to general direction and/or orientation, and are only intended for illustrative purposes only, and not to limit the disclosure.
100941 Connection(s), couplings, or other forms of contact between parts, components, and so forth may include conventional items, such as lubricant, additional sealing materials, such as a gasket between flanges, PTFE between threads, and the like. The make and manufacture of any particular component, subcomponent, etc., may be as would be apparent to one of skill in the art, such as molding, forming, press extrusion, machining, or additive manufacturing. Embodiments of the disclosure provide for one or more components to be new, used, and/or retrofitted to existing machines and systems.
Terms 100951 The term "noise" as used herein can refer to a sound, including an undesirous sound.
100961 The term "sound" as used herein can refer to a vibration(s) that travels through the air or another medium, and can be detectable or discernable to the human ear or an instrument. Sound can be referred to as a pressure wave resulting in pressure variations. A loud noise usually has a larger pressure variation and a weak one has smaller pressure variation. The more readily referred to measurement of loudness of sound is a logarithmic scale of Pascals, the decibel (dB).
Sound and noise can be interchangeable, or have comparable meaning.
100971 The term "noise absorbing material" as used herein can refer to a material having a physical characteristic of being able to reduce amplitude of a noise or sound.
That is, reduce a pressure variation. 'Noise absorbing' can be interchangeable to noise reduction, noise absorbent, abatement by absorbing, and so forth. The material can be a fibrous material, such as mineral wool.
100981 The term "noise barrier" can refer to a material or component capable of stopping noise from passing therethrough. In aspects, a noise barrier material can be adhered (such as glued) to a component. The noise barrier material can be vinyl.
100991 The term "frequency" as used herein can refer to the rate at which a vibration (of a respective sound) occurs over a period of time. The number of pressure variations per second is called the frequency of sound, and is measured in Hertz (Hz) which is defined as cycles per second. The higher the frequency, the more high-pitched a sound is perceived.
1001001 The term "dominant acoustic frequency" can refer to a respective sound that is most discernable or noticeable to a human car or instrument.
1001011 The term "engine" as used herein can refer to a machine with moving parts that converts power into motion, such as rotary motion. The engine can be powered by a source, such as internal combustion.
1001021 The term "motor" as used herein can be analogous to engine. The motor can be powered by a source, such as electricity, pneumatic, or hydraulic.

1001031 The term "drive" (or drive shaft) as used herein can refer to a mechanism that controls or imparts rotation of a motor(s) or engine(s).
1001041 The term "pump" as used herein can refer to a mechanical device suitable to use an action such as suction or pressure to raise or move liquids, compress gases, and so forth. 'Pump' can further refer to or include all necessary subcomponents operable together, such as impeller (or vanes, etc.), housing, drive shaft, bearings, etc. Although not always the case, 'pump' can further include reference to a driver, such as an engine and drive shaft.
Types of pumps include gas powered, hydraulic, pneumatic, and electrical.
1001051 The term "frac pump" as used herein can refer to a pump that is usable with a frac operation, including being able to provide high pressure injection of a slurry into a wellbore.
The frac pump can be operable in connection with a motor or engine. In some instances, and for brevity, 'frac pump' can refer to the combination of a pump and a driver together.
1001061 The term "frac truck" as used herein can refer to a truck (or truck and trailer) useable to transport various equipment related to a frac operation, such as a frac pump and engine, and a radiator.
1001071 The term "frac operation" as used herein can refer to fractionation of a downhole well that has already been drilled. 'Frac operation' can also be referred to and interchangeable with the terms fractionation, hydrofracturing, hydrofracking, fracking, fracing, and frac. A frac operation can be land or water based.
1001081 The term "radiator" can also be referred to or interchangeable with the term 'heat exchanger' or 'heat exchanger panel'. The radiator can be a heat exchanger used to transfer then-nal energy from one medium to another for the purpose of cooling and/or heating.
1001091 The term "cooler" as used herein can refer to a radiator made up of tubes or other structure surrounded by fins (or 'core') that can be configured to extract heat from a fluid moved through the cooler. The term can be interchangeable with 'heat exchanger panel' or comparable.
lheat can also be exchanged to another fluid, such as air.
1001101 The term "cooling circuit" as used herein can refer to a cooler and respective components.
1001111 The term "core" as used herein can refer to part of a cooler, and can include multiple layers of fins or fin elements.

1001121 The term "heat exchanger unit" as used herein can refer to a device or configuration that uses one or more coolers along with other components, such as a fan, mounts, tubing, frame, and so on. The heat exchanger unit can be independent and standalone or can be directly mounted to a heat generating device. The heat exchanger unit can be operable to pull (draw) ambient air in through the coolers in order to cool one or more service fluids. The heated air is moved or blown out as a waste exhaust stream.
1001131 The tern1 "heat generating device" (or sometimes `1-1GD') as used herein can refer to an operable device, machine, etc. that emits or otherwise generates heat during its operation, such as an engine, motor, a genset, or a frac pump (including the pump and/or respective engine). The HGD can be for an industrial or a residential setting.
1001141 The term "genset" (or generator set) as used herein can refer to a 'diesel generator' or the combination of a diesel engine (or comparable) and an electric generator. The genset can convert mechanical energy to electrical energy.
1001151 The term "utility fluid" as used herein can refer to a fluid used in connection with the operation of a heat generating device, such as a lubricant or water. The utility fluid can be for heating, cooling, lubricating, or other type of utility. 'Utility fluid' can also be referred to and interchangeable with 'service fluid' or comparable.
1001161 The term "mesh" as used herein can refer to a material made of a network of wire or thread, or an interlaced/interconnected structure.
1001171 The term "brazed" as used herein can refer to the process of joining two metals by heating and melting a filler (alloy) that bonds the two pieces of metal and joins them. The filler may have a melting temperature below that of the two metal pieces.
1001181 The term "welded" as used herein can refer to a process that uses high temperatures to melt and join two metal parts, which are typically the same. Such a process can refer to different types of welding, including T1G weld, metal inert gas (MIG), arc, electron beam, laser, and stir friction.
1001191 The term "deformable" as used herein can refer to an ability for a material to experience a change in shape from an original shape, such as from a force, and then substantially return to the original shape.
1001201 The term "effective mass" as used herein can refer to the mass of part of a component, or partial mass of the component. For example, a core may have a core end, and the core end may have an effective mass, or a core end mass. The mass of the core end is less than the mass of the whole core.
1001211 The term "mounted" as used herein can refer to a connection between a respective component (or subcomponent) and another component (or another subcomponent), which can be fixed, movable, direct, indirect, and analogous to engaged, coupled, disposed, etc., and can be by screw, nut/bolt, weld, and so forth.
1001221 The term "shim" as used herein can refer to a thin piece of material used in a small gap between objects. The shim can help align parts, reduce wear, and absorb tolerances between proximate components. The shim can be a precision shim.
1001231 The term "bearing" as used herein can refer to a rotary-type ball bearing that can have an inner ring independently movingly connected with an outer ring, and balls therebetween.
1001241 The term "sensor" as used herein can refer to a device that detects or measures a physical property and may record, indicate, or otherwise respond to it. The output of a sensor can be an analog or digital signal.
1001251 The term "Hall effect sensor" as used herein can refer to a sensor with respective circuitry suitable to generate a digital signal or pulse, or work as a magnetic switch latch, based on a change in magnetic field. The sensor can include a device or element having an electric current running through it, and can further be associated with an amplifier and a trigger.
1001261 The term "airflow sensor" as used herein can refer to a sensor used to detect or otherwise be able to measure (directly or indirectly) airflow.
1001271 The term "airflow sensor assembly" as used herein can refer to a device with operable connectivity between various components and subcomponents, and being useable to detect or otherwise be able to measure (directly or indirectly) airflow.
1001281 The term "circuit board" (also 'printed' circuit board) as used herein can refer to a board that mechanically supports and electrically connects electronic components using conductive tracks, pads and other features. Components (e.g., capacitors, resistors, etc.) can be soldered onto the circuit board and connected via various conductivity paths.
1001291 The term "transceiver" (also transceiver IC) as used herein can refer to a device or circuit that contains a signal transmitter and a signal receiver which are both combined and share common circuitry. The transceiver can 'translate' data for communicating via protocol requirements.

1001301 The term "bus network" as used herein can refer to the connectivity between various components, directly or indirectly. The bus network can utilize communication protocol to transmit information via any kind of variation of a physical quantity.
Protocols may be implemented by hardware, software, or a combination of both.
1001311 The term "microprocessor" as used herein can refer to a logic chip or a computer processor on a microchip. The microprocessor may have most or all central processing unit (CPU) functions.
1001321 The term "microcontroller" as used herein can refer to a CPU with additional function or structure, such as RAM, ROM, and or peripherals like 1/0 all embedded on a single chip.
1001331 The term "voltage regulator" as used herein can refer to a device or logic circuit that maintains a constant voltage level.
1001341 The term "computer readable medium" (CRM) as used herein can refer to any type of medium that can store programming for use by or in connection with an instruction execution system, apparatus, or device. The CRM may be, for example, a device, apparatus, or system based on electronic, magnetic, optical, electromagnetic, or semiconductor function. By way of further example, the CRM may include an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic or optical), a random access memory (RAM) (electronic), a read-only memory (ROM) (electronic), an erasable programmable read-only memory (EPROM, EEPROM, or Flash memory) (electronic), an optical fiber (optical), and a portable compact disc memory (CDROM, CD R/W) (optical).
1001351 The term "solid data storage" as used herein can refer to a CRM having an array of data, including one or more lookup tables (LUT).
1001361 The term "lookup table" (or LUT) as used herein can refer to a data array that may include predetermined or reference data useable for comparison. A LUT(s) can be stored in static program storage, including solid data storage.
1001371 The term "Wi-Fi module" as used herein can refer to a device or logic circuit that provides ability for a microcontroller to communicate data to a network, as well as update firmware and code inside the microcontroller.
1001381 The term "GSM module" as used herein can refer to a device or logic circuit that provides ability for a microcontroller to communicate data or signal to a Global System for Mobile communication (GSM). The microcontroller can thus initiate, for example, the sending of information in a SMS message.
1001391 The term "CAN-Bus module" as used herein can refer to a message-based protocol that allows a microcontroller to communicate with other devices, which can include industrial or large pieces of equipment associated with a respective microcontroller.
1001401 Embodiments herein pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device, with an at least one service fluid being transferable therebetween. The HX unit may include a frame; and at least one cooler coupled with the frame, the at least one cooler having an airflow-in side and a service fluid-in side.
1001411 The system may include a monitoring module coupled to the heat exchanger unit. The monitoring module may include a panel (or cover panel); an at least one sensor coupled with the cover panel; an at least one controller housing coupled with the cover panel;
and a microcontroller disposed within the controller housing and in operable communication with the at least one sensor.
1001421 The at least one sensor may include a rotating member configured to generate a system signal proportional to an amount of rotation of the rotating member. In aspects, the microcontroller may be provided with computer instructions, and may be otherwise operable, for processing the system signal.
1001431 The monitoring module may include a plurality of sensors. One or more of the plurality of sensors may be in operable communication with the microcontroller. In aspects, at least one of the plurality of sensors or the microcontroller may be powered at least partially, directly or indirectly, by rotation of the rotating member.
1001441 The at least one sensor may include a plurality of blades extending (such as generally radially) from the rotating member. The system signal may pertain to or be based on an amount of fouling associated with the airflow side of the at least one cooler.
1001451 The monitoring module may include one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module. Each may be disposed within the controller housing and may be in operable communication with the microcontroller. Accordingly, the the microcontroller may be provided with computer instructions for communicating with one or more of the solid data storage, the Wi-H module, the GSM module, and the CAN-Bus module.

1001461 The at least one service fluid comprises one of lube oil, hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and engine cooler. The heat generation device may be a diesel engine. In aspects, the heat exchanger unit may have four respective sides (and thus cubical or rectangular prism shaped). Each side may have a respective cooler mounted to the frame.
1001471 The heat exchanger unit may include a vertical axis; a frame comprising a top region, a bottom region, and a plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region of the plurality of side regions. Each of the plurality of coolers may have an outer surface and an inner surface. There may be an airflow region within the heat exchanger unit.
1001481 The heat exchanger unit may include a first set of baffles disposed therein. One or more of the first set of baffles may be configured or otherwise oriented at a first angle to the vertical axis.
1001491 The heat exchanger unit may include a second set of baffles disposed therein, each baffle of the second set of baffles configured at a second angle to the vertical axis. The heat exchanger unit may include a third set of baffles, each baffle of the third set of baffles configured at a third angle to the vertical axis. In aspects, the heat exchanger unit may include a fourth set of panels.
1001501 The first set of baffles, the second set of baffles, and the third set of baffles may have about three to about five baffles. One or more baffle of the first set of baffles, the second set of baffles, and/or the third set of baffles may include a sound absorbing material.
1001511 One or more baffles may be generally isosceles trapezoidal in shape.
On or more baffles may have mineral wool disposed therein. One or more baffles may be configured (positioned, mounted, oriented, etc.) at a respective angle in the range of about 30 to about 60 degrees.
1001521 The heat exchanger unit may include a fan mount bar; a shroud coupled to a top surface;
an aeroring; and a fan mounted to the fan mount bar. The fan may have a motor and a one or more fan blades, including in the range of about 8 to about 12. The heat exchanger unit may have an exhaust outlet.
1001531 The heat exchanger unit may have a plurality of coolers configured to permit airflow to pass therethrough. In aspects, operation of a fan may result in airflow through each of the plurality of coolers, into the airflow region, and out of the outlet. The frame of the heat exchanger unit may include a plurality of horizontal members and vertical member configured together in a manner that results in a generally cube-shaped frame.

1001541 The heat exchanger unit of the system may include other configurations, such as a frame comprising a top region, a bottom region, and plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region, and each of the plurality of coolers comprising a core welded with a tank. Each core further may include a core end having a core end mass. Each tank further may include a tank end having a tank end mass. In aspects, each core end mass may be greater than each respective tank end mass.
1001551 The heat exchanger system may include the HX unit having a frame with a top region, a bottom region, and an at least one side region. There may be at least one cooler coupled with the frame proximate to the at least one side region. The cooler may have an outer surface and an inner surface.
1001561 The system may include the use of a mount assembly for coupling a cooler to the frame of the HX unit. The mount assembly may include an elongated fastening member;
a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring, 1001571 At least one cooler may include a mounting slot. In aspects, the elongated fastening member may extend through the rigid inner ring and at least partially into the frame.
1001581 Other embodiments of the disclosure pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement (including fluid communication) with a heat generating device. There may be an at least one service fluid transferable therebetween.
The heat exchanger unit may include a frame; and at least one cooler coupled with the frame, the at least one cooler having an airflow side and a service fluid side fluidly separated from each other.
1001591 The monitored system may include a monitoring module coupled to the heat exchanger unit. The monitoring module may include a cover panel; an at least one sensor coupled with the cover panel; at least one controller housing proximate with the cover panel;
and a microcontroller mountingly disposed within the controller housing and in operable communication with the at least one sensor.
1001601 The at least one sensor may include a rotating member configured to generate a system signal proportional to an amount of rotation of the rotating member. The microcontroller may be provided with computer instructions for processing the system signal. In aspects, an amount of rotation of the rotating member maybe dependent upon an amount of fouling in the airflow side.
1001611 The monitoring module may include a plurality of sensors. One or more of the plurality of sensors may be in operable communication with the microcontroller. In aspects, at least one of the plurality of sensors or the microcontroller may be powered at least partially, directly or indirectly, by rotation of the rotating member.
1001621 The monitoring module may include one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module. Any of which may be mountingly disposed within the controller housing and may be in operable communication with the microcontroller.
Accordingly, the microcontroller may be provided with computer instructions for communicating and otherwise operating with with one or more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1001631 The at least one service fluid may be one of lube oil, hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and engine cooler. The heat generation device may be a diesel engine. The heat exchanger unit may have a plurality of sides, such as about three sides to about five sides. In aspects, there may be four sides. Any of the sides may have a respective cooler mounted to the frame proximate thereto. Any of the sides may have a respective monitoring module operably associated therewith.
1001641 The heat exchanger unit of the monitored system may include a frame having a top region, a bottom region, and plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region, and each of the plurality of coolers comprising a core welded with a tank; and a first set of baffles, each baffle of the first set of baffles configured at a first angle to an axis.
1001651 In aspects, one or more cores may have a core end having a core end mass. In aspects, one or more tanks may have a tank end having a tank end mass. In aspects, the core end mass may be greater than the tank end mass of a respective core.
1001661 The heat exchanger unit may include a second set of baffles, each baffle of the second set of baffles configured at a second angle to the axis. Any of the baffles may have a sound absorbing material therein. The first angle and/or the second angle may be in the range of about 30 degrees to about 60 degrees. The sound absorbing material may be mineral wool.

1001671 The heat exchanger unit of the system may include a frame comprising a top region, a bottom region, and one or more side regions. There may be one or more coolers coupled with the frame proximate to a respective side region. Any cooler may have a core welded with a tank.
The unit may include a first set of baffles, any of which may be configured at a first angle to an axis. Any core may include a core end having a core end mass. Any tank may have a tank end having a tank end mass. For any respective core, the core end mass may be greater than each respective tank end mass.
1001681 The heat exchanger unit may include a mount assembly associated therewith. The mount assembly may be configured for coupling a respective cooler to the frame. The mount assembly may include an elongated fastening member; a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring. The respective cooler may include at least one mounting slot, whereby the elongated fastening member may extend through the rigid inner ring and at least partially into the frame.
1001691 The heat exchanger unit may include a vertical axis; an airflow region within the heat exchanger unit; and a first set of baffles, each of the first set of baffles configured at an angle to the vertical axis.
1001701 Any of the baffles may have a sound absorbing material, such as mineral well, disposed therein (or therewith). An orientation angle of the baffle within the heat exchanger unit may be in the range of about 30 to about 60 degrees.
1001711 The heat exchanger unit of the system may include a fan mount bar extending between one of the plurality of side regions and another of the plurality of side regions; and a fan mounted to the fan mount bar. The fan may include a motor and a plurality of fan blades in the range of about 8 to about 12. The fan may include a hydraulic motor. The motor may be powered by a pressurized hydraulic fluid pressurized to a range of about 2000 to about 6000 psi. The pressurized fluid may be cooled by the heat exchanger unit.
1001721 Any respective cooler may include a weld between the tank end and the core end that may be a v-groove weld.
1001731 The heat exchanger unit may include between about one set of baffles to about four sets of baffles, any of which may include the sound absorbing material, which may include mineral wool. Baffles of the sets may have various orientation angles, including, in the range of about 30 degrees to about 60 degrees. Baffles of the sets may have various shapes, any of which may be generally isosceles trapezoidal in shape.
1001741 Embodiments of the disclosure pertain to a monitoring module for monitoring operation of a heat exchanger unit that may include a cover panel configured for direct or indirect coupling to the heat exchanger unit; one or more sensors coupled with the cover panel.
Any of the one or more sensors may have a respective rotating member with a plurality of blades extending therefrom.
1001751 The module may include a logic circuit in operable communication with the plurality of sensors, and further comprising: a microcontroller and a data storage. The microcontroller may be configured with computer instructions for performing one or more of the tasks of: acquiring a set of data from at least one of the plurality of sensors; sampling the set of data over a predetermined period of time; computing an average and a standard deviation of the set of data;
comparing the standard deviation with predetermined data; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data; and providing an indication based on a result of the comparing the set of data to the set of lookup data step.
1001761 The microcontroller may be powered at least partially, directly or indirectly, by at least one of the plurality of sensors.
1001771 The indication may be communicated to an end user by way of at least one of: a text message, an email, an audio signal, a visual indicator, and combinations thereof.
1001781 The logic circuit may include the microcontroller in operable communication with one or more of: a Wi-Fi module, a GSM module, and a CAN-Bus module. Accordingly, the microcontroller may be provided with computer instructions for communicating with one or more of: the Wi-Fi module, the GSM module, and the CAN-Bus module.
1001791 Other embodiments of the disclosure pertain to a monitoring module that may include a cover panel mountingly associated with an airflow side of the heat exchanger unit; a plurality of sensors coupled with the cover panel, each of the sensors having a respective rotating member with a plurality of blades extending therefrom; a logic circuit in operable communication with the plurality of sensors. The logic circuit may include a a microcontroller configured with computer instructions for performing one or more of the tasks of: acquiring a set of data from at least one of the plurality of sensors; sampling the set of data over a predetermined period of time of less than 120 seconds; computing an average and a standard deviation of the set of data;
comparing the standard deviation with predetermined data stored in a data storage; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data;
and providing an indication based on a result of the comparing the set of data to the set of lookup data step.
1001801 The logic circuit may include the microcontroller in operable communication with one or more of a Wi-Fi module, a GSM module, and a CAN-Bus module. Thus the microcontroller may have computer instructions programmed therein for communicating with one or more of the Wi-Fi module, the GSM module, and the CAN-Bus module.
1001811 The monitoring module rnay be operable to provide the indication as it pertains to an amount of fouling on the airflow side.
1001821 The microcontroller may be powered at least partially by at least one of the plurality of sensors.
1001831 A method for monitoring a heat exchanger unit coupling the heat exchanger unit with a heat generating device; associating a monitoring module with an airflow side of the heat exchanger unit. The monitoring module may include a cover panel configured for direct or indirect coupling to the heat exchanger unit; an at least one sensor coupled with the cover panel, the at least one sensor having a respective rotating member with a plurality of blades extending therefrom.
1001841 The logic circuit may be in operable communication with the at least one sensor. The microcontroller may have computer instructions for performing one more of the tasks of:
acquiring a set of data from the at least one sensor; sampling the set of data over a predetermined period of time; computing an average and a standard deviation; comparing the standard deviation with predetermined data stored on a data storage; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data; providing an indication based on a result of the comparing the set of data to the set of lookup data step; and performing an action based on the indication.
1001851 In aspects, the microcontroller is powered at least partially by at the at least one sensor.
The indication is communicated to an end user by way of at least one of: a text message, an email, an audio signal, display, a visual indicator, and combinations thereof.
The indication may be related to an amount of fouling present within the airflow side.
1001861 The monitoring module may include a plurality of sensors, any of which may be in operable communication with the microcontroller.
1001871 The method may include where the monitoring module may have one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module being disposed within the controller housing, one or more of which may be in operable communication with the microcontroller. Thus the microcontroller may be programmed with respective computer instructions for communicating therewith, as applicable.
1001881 The method may include the use of at least one service fluid transferable between the heat exchanger unit and the heat generation device. The service fluid may be one of lube oil, hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and engine cooler. There may be multiple service fluids transferable between the heat exchanger unit and the heat generation device.
1001891 In aspects, the generation device of the method may be a diesel engine. The heat exchanger unit may have four sides, each side having a respective cooler mounted to the frame.
1001901 The method may include the use of the heat exchanger unit having one or more of a vertical axis; a frame comprising a top region, a bottom region, and a plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region of the plurality of side regions, and each of the plurality of coolers having an outer surface and an inner surface; an airflow region within the heat exchanger unit; and a first set of baffles, each baffle of the first set of baffles configured at a first angle to the vertical ax is.
1001911 The heat exchanger unit of the method may further have a second set of baffles, one or more of which may be configured at a second angle to the vertical axis. There may be a third set of baffles, one or more of which may be configured at a third angle to the vertical axis. There may be a fourth set of baffles. Any baffle of the fourth set of baffles may be configured at a fourth angle to the vertical axis. Any of the first, second, third, and fourth angles may be in the range of about 30 degrees to about 60 degrees. Any of the sets of baffles may have about four baffles. Any of the baffles may comprise a sound absorbing material associated therewith. Any of the baffles may be generally isosceles trapezoidal in shape 1001921 The heat exchanger unit of the method may further include one or more of a fan mount bar; a shroud coupled to a top surface; an aeroring; and a fan mounted to the fan mount bar. The fan may include a motor and a plurality of fan blades in the range of about 8 to about 12. The unit may have an exhaust outlet.
1001931 The heat exchanger unit of the method may include one or more of a frame comprising a top region, a bottom region, and plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region, and each of the plurality of coolers comprising a core welded with a tank; and a first set of baffles, each baffle of the first set of baffles configured at a first angle to an axis 1001941 Any cooler of the heat exchanger unit may have a core end mass. Any cooler of the heat exchanger unit may have a tank end mass. In aspects, the core end mass may be greater than the tank end mass of any of the respective coolers.
1001951 The method may include configuring the exchanger unit with a mount assembly. The mount assembly may include an elongated fastening member; a rigid outer ring;
a rigid inner ring; a deformable ring disposed between the rigid outer ring and the inner outer ring. At least one of the plurality of coolers may include a mounting slot. In aspects, the elongated fastening member may extend through the rigid inner ring and at least partially into the frame.
1001961 The method may include the heat exchanger unit having an airflow region therein. The heat exchanger unit may include a fan mount bar extending between one of the plurality of side regions and another of the plurality of side regions. There may be a fan mounted to the fan mount bar, the fan further having a motor and a plurality of fan blades in the range of about 8 to about 12.
1001971 A respective cooler of the heat exchanger unit may have a weld between the first tank end and the core end that may be a v-groove weld.
1001981 Yet other embodiments of the disclosure pertain to a method for monitoring a heat exchanger unit that may include one or more steps of coupling the heat exchanger unit in fluid communication with a heat generating device; and associating a monitoring module with an airflow side of the heat exchanger unit 1001991 The monitoring module may include one or more of a cover panel coupled to the heat exchanger unit; a plurality of sensors, each having a respective rotating member with a plurality of blades extending therefrom; and a logic circuit in operable communication with the plurality of sensors. The logic circuit may include a microcontroller that may be programmable and programmed for performing various tasks that may include any of: acquiring a set of data from at least one of the plurality of sensors; sampling the set of data over a predetermined period of time; determining whether the set of daJa is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed; comparing the set of data to the set of lookup data; providing an indication based on a result of the comparing the set of data to the set of lookup data step; based on the indication, performing a cleaning action on the heat exchanger unit.
1002001 The monitoring module may include one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module being disposed within the controller housing and in operable communication with the microcontroller. Accordingly the microcontroller may be provided with computer instructions for communicating with one or more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1002011 The method may include an at least one service fluid transferable between the heat exchanger unit and the heat generation device. The service fluid may be one of lube oil, hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and engine cooler.
1002021 In aspects, the heat generation device may be a diesel engine. The heat exchanger unit may include four sides, each side having a respective cooler mounted to the frame.
1002031 The heat exchanger unit of the method may include a vertical axis; a frame comprising a top region, a bottom region, and a plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region of the plurality of side regions, and each of the plurality of coolers having an outer surface and an inner surface;
an airflow region within the heat exchanger unit; and a first set of baffles, each baffle of the first set of baffles configured at a first angle to the vertical axis.
1002041 The heat exchanger unit may further include a second set of baffles, each baffle of the second set of baffles configured at a second angle to the vertical axis. There may be a third set of baffles, each baffle of the third set of baffles configured at a third angle to the vertical axis.
Any of the sets of baffles may have between about 1 to about 8 baffles. In aspects, any of the sets of baffles may have about four baffles. Any of the baffles may include a sound absorbing material.
1002051 The heat exchanger unit may include any of a fan mount bar; a shroud coupled to a top surface; an acroring; and a fan mounted to the fan mount bar. The fan may have a motor and a plurality of fan blades in the range of about 8 to about 12. There may be an exhaust outlet.
1002061 Embodiments of the disclosure pertain to a business method (or a method of doing business) that may include one or more steps of: entering into a transaction with a first recipient;
per terms of the transaction, providing a monitoring module for a heat exchanger unit; operably associating the monitoring module with the heat exchanger unit, the monitoring module being operable to monitor a fouling condition of the heat exchanger unit; receiving an indication from the monitoring module related to the fouling condition; and performing a cleaning action of the heat exchanger unit upon based on the indication.
1002071 In aspects, the transaction may have one or more terms related to equipment purchase, installation, software license, data sharing, cleaning service, and combinations thereof.
1002081 The business method may pertain to use of the monitoring module having a plurality of sensors mounted proximate to an airflow side of the heat exchanger unit, one or more of the sensors having a respective rotating member with a plurality of blades extending therefrom.
There may be a logic circuit in operable communication with the plurality of sensors. The logic circuit may include a microcontroller and a data storage. The microcontroller may be configured with computer instructions for performing one or more tasks of: acquiring a set of data from at least one of the plurality of sensors; sampling the set of data over a predetermined period of time, and computing an average and a standard deviation; comparing the standard deviation with predetermined data; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data; and providing the indication based on a result of the comparing the set of data to the set of lookup data step.
1002091 In aspects, the transaction may pertain to a one-time or ongoing fee associated with the use and operation of the monitoring module. The method may include providing data acquired by the monitoring module to the first recipient. The method may include providing an incentive to the recipient when the transaction pertains to at least two of: equipment purchase, installation, software license, data sharing, and cleaning service.
1002101 The method may include, per terms of the transaction, performing at least one of:
coupling the heat exchanger unit in fluid communication with a heat generating device, and associating the monitoring module with an airflow side of the heat exchanger unit.
1002111 The monitoring module of the method may have one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module being disposed within the controller housing and in operable communication with the microcontroller. The microcontroller may be provided with computer instructions for communicating with one or more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1002121 There may be an at least one service fluid if transferable between the heat exchanger unit and a heat generation device coupled in fluid communication therewith, and wherein the at least one service fluid comprises one of lube oil, hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and engine cooler.
1002131 In aspects, the heat generation device may be a diesel engine. The heat exchanger unit may include four sides. One or more sides may have a respective cooler mounted to the frame.
1002141 The heat exchanger unit of the method may include a vertical axis; a frame comprising a top region, a bottom region, and a plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region of the plurality of side regions, and each of the plurality of coolers having an outer surface and an inner surface;
an airflow region within the heat exchanger unit; and a first set of baffles, each baffle of the first set of baffles configured at a first angle to the vertical axis.
1002151 The heat exchanger unit may further include a second set of baffles, each baffle of the second set of baffles configured at a second angle to the vertical axis; and a third set of baffles, each baffle of the third set of baffles configured at a third angle to the vertical axis. The first set of baffles, the second set of baffles, and the third set of baffles may each have about four baffles.
Any of the baffles may include a sound absorbing material, such as mineral wool.
1002161 The heat exchanger unit of the method may include a fan mount bar; a shroud coupled to a top surface; an aeroring; and a fan mounted to the fan mount bar. The fan may have a motor and a plurality of fan blades in the range of about 8 to about 12, and an exhaust outlet.

1002171 The heat exchanger unit may have at least one cooler having a core welded with a tank.
The more may have a core end mass. The tank may have a tank end mass. In aspects, the core end mass may be greater than the tank end mass, of any respective core.
1002181 The heat exchanger unit may include the use of one or more mount assemblies. The mount assembly may be configured for coupling at least one cooler to the frame. The mount assembly may include: an elongated fastening member; a rigid outer ring; a rigid inner ring; a deformable ring disposed between the rigid outer ring and the inner outer ring. There may be at least one cooler having a mounting slot. The elongated fastening member may extend through the rigid inner ring and at least partially into the frame.
1002191 Embodiments herein pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device, with an at least one service fluid being transferable therebetween, the heat exchanger unit further having a frame.
There may be at least one cooler coupled with the frame, the at least one cooler having an airflow side and a service fluid side.
1002201 The system may include a controller housing coupled to the heat exchanger unit; a primary microcontroller disposed within the controller housing; and an at least one sensor assembly in operable communication with the primary microcontroller.
1002211 The at least one sensor assembly may include a mounting frame coupled to the heat exchanger unit; a support platform fixedly connected with the mounting frame, and may further have a platform hollow and a top platform surface; a shaft disposed or otherwise positioned in the platform hollow; a circuit board disposed on the top platform surface, and may be configured with an operable logic circuit that may include a secondary microcontroller, a Hall effect sensor, a transceiver, and may further have sufficient wiring, power, programmable instructions for communicating with (or providing the ability for communication to occur with) the primary microcontroller.
1002221 The sensor assembly may include an inner sensor housing disposed around the shaft. The inner sensor housing may be configured to extend out and around the circuit board and the support platform. There may be an at least one magnet coupled with the inner sensor housing.
There may be a rotating member configured to generate, directly or indirectly, a system signal proportional to an amount of rotation of the rotating member. In aspects, the primary microcontroller is provided with computer instructions for processing the system signal.

1002231 The system may include a plurality of sensor assemblies, each of identical nature, and with each of the plurality of sensor assemblies having a respective operable logic circuit in operable communication with the primary microcontroller.
1002241 The controller housing may include one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module being disposed therein, and any of which may be in operable communication with the primary microcontroller. Thus, the primary microcontroller may be provided with computer instructions for communicating with one or more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1002251 The heat exchanger unit of the system may include at least one baffle configured Or otherwise oriented at an angle to an axis in the range of about 30 degrees to about 60 degrees.
The at least one baffle may include a sound absorbing material.
1002261 The cooler may have a core welded with a tank. The core may have a core end having a core end mass that may be associated with a core end volume of material. The tank may have a tank end mass that may be associated with a first tank end volume of material.
In aspects, the core end mass may be greater than each respective tank end mass.
1002271 The heat exchanger unit of the system may include a mount assembly for coupling the at least one cooler to the frame. The mount assembly may include an elongated fastening member;
a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring. The at least one cooler may include a mounting slot.
The elongated fastening member may extend through the rigid inner ring, through the mounting slot, and at least partially into at least one of the frame, an associated vertical member, an associated horizontal member, and combinations thereof.
1002281 Embodiments herein pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device, with an at least one service fluid being transferable therebetween. The heat exchanger unit may further include: a frame; and an at least one cooler coupled with the frame, the at least one cooler having an airflow side and a service fluid side fluidly separated from each other. There may be a primary microcontroller operably associated with the heat exchanger unit. There may be an at least one sensor assembly in operable communication with the primary microcontroller.
1002291 The at least one sensor assembly may include a mounting frame coupled to the heat exchanger unit; a protected logic circuit comprising a secondary microcontroller and a Hall effect sensor. There may be sufficient wiring, power, programmable instructions and so forth whereby the circuit board logic circuit and the primary microcontroller may be in operable communication with each other.
1002301 The sensor assembly may include a rotating member rotatably disposed around a shaft, the rotating member being configured to generate or cause, directly or indirectly, a system signal proportional to an amount of rotation of the rotating member. There may be at least one magnet associated with the rotating member.
1002311 In aspects, the primary microcontroller may be provided with computer instructions for processing the system signal. The at least one service fluid may be one of lube oil, hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and engine cooler.
There may be multiple service fluids. The heat generation device may be a diesel engine. The sensor assembly may include: a support platform fixedly connected with the mounting frame, the support platform further having a platform hollow and a top platform surface. The shaft may be movably, such as rotatably, disposed in the platform hollow.
1002321 The primary microcontroller may be configured with computer instructions suitable for the execution or performing the tasks of: acquiring a set of data from the at least one sensor assembly; sampling the set of data over a predetermined period of time;
computing an average and a standard deviation of the set of data; comparing the standard deviation with predetermined data; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data; and providing an indication based on a result of the comparing the set of data to the set of lookup data step.
1002331 The heat exchanger unit may have at least one inner baffle. There may be a first set of baffles mounted at a first angle to a vertical axis. One or more of the baffles may include a sound absorbing material.
1002341 The at least one cooler may include a first tank end welded to a core end. A mass of a first tank end volume may be less than a core end mass of a core end volume.
In aspects, there may be a weld between the first tank end and the core end. The weld may be a v-groove weld.
1002351 The heat exchanger unit may include a mount assembly for coupling the at least one cooler to the frame. The mount may include an elongated fastening member; a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring. The at least one cooler may include a mounting slot. The rigid outer ring, the rigid inner ring, and the deformable ring may be disposed within the mounting slot. The elongated fastening member may extend through the rigid inner ring and at least partially into the frame.
1002361 Embodiments of the disclosure pertain to a monitored heat exchanger system that may include a heat exchanger unit in operable engagement with a heat generating device. There may be an at least one service fluid being transferable therebetween. The heat exchanger unit may include a frame; and an at least one cooler coupled with the frame. The at least one cooler may have an airflow side and a service fluid side fluidly separated from each other.
1002371 There may be a controller housing associated with the heat exchanger unit. There may be a primary microcontroller disposed within the controller housing. There may be an at least one sensor assembly coupled with the heat exchanger unit. The primary microcontroller may be operable coupled with the at least one sensor assembly. The at least one sensor assembly may include a rotating member configured to generate, such as directly or indirectly, a system signal proportional to an amount of rotation of the rotating member. The primary microcontroller may be provided with computer instructions for processing the system signal. The amount of rotation of the rotating member may be dependent upon an amount of fouling in the airflow side.
1002381 The system may further include a plurality of sensor assemblies. Any or all of the plurality of sensors may be in operable communication with the primary microcontroller. There may be at least one of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module disposed within the controller housing and in operable communication with the primary microcontroller. As such the primary microcontroller may be provided with computer instructions for communicating with one or more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1002391 The at least one sensor assembly may include: a mounting frame coupled to the heat exchanger unit; and a support platform fixedly connected with the mounting frame. The support platform may further include a platform hollow and a top platform surface.
There may be a shaft movably disposed in the platform hollow. There may be a circuit board disposed on the top platform surface. The circuit board may be configured with an operable logic circuit further comprising a secondary microcontroller and a Hall effect sensor. There may be sufficient wiring, power, programmable instructions to provide for communicating between the secondary microcontroller with the primary microcontroller.
1002401 There may be an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform. There may be an at least one magnet coupled with the inner sensor housing.
1002411 In aspects, the heat exchanger unit may include one or more coolers having a core welded with a tank. The core may have a core end with a core end mass. The tank may have a tank end with a tank end mass. The core end mass may be greater than the tank end mass.
1002421 The heat exchanger unit may include at least one baffle having a sound absorbing material associated therewith.
1002431 The heat exchanger unit may include an at least one mount assembly configured for coupling a respective cooler to the frame. The mount assembly may include an elongated fastening member; a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring.
1002441 The heat exchanger may include a tubular fan mount bar; a shroud; and an aeroring.
There may be a fan mount coupled to the tubular fan mount bar. There may be a fan coupled to the fan mount. The fan may further include a motor. In aspects the motor may be a hydraulic motor that may be powered by a pressurized hydraulic fluid pressurized to a range of about 2000 to about 6000 psi.
1002451 Embodiments herein pertain to a monitoring module for monitoring operation of a heat exchanger unit that may include one or more sensor assemblies coupled therewith. At least one of the sensor assemblies may include a mounting frame configured for coupling to the heat exchanger unit. There may be a support platform connected with the mounting frame. The support platform may further include a platform hollow and a top platform surface. There may be a shaft rotatably disposed in the platform hollow.
1002461 The sensor assembly may include a circuit board, which may be disposed or otherwise positioned on the top platform surface. The circuit board may be configured with an operable logic circuit that may include a secondary microcontroller and a Hall effect sensor. The logic circuit may further include a transceiver. There may be sufficient wiring, power, programmable instructions for communicating (or for providing the ability to communicate) with a primary in 1002471 The sensor assembly may include an inner sensor housing disposed around the shaft. The inner sensor housing may be configured to extend out and around the circuit board and the support platform. There may be a first magnet coupled with the inner sensor housing. There may be a second magnet coupled with the inner sensor housing. The assembly may include a rotating member configured to rotate. Upon rotation of the rotating member, at least the first magnet may disrupt a magnetic field of the Hall effect sensor. The magnetic disruption may result in the generation of a system signal. The system signal may be proportional to an amount of rotation of the rotating member, and/or the system signal may be proportional to an amount of fouling of the heat exchanger unit.
1002481 There may be a monitoring logic circuit in operable communication with at least one of the plurality of sensors. The monitoring logic circuit may include a primary microcontroller and a data storage. The primary microcontroller may be configured with computer instructions for performing one or more tasks of: acquiring a set of data from at least one of the plurality of sensors; sampling the set of data over a predetermined period of time;
computing an average and a standard deviation of the set of data; comparing the standard deviation with predetermined data; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data; and providing an indication based on a result of the comparing the set of data to the set of lookup data step.
1002491 In aspects, the indication may be communicated to an end user by way of at least one of:
a text message, an email, an audio signal, a visual indicator, and combinations thereof 1002501 The monitoring logic circuit may further include the primary microcontroller in operable communication with one or more of a Wi-Fi module, a GSM module, and a CAN-Bus module.
The primary microcontroller may be provided with computer instructions for communicating with any of the Wi-Fi module, the GSM module, and the CAN-Bus module.
1002511 Yet other embodiments of the disclosure pertain to a method for monitoring a heat exchanger unit that may include one or more steps of: coupling the heat exchanger unit with a heat generating device; and associating a monitoring module with an airflow side of the heat exchanger unit. The monitoring module may include a sensor assembly that further includes a mounting frame; a support platform coupled with the mounting frame, the support platform further comprising, a platform hollow and a top platform surface; a shaft rotatably disposed in the platform hollow; a circuit board disposed proximate to the top platform surface, the circuit board being configured with a secondary microcontroller, a Hall effect sensor, a transceiver, and sufficient wiring, power, programmable instructions for communicating (or providing the ability for communicating with a primary microcontroller; an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform; an at least one magnet coupled with the inner sensor housing; and a rotating member configured to rotate. Upon rotation of the rotating member, the at least one magnet may be configured in manner whereby a magnetic field of the Hall effect sensor is effected or otherwise disrupted, thereby generating (or causing to be generated) a system signal. The system signal may be proportional to one of an amount of rotation of the rotating member, an amount of fouling of the heat exchanger unit, or both.
1002521 In aspects, the primary microcontroller may be configured with computer instructions for executed of or performing the tasks of at least one or more of: acquiring a set of data from the sensor assembly; comparing the set of data to a set of lookup data; and providing an indication based on a result of the comparing the set of data to the set of lookup data step. The method may further include the step of performing an action based on the indication.
1002531 The method may pertain to the heat exchanger unit having a vertical axis; a frame comprising a top region, a bottom region, and a plurality of side regions; a plurality of coolers, each of the plurality of coolers coupled with the frame proximate to a respective side region of the plurality of side regions, and each of the plurality of coolers having an outer surface and an inner surface; an airflow region within the heat exchanger unit; and a first set of baffles, each baffle of the first set of baffles configured at a first angle to the vertical axis. Any of the baffles may include a sound absorbing material. The sound absorbing material may be mineral wool.
The first angle may be in the range of about 30 degrees to about 60 degrees.
1002541 The method may pertain to the heat exchanger unit having one or more of a fan mount bar; a shroud; an aeroring; and a fan mounted to the fan mount bar. The fan may have a plurality of fan blades in the range of about 8 to about 12.
1002551 The method may pertain to the heat exchanger unit having a frame with an at least one cooler coupled therewith. The at least one cooler further may include a core welded with a tank.

The core may include a core end having a core end mass. The tank may include a tank end having a tank end mass. The core end mass may be greater than the tank end mass.
1002561 The method may pertain to the heat exchanger unit having at least one a mount assembly configured for coupling the at least one cooler to the frame. The mount assembly may include an elongated fastening member; a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring. The at least one cooler may include a mounting slot. The elongated fastening member may extend through the rigid inner ring and at least partially into the frame.
1002571 Yet other embodiments of the disclosure pertain to a method for monitoring_ a heat exchanger unit that may include one or more steps of coupling the heat exchanger unit in fluid communication with a heat generating device; associating a monitoring module with an airflow side of the heat exchanger unit; and based on an indication, performing a cleaning action on the heat exchanger unit.
1002581 In aspects, monitoring module may include one or more sensor assemblies. Any sensor assembly may have a respective rotating member configured with a plurality of blades extending therefrom. The rotating member may be operably associated with a respective secondary mi crocontroller.
1002591 The module may include a primary microcontroller in operable communication with any respective secondary microcontroller. The primary microcontroller may be operable with computer instructions for performing any of the tasks of: acquiring a set of data from at least one of the plurality of sensors; sampling the set of data over a predetermined period of time;
determining whether the set of data is acceptable within a defined parameter;
determining whether a first lookup table comprising a set of lookup data has been completed; comparing the set of data to the set of lookup data; and providing an indication based on a result of the comparing the set of data to the set of lookup data step; and 1002601 The monitoring module may include one or more of a solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module, any of which may be in operable communication with the primary microcontroller. The primary microcontroller may be provided with computer instructions for communicating with one or more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.

1002611 Still other embodiments pertain to a method of doing business that may in include the steps of entering into a transaction with a first recipient; per terms of the transaction, providing a monitoring module for a heat exchanger unit, operably associating the monitoring module with the heat exchanger unit, the monitoring module being operable to monitor a fouling condition of the heat exchanger unit, the monitoring module including a sensor assembly in operable communication with a primary microcontroller; receiving an indication from the monitoring module related to the fouling condition; and performing a cleaning action of the heat exchanger unit upon based on the indication. In aspects, the transaction may include terms pertaining to at least one of: equipment purchase, installation, software license, data sharing, cleaning service, and combinations thereof.
1002621 The sensor assembly may be coupled with the heat exchanger unit. The sensor assembly may include a rotating member configured with one or more blades extending therefrom. There may be a monitoring logic circuit that includes the primary microcontroller, and may further include a data storage. The primary microcontroller may be configured with computer instructions for performing one or more tasks of: acquiring a set of data from the at least one sensor; sampling the set of data over a predetermined period of time, and computing an average and a standard deviation; comparing the standard deviation with predetermined data; determining whether the set of data is acceptable within a defined parameter; determining whether a first lookup table comprising a set of lookup data has been completed, and creating the first lookup table using an averaging method if it has not; comparing the set of data to the set of lookup data;
and providing the indication based on a result of the comparing the set of data to the set of lookup data step.
1002631 The transaction may include a one-time or ongoing fee associated with the use and operation of the monitoring module. The method may further include providing data acquired to the first recipient.
1002641 Embodiments of the disclosure pertain to an airflow sensor assembly that may include: a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening; a mounting frame disposed proximate to the casing bottom side, the mounting frame further comprising a central segment; a guard disposed proximate to the casing topside; a support platform coupled with the central segment, and further comprising:
a platform hollow; and a top platform surface; a shaft centrally positioned within the casing opening and further disposed in the platform hollow; a plurality of assembly screws disposed through the casing, the mounting frame, and the guard; a plurality of fasteners configured for connecting with the plurality of assembly screws; a first bearing disposed around the shaft and proximate the support platform; a second bearing disposed around the shaft and on top of the first bearing, and proximate the support platform; a circuit board positioned onto the top platform surface, the circuit board being configured with an operable logic circuit further comprising a secondary microcontroller, a Hall effect sensor, and a transceiver; a first lock nut threadingly engaged around the shaft in an amount sufficient to engage the second bearing;
an inner sensor housing disposed around the, shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform; an at least one magnet coupled with the inner sensor housing; a rotating member comprising a plurality of blades, and the rotating member being disposed around the shaft; a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member.
1002651 In operation, airflow may impact the plurality of blades thereby causing the rotating member to rotate, and resultantly causing the shaft to rotate. The shaft may cause to rotate, directly or indirectly, the at least one magnet periodically into proximity with the Hall effect sensor. A digital signal may be generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet passing in proximity thereby.
1002661 Embodiments herein pertain to an airflow sensor assembly for a monitored heat exchanger system that may include a mounting frame configured for coupling the assembly with the heat exchanger unit, the mounting frame further having a central segment.
There may be a support platform coupled with the central segment. The support platform may include a plat form hollow; and a top platform surface.
1002671 The sensor assembly may include a shaft disposed in the platform hollow. There may be a first bearing disposed around the shaft and proximate the support platform.
There may be a circuit board positioned onto the top platform surface. The circuit board may be configured with an operable sensor logic circuit further that may include a secondary microcontroller and a Hall effect sensor. The assembly may include a rotating member having one or more blades. The rotating member may be disposed around the shaft.
1002681 The sensor assembly may include a lock nut threadingly engaged around the shaft sufficiently enough to engage a rotating member mounting ring.

1002691 In operation, as airflow impacts the one or more blades, the rotating member may rotate in response thereto. This may resultantly cause the shaft to rotate. As the shaft rotates, the at least one magnet may periodically come into proximity with the Hall effect sensor. A digital signal may be generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.
1002701 Still other embodiments of the disclosure pertain to a sensor assembly comprising having a mounting frame further comprising a central segment; a support platform coupled with the central segment, and further comprising: a platform hollow; and a top platform surface; a shaft disposed in the platform hollow; a first bearing disposed around the shaft, and also disposed at least partially in the platform hollow.
1002711 The sensor assembly may include a circuit board positioned onto the top platform surface. The circuit board may be configured with a secondary microcontroller and a Hall effect sensor. There may be a first lock nut threadingly engaged around the shaft sufficiently enough to exert a holding pressure against the first bearing. There may be an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform. There may be a rotating member comprising a plurality of blades and a rotating member mounting ring, the rotating member being disposed around the shaft and on top of the inner sensor housing. There may be a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring.
1002721 The sensor assembly may include a casing further having a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening. There may be a guard disposed proximate to the casing topside. There may be a plurality of assembly screws disposed through the casing, the mounting frame, and the guard. There may be a plurality of fasteners configured for connecting with the plurality of assembly screws.
There may be a second bearing disposed around the shaft and on top of the first bearing.
1002731 The sensor assembly may include a shim disposed around the shaft and between the first bearing and the second bearing. The shim may be a precision shim. There may be support plate disposed on top of the second bearing. The support plate may be tri-wing shaped. There may be an at least one binding screw mated with a respective binding post coupled together, whereby the support plate, the circuit board, the support platform, and the central segment may be resultantly coupled together.

1002741 Yet other embodiments of the disclosure pertain to a sensor assembly that may include a mounting frame; and a cylindrical support platform coupled with the mounting frame. The support platform may include a platform hollow; and a top platform surface.
The assembly may include a circuit board positioned or otherwise mounted onto the top platform surface. The circuit board may be configured with a secondary microcontroller and a Hall effect sensor.
There may be an inner sensor housing configured to extend out and around the circuit board and the support platform. There may be a first magnet coupled to an underside of the inner sensor housing. There may be a rotating member configured with a plurality of blades and a rotating member mounting ring. The rotating member may be proximately disposed on top of the inner sensor housing.
1002751 The sensor assembly may include a shaft disposed in the platform hollow. There may be a first bearing disposed around the shaft, and also disposed at least partially in the platform hollow. There may be a first lock nut threadingly engaged around the shaft sufficiently enough to exert a holding pressure against the first bearing. There may be a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring. The rotating member mounting ring may be disposed around the shaft.
1002761 In operation, airflow may impact the plurality of blades thereby causing the rotating member to rotate. This may resultantly cause the shaft to rotate. As the shaft rotates the at least one magnet may periodically come into proximity with the Hall effect sensor. A
digital signal may be generated based on a change in a disruption of magnetic field of the Hall effect sensor by the at least one magnet as it passes thereby.
1002771 The sensor assembly may include a second magnet coupled to the underside of the inner sensor housing. The first magnet may be oriented in a N/S pole orientation, and the second magnet may be oriented in a S/N pole orientation, or vice versa. In aspects, a first digital signal may be generated based on a change in a magnetic field of the Hall effect sensor caused by the first magnet. A second digital signal may be generated based on a change in a magnetic field of the Hall effect sensor caused by the second magnet.
1002781 Referring now to Figures 2A and 2B together, a side view of a heat exchanger unit coupled with a heat generation device, and an isometric view of a frame of the heat exchanger unit, respectively, in accordance with embodiments disclosed herein, are shown.
Embodiments herein apply to a heat exchanger unit that may be an inclusive assembly of a number of components and subcomponents. The heat exchanger unit 200 may include a solid integral frame (or skeletal frame) or may be a frame 202 that includes a number of elements arranged and coupled together, such as a plurality of horizontal elements 250 and a plurality of vertical elements 251.
1002791 Although the shape of the frame 202 need not be limited, Figure 2B
illustrates a generally cubical shape (i.e., four side regions, a top region, and a bottom region) that results from the horizontal elements 250 and the vertical elements 251 being connected at various corners and generally perpendicular to one another. Other shapes of the frame 202 could include cylindrical, hexagonal, pyramidal, and so forth. As the shape of the frame 202 may vary, so may the shape of frame elements 250, 251. It is within the scope of the disclosure that heat exchanger unit 200 may have a single side (or region), and thus a single frame side.
1002801 The frame 202 may include additional frame support plates, which may be suitable for further coupling elements 250 and 251 together, as well as providing additional surface area or contact points for which other components may be coupled therewith. One or more frame support plates 252a may have a generally vertical orientation, whereas one or more frame support plates 252b may have a generally horizontal orientation. One or more frame support plates 252 (or 252a, b etc.) may include a support plate slot or groove 253.
1002811 The horizontal or vertical members 250, 251 may include one or more core support mount slots 282, whereby a radiator core (or 'core') 206 may be coupled to the frame 202 via therewith. There may be a plurality of such slots 282 configured and arranged in a manner (of respective members 250 or 251) whereby a plurality of cores 206 may be coupled therewith.
One or more coolers (comprising a respective core 206) may be coupled to the frame with respective mount assemblies (e.g., 1000, 1000a Figures 5A-5E). One or more cores 206 may be associated with and proximate to a respective protective grate 248, which may be useful for protecting fins of the core 206.
1002821 The frame 202 may include yet other additional support or structural elements, such as one or more frame support bars 254. The support bar(s) 254 may be coupled between various elements 250, 251, such as in a horizontal, vertical, or diagonal manner. The support bars 254 may be arranged in a 'turnbuckle' configuration. The support bar(s) 254 may be coupled to elements in a known manner, such as rivet, weld, nut-and-bolt, etc. The bars 254 may be tubular in shape, which may help improve airflow and reduce pressure drop thereacross.

1002831 The frame 202 may also include a top plate 255, which may have a top plate opening 256. The top plate opening 256 may be of a shape and size suitable for accommodating airflow therethrough. The HX unit 200 may include a fan system 257. The fan system 257 may include related subcomponents, such as a fan 208 that may be understood to include a rotating member with a plurality of fan blades 211 extending therefrom. The fan 208 may be a Multi-Wing fan from Multi-Wing International or a Horton fan.
1002841 There may be in the range of about 4 to about 16 blades 210 attached in a generally symmetrical manner. The blades 211 may be oriented at a blade angle to the horizontal axis 226 in the range of about 10 degrees to about 50 degrees. The angle of blades 211 may be adjusted to promote optimal and efficient cooling of the HX unit 200.
1002851 The blades 211 may have an effective blade diameter in the range of about 10 inches to about 100 inches. The fan 208 may be operable by way of a suitable driver, such as a fan motor 212, which may be hydraulic, electrical, gas-powered, etc. The fan motor 212 may receive power through various power cords, conduits (e.g., conduit and cabling 258), etc., as would be apparent to one of skill in the art. The conduits 258 may be configured for the transfer of pressurized hydraulic fluid to and from the motor 212. As such, pressurized hydraulic fluid may be used to power the motor 212. The pressure of the hydraulic fluid may be in the range of about 2,000 psi to about 6,000 psi. Hydraulic fluid may exit the motor 212, and be cooled via the HX
unit 200, repressurized, and recirculated back to the motor 212.
1002861 The fan 208 may operate in the range of about 200 rpm to about 1200 rpm. The fan 208 may operate in a manner to provide airflow in the range of about 10,000 cfm to about 200,000 cfm. The originating noise of the fan 208 may be the range of about 70 dB's to about 120 dB's.
The frequency of noise from the fan 208 may be in the range of about 20 hz to about 20,000 hz.
1002871 The frame 202 may include a fan rock guard mount 210, which may be used for the coupling of a fan rock guard 247 thereto. The frame 202 may include a fan mount plate 249.
The fan mount plate 249 may include a generally planar surface for coupling with respective fan mounts of the fan 208. The fan mount plate 249 may be connected to a fan mount bar 209. The mount bar 209 may be a rigid bar or beam that extends from one side 259a of the HX unit 200 to another side 259b. The mount bar 209 may be generally cylindrical or tubular shaped, and may be integral to the frame 202 or coupled therewith. In aspects, the bar 209 may be welded to the frame 202 (such as to horizontal members 250 a,b ¨ see Figure 6A).

1002881 The fan mount bar 209 may be suitable to provide a synergistic effect of sufficient strength for supporting the fan 208, as well as have smooth surfaces that reduce noise as a result of a decrease in a pressure variation from air flowing over surface area of the bar 209. The fan 208 may have a drive that extends downwardly through fan motor slot 249a.
1002891 The fan system 257 may include a fan shroud 213, which may be generally annular. The fan shroud 213 may be coupled to the frame 202 via connection with the top plate 255. The rock guard 247 may be coupled to the shroud 213. The shroud 213 may include one or more lateral openings 260 to accommodate the passing of the mount bar 209 therethrough. The fan 208 may have a central rotational axis around the vertical axis 227. The shroud 213 may be positioned with respect to the central rotational axis such that fan blades 211 may be extended within desired manufacturing tolerances whereby a clearance exists between the fan blades 211 and a shroud inner surface 213a. The shroud 213 may be a unitary piece or the combination of multiple pieces. The size of the shroud 213, including its height and diameter may be as desired to accommodate airflow through and out of the HX unit 200.
1002901 The shroud 213 may be proximate to an aeroring (223, Figure 2C). The aeroring (223) may be annular in nature, and have a ring cross-section that may have a radius of curvature.
Thus, the aeroring (223) may have a rounded surface that may aid in improving airflow and reducing pressure in and around the fan system 257. Without the aeroring (223), eddies and other undesired airflow may occur in corners of the top of the frame 202.
1002911 The configuration of the shroud and aeroring may provide added ability for further streamlining airflow, which may beneficially reduce overall power requirements.
1002921 The fan system 257 can be operable to draw in and direct the flow of air 216. The air 216 may be drawn through the sides of the HX unit 200 (and respective cores, which may then be used to cool one or more utility fluids F) and out as heated exhaust 218. The benefit of such a configuration is the ability to provide cooling in parallel, versus series, in a series configuration (i.e., a typical horizontal orientation ¨ see Figure IC), the airflow becomes progressively hotter as it passes through each cooling circuit, resulting in a loss in cooling efficiency. This can be especially problematic where ambient air temperature is usually hotter, like Texas and Oklahoma.

1002931 Utility fluid F (or multiple F's) may include by way of example, lube oil, jacket water, turbo (such as for an engine), transmission fluid (such as for a pump), and hydraulic fluid (such as for fan drive 212).
1002941 One of skill in the art would appreciate that airflow through the core 206 may be generally in a path parallel to horizontal axis 226. In an analogous manner, the fan 208 may have an axis of rotation generally parallel to vertical axis 227. In aspects, airflow through the core 206 may be generally perpendicular to the fan 208 axis of rotation.
Accordingly, airflow through the HX unit 200 may be transitioned from (approximately) horizontal to vertical as the airflow moves through the core 206 and out the fan exhaust 218.
1002951 As such, by way of example, utility fluid F1 may be transferred from a heat generating device 203 at a hot temperature into an HX unit inlet 278, cooled with airflow via core 206, and transferred out of an HX unit outlet 284 back to the HGD 203 at a cooler temperature. While not meant to be limited, HGD 203 may be an engine, a genset, a motor, a pump, or other comparable equipment that operates in a manner whereby a utility fluid is heated.
1002961 There may be one or more cores 206. A 'cooler' or 'cooling circuit' may include one or more cores 206. The HX unit 200 may have between about 1 to about 8 cooling circuits, which each may be configured for cooling in parallel to each other.
1002971 Referring now to Figures 5A, 5B, and 5C together, a close-up view of a radiator core mounted to a frame of a heat exchanger unit, a component breakout view of a flexible mount assembly, and a partial side cross-sectional view of a flexible mount assembly used with a bracket and a frame of a heat exchanger unit, respectively, in accordance with embodiments disclosed herein, are shown.
1002981 Any cooler 204 (or core 206) of the disclosure may be mounted to a frame 202 with a flexible mount assembly 1000. The flexible mount 1000 provides for the ability to have one or more degrees of movement between the core(s) 206 and the frame 202, such as movement that may be caused by thermal expansion of the core 206. As shown, the mount assembly 1000 includes various components, including a bolt 1002 with elongated member or shaft 1001, a first washer 1004, a top plate 1006, an outer rigid ring 1008, an inner rigid (spacer) ring 1012, and a deformable ring 1010, and a bottom (or back) plate 1014 (with plate slot 1014a). Although not shown here, the flexible mount assembly 1000 may be coupled to the frame 202 (or also vertical member 251 and/or horizontal member 250) via a nut plate or threaded receptacle.

1002991 The core 206 may have various structure configured for coupling to the frame 202. For example, there may be one or more core mounts or core mount brackets 287, which may each have one or more core mount slots 288. The bracket 287 may be an integral piece of the core 206 formed at the time of manufacture, or may be connected therewith, such as via a welding process. In addition or alternative, there may be a bracket 287 coupled with a tank 277 of a cooler (204).
1003001 The OD of the outer rigid ring 1008, and ID's of bottom plate slot 1014a and core mount slot 288 may be substantially equivalent, or to the point where ring 1008 may fit (including with tight tolerance fit) within one or both of the bottom plate slot 1014a and core mount slot 288.
1003011 Outer ring 1008 may have an ID configured or otherwise sized in a manner whereby the deformable ring 1010 may fit therein. Similarly the deformable ring 1010 may have an ID
(defined by the presence or ring slot 1010a) configured or otherwise sized in a manner whereby the inner rigid ring 1012 may fit therein. And each of the inner rigid ring 1012, the top plate 106, the washer 1004, and a core mount slot 282 may have a respective slot or orifice size configured to receive a bolt shaft 1002a, including with tight tolerance fit.
The mount assembly 1000 may be matable with a mount slot 282a of a respective member 250 and/or 251.
1003021 The deformable ring 1010 may have a generally cylindrical shape, with the ring slot 1010a. The ring slot 1010a may be concentric with respect to the ring 1010 (e.g., see Figure 5E), or may be eccentric. The clearance between the top plate 1006 and the bottom plate 1014 may accommodate movement of the mount 287, which may result from thermal expansion or contraction of the core 206.
1003031 The deformable ring 1010 may be of such a material that the movement in one or more vectors may be accommodated (such as laterally and axially, and so forth). As shown in Figure 5C, the mount 287 may move back and forth along a path of the directional arrow. In aspects the deformable ring 1010 may be a rubbery material, such as neoprene. The deformable ring 1010 may have the characteristic of having an original shape, being deformed as a result of a force, and then returning (substantially or even exactly) to the original shape. The deformable ring 1010 may have excellent chemical stability and maintain flexibility over a wide temperature range. The force may be that which is incurred as a result of thermal expansion of the core 206, and thus movement of mount 287.

1003041 Referring now to Figures 5D, 5E, and 5F together, a component breakout view of a mount assembly, a side cross-sectional view of a mount assembly used with a bracket and a frame of a heat exchanger unit, and a close-up view of a radiator core mounted to a frame of a heat exchanger unit, respectively, in accordance with embodiments disclosed herein, are shown.
1003051 Any core 206 (or cooler) may be mounted to a frame 202 (or member(s) 250/251) with a flex mount 1000a. The flex mount 1000a provides for the ability to have one or more degrees of movement between the core(s) (206) and the frame 202, such as movement that may be caused by thermal expansion of the core. As shown, the flex mount 1000a may include various components including a bolt 1002a, a first washer 1004a, a top plate 1006a, an outer rigid ring 1008a, an inner rigid (spacer) ring 1012a, and a deformable ring 1010b, and a bottom (or back) plate 1014b (with plate slot 1014c). Although not shown here, the flex mount 1000a may be coupled to the frame 202 (or members 250 and/or 251) via a nut plate or threaded receptacle.
Alternatively, the flex mount 1000a may be bolted or coupled with the respective cooler 204.
1003061 The cooler (or core 206) may have one or more core mounts or core mount brackets 287, which may each have one or more core mount slots 288.
1003071 As the flexible mount 1000a may be comparable to flexible mount 1000, flexible mount 1000a is only discussed in brevity. Of note, is the presence of one or more clearance regions 1018, which may promote or otherwise accommodate movement of the core 206 in one more vectors, such as illustrated by way of example via the directional arrows.
1003081 Referring now to Figures 2C, 2D, and 2E together, a side cross-sectional view of an HX
unit 'configured with a plurality of baffles, an isometric view of a set of a plurality of baffles, and a close-up partial side view of a baffle coupled to a vertical member, respectively, in accordance with embodiments disclosed herein, are shown.
1003091 Airflow through an FIX unit 200 may be turbulent and otherwise chaotic. In addition, a fan 208 may be so loud in noise emission that it may be impossible to have a conversation between operators in an area of proximity near the fan 208 (or HX unit 200).
In addition or the alternative, the noise from the fan 208 may exceed a regulation, which is of even greater significance in the event the HX unit 200 is used in or proximate to a residential setting.
1003101 As illustrated by way of example in Figure 2C, the HX unit 200 may be configured with one or more baffles 222, which may be arranged or otherwise installed on a pseudo-interior side 229 of the unit 200 (the "exterior" 229a and "interior" 229 of the HX unit 200 may be thought of as positionally relative to where ambient air and heated air are).
1003111 Although numerous components around or proximate to an HGD (203, Figure 2A) may be a source of noise, a fan 208 may produce a noise having dominant acoustic frequency 'I" with initial amplitude Ai. To reduce noise emitted from the fan 208, the HX unit 200 may be configured with one or more baffles 222 coupled to a frame 202. It was initially contemplated that the use of baffles 222 could be problematic (restrictive) to airflow; however, in field testing it was unexpectedly discovered that airflow through HX unit 200 had actually increased as a result of the presence of baffles 222. This synergistic effect is believed attributable to the baffles 222 (and position of the baffles) helping to streamline the airflow, rather than acting as a restriction.
1003121 Thus, instead of chaotic turbulence within the interior of the HX unit 200, a baffle shape and an angled orientation of the baffles 222 may result in smoothing out the transition of the airflow from generally horizontal to generally vertical, reducing the airflow recirculation within the interior of HX unit 200, and thus reducing restriction and increasing airflow. The angled orientation may allow for a wider baffle width, which when paired with the proper baffle spacing and absorption material, may work to reduce undesirous fan noise. Spacing may be done in a manner to account for a quarter wave length (Q1 ¨ Q4) of the fan noise.
1003131 While the baffles 222 may be shown herein as having a generally planar face 261, it will be understood that baffles 222 may have other shapes, such as curved (thus a non-planar face).
The positioning of any baffle 222 herein may depend on an angle at which the respective baffle 222 is mounted, and will generally be at an angle a between 0 degrees to 90 degrees relative to the vertical axis (i.e., an angle defined by where a plane of face 261 intersects a vertical axis 227), as illustrated by way of example in Figure 2E. In aspects, the angle a may be in the range of about 30 degrees to about 60 degrees. Dimensions of baffles 222 herein may be dependent upon variables, such as the size of the HX unit 200, proximity of other baffles 222, and the angle a of the baffle orientation, and may change from those depicted. The angle a of baffle orientation may help direct airflow into and toward the exhaust outlet 218a, such that air may be more easily drawn through the HX unit 200.
1003141 The dominant acoustic frequency f of the fan 208 may depend on the intended operating speed of the fan 208 and/or number of fan blades 211. The baffle(s) 222 may be designed, configured, and oriented (positioned) to optimize a reduction in amplitude of fan noise. One or more baffles 222 may be made to include or be fitted with a sound absorbing material 262. The material 262 may be mineral wool or another suitable material. The sound absorbing material 262 may be capable of reducing the level of at least the dominant acoustic frequency by 10 dB or more. In an analogous manner, the sound absorbing material may reduce the amplitude of the original fan noise.
1003151 One or more baffles 222 may be positioned approximately a quarter wavelength Qi below where the fan 208 is mounted. The quarter wavelength Qi may be calculated based on the dominant acoustic frequency f generated by the fan 208. By referring to a quarter wavelength distance, it will be understood that it may be a multiple of the quarter wavelength, i.e., at or close to the position at which the acoustic wavelength is at its maximum.
1003161 In the instance of using a plurality of sets of baffles 222, it may be desirous to arrange baffles 222 in sets postionable at the quarter wavelength (e.g., Qi to Q4) of a different acoustic frequency in order to target different frequencies for acoustic damping. In this respect, baffles 222 of respective sets may be oriented at various angles ax. As the baffles 222 may be at varied angles ax, the entire face of the respective baffle 222 may not be at the same quarter wavelength position, which allows for some variation in the position of the baffles.
Generally speaking, a baffle midpoint 224 of the baffle 222 may be positioned at the respective quarter wavelength position, but this may depend on the acoustic profile of the fan 208.
1003171 In aspects, there may be a first (or 'upper') set of baffles 263. One or more of the first set of baffles 263 may be configured in a manner whereby a first baffle plane 261 (respective to a first baffle planar surface) intersects the vertical axis 227 of the frame at an angle a. The angle a may be in the range of about 30 degrees to about 60 degrees. In embodiments, each baffle 222 of the first set of baffles 263 may be coupled to the frame 202 in a manner whereby the respective angle a of each of the first set of the baffles 263 is in the range of about 30 degrees to about 60 degrees. It is within the scope of the disclosure that the angle a of each respective baffle 222 of the first set of baffles 263 may be substantially similar; however, the angle a of each baffle 222 may also be varied with respect to the angles of the other baffles.
1003181 The sets of baffles may each have a respective angle a, such as al for the first set, co for the second set, etc. In aspects, the angle of each may be substantially the same, such as within about 1 to about 5 degrees.

1003191 The baffles 222 may be pivotablly connected directly to the frame 202.
Alternatively, the baffles 222 may be fixedly connected to the frame 202, such as with a nut-bolt connection or weld.
In this respect, one or more baffle mount couplers 221 may be connected to the frame 202 via coupling to multiple points of either or both of horizontal and vertical members 250, 251. In general, the vertical member 251 may have a plurality of baffle mount couplers 221 thereon. In aspects, each vertical member 251 may have in the range of about three to about five baffle mount couplers 221. The baffle mount coupler 221 may have a hole or slot configured to align with a corresponding frame hole or slot, whereby a bolt or pin from the baffle 222 may be inserted therethrough.
1003201 The HX unit 200 may be optimized for the greatest amount of sound absorption by taking into account variables such as the number of baffles 222, distance between baffles 222 (or sets of baffles), baffle length, and density of sound absorbing material.
1003211 As shown in Figure 2D, a lower part (or bottom region) of the frame 202 may be defined by a plurality of horizontal members 250 and/or horizontal support plates 252b.
Various support plates 252b may have one or more baffle mount couplers 221b installed or mounted thereon. The lower part of the frame 202 may be configured in a manner to accommodate various equipment, piping, ducts, or other structure within the HX unit 200, such as housing 245.
Accordingly, baffles 222, such as baffles that are part of a lower set of baffles 246, one or more of which may be non-isosceles trapezoidal in shape, may also be configured in a manner to accommodate various equipment piping, ducts, etc.
1003221 The lower set of baffles 246 may include one or more asymmetrical baffles 222, with one or more of which that may be polygonal. The housing 245 may have one or more baffle mount couplers 221b installed or mounted thereon. Equipment and components in the lower part of the frame 202 may have a noise blocking material associated therewith. In aspects, the noise blocking material may be vinyl. The noise blocking material may be adhered to a respective surface. Other parts or components of FIX unit 200 may include noise blocking material adhered thereto.
1003231 The baffle mount coupler(s) 221 may be integral to respective vertical member 251 (or other mountable structure, such as horizontal support plate 252b), or may be coupled therewith via rigid and sturdy connection, such as a weld, rivet, or other suitable manner. The baffle mount coupler 221 (or 221b) may include an extended baffle mount element 233 (or 233b) oriented to or at a predeten-nined angle 13. In this respect, when the respective baffle 222 is coupled therewith, the baffle angle a may be substantially equal to the predetermined angle p, as shown by way of example in Figure 2E.
1003241 The first set of baffles 263 may include in the range of about three to about five baffles 222. The first set of baffles 263 may be arranged in a generally symmetrical manner to each other, such that a first baffle 222 is associated with a first side region 242a, a second baffle 222 is associated with the second side region 242b, and so on. The configuration of the set of baffles may result in a first airflow region 230. As would be apparent to one of skill in the art, the volume of airflow in the first region 230 may be greater than at other regions, and thus a larger region 230 (relatively) may be desirous. Figore 2C illustrates the sets of baffles may be configured in a manner whereby the positioning of baffles form a pseudo 'chevron' shape 220 (in cross-sectional) within the interior 229.
1003251 While baffle shape is not meant to be limited, and may vary amongst respective baffles of the first set of baffles 263, the baffle shape may be generally isosceles trapezoidal in nature. In this respect the baffles 222 of the first set 263 may have at least some minimal clearance with respect to each other upon installation and orientation within the HX unit 200.
1003261 There may be additional baffles 222, such as a second set of baffles 268, a third set of baffles 269, and so forth. The configuration of the second set of baffles 268 may result in a second airflow region proximate thereto, and similarly, the configuration of the third set of baffles 269 may result in a third airflow region proximate thereto.
1003271 While the number of baffles 222 (including sets of baffles) is not meant to be limited, there may be spatial and operational constraints and considerations. For example, too many baffles may result in inability for adequate airflow, and too few baffles may have no effect on negating unwanted noise.
1003281 At the same time, a sound absorbing material 262 (sec also Figure 3B) within the baffle(s) may provide the synergistic effect of reducing decibels of the noise attributable to operation of the fan 208. A person standing next to a fan and radiator may not be able to have an audible conversation with another person standing relatively adjacent thereto, as the loudness may be in excess of 70 dBs. In contrast, beneficially the operation of the 1-1.X unit 200 configured with the baffles 222 in accordance with embodiments of the disclosure results in significantly reduced noise whereby person-to-person conversation in the proximate vicinity of the HX unit 200 is possible.
The reduced loudness may be in the range of about to 20 dB's to about 65 dB's.

1003291 Accordingly, the HX unit 200 may include the second set of baffles 268, each of the second set of baffles configured at an angle a to the vertical axis 227. While not meant to be limited, the angle a of any of the baffles 222 may be in the range of about 0 degrees to about 90 degrees. In aspects, the angle a of any of the baffles 222 of the second set of baffles 268 may be in the range of about 30 degrees to about 60 degrees. Each of the second set of baffles 268 may be connected to the frame 202 in a manner comparable to that of the first set 263. As such, the second set of baffles 268 may be connected to respective baffle mount couplers 221.
1003301 The HX unit 200 may include additional sets of baffles, such as a third set of baffles, fourth (or 'lower') set of baffles, and so forth. Each and every baffle of any respective set of baffles may be coupled to the frame 222 via the respective and corresponding baffle mount couplers. Each of the third set of baffles 269 may be configured with an orientation at an angle a to the vertical axis 237. That is, each respective baffle 222 of the third set 269 may have a plane 261 that intersects the vertical axis 237 at the angle a. The angle a may be in the range of about 30 to about 60 degrees.
1003311 It is within the scope of the disclosure that respective baffles of any particular set of baffles may be asymmetrical. Thus, as an example, one or more of the baffles of the first set of baffles may be generally isosceles trapezoidal in shape, while the remaining baffles of the first set are not (i.e., the remaining baffles are other quadrilateral in shape, polygonoal, hemispherical, and so on). The shape of the baffle may need to made to account other internals of the HX unit 200, such as piping, ducts, other subcomponents, etc. (e.g., housing 245, Figure 2D).
1003321 In aspects, the HX unit 200 may include four sets of baffles. One or more, including all, baffles 222 may have a respective plane 261 (associated to an effective planar baffle face surface).
The respective plane 261 may intersect the vertical axis 227 at an angle a in the range of about 0 to about 90 degrees. In aspects, the respective angle a may be in the range of about 30 to about 60 degrees.
1003331 The core(s) 206 may be coupled to the frame 202 in accordance with embodiments disclosed herein, including directly, or indirectly via mounting a cooler 204 to the frame 202. The cooler 204 may include the core 206 and a tank. The core(s) 206 may include one or more tanks (such as inlet tank 277 and outlet tank 280) welded thereto. The inlet tank 277 may be associated with a tank inlet 278. Similarly, the outlet tank 280 may be associated with a tank outlet 284.
1003341 As shown in the drawings and as would be understood by one of skill in the art, each set of baffles may have a respective first baffle associated with a first side region of the HX unit 200. As it follows, each set of baffles may have a respective second baffle associated with a second side region of the FIX unit 200, a respective third baffle associated with a third side region, respective fourth baffle associated with a fourth side region, and so on.
1003351 Referring now to Figures 3A and 3B together, an isometric view of a baffle, and a lateral cross-sectional view of a baffle, respectively, in accordance with embodiments disclosed herein, are shown. As illustrated by way of example, the baffle (including any baffle of the disclosure) 222 may include one or more rigid members 237. The rigid member 237 may be a mesh. The mesh 237 may include various cross-linking or interconnected structure that may result in a plurality of orifices or openings 238. The orifices 238 may be in the range of about 0.1 inches to about 2 inches in mesh size.
1003361 The baffle 222 may include a baffle frame 264. The baffle frame 264 may be a unitary piece, or the combination of multiple subpieces. As shown, the baffle frame 264 may have a generally elongated linear member 239, as well as a non-linear member 240 (as a result of a curve, plurality of linear segments, bend, etc.). While other shapes are within the scope of the disclosure, one or both of the elongated member 239 and the non-linear member 240 may have a generally u-shape cross-sectional 241, as shown in Figure 3B.
1003371 As such, each of the elongated member 239 and the non-linear member 240 may have a first side 265 a,b, a middle 266 a,b, and a second side 267 a,b, respectively. There may be a first mesh 237a connected to the first side 265a of the elongated member 239 and the corresponding first side 265b of the non-linear member 240. In a similar manner, there may be a second mesh 237b connected to the second side 267a of the elongated member 239 and corresponding second side 267b of the non-linear member 240.
1003381 The mesh 237 a,b may be connected to the members 239, 240 in a secured or other fixed manner, such as weld or other suitable form of attachment. As shown in Figure 3B, the baffle 222 may form an effective enclosure or have a resultant baffle chamber 236. The baffle chamber 236 may be filled with a material 262, which may be sound absorbing. The material 262 may be mineral wool, such as a mineral wool product provided by Roxul, Inc.
(subsidiary of Rockwool International). The material 262 may have other characteristics, such as non-combustible, high melting point, fire retardant, hypoallergenic, and chemically inert, any of which may be useful for the environment associated with a HGD (e.g., 203, Figure 2A). The material 262 may be a 'green' material made from recycled materials.

1003391 While the baffle 222 may be constructed and otherwise completed prior to insertion of the material 262, ease of insertion of the material 262 may be achieved prior to final construction. For example, the first mesh 237a may be welded to the first side 265a of the non-linear member 239, then the second mesh 237b may be welded to the second side 267a of the linear member 239, and then the material 262 may be inserted into chamber 236.
Once the material 262 is inserted, each side 2656 and 267b the non-linear member 240 may be con-espondingly welded with the first and second mesh.
1003401 One or more, including all, baffles 222 may include the material 262.
The presence of the sound absorbing material may contribute to a reduction of the loudness of the dominant acoustic frequency of the fan by at least 10 dB. At least one of the sets of baffles may be positioned approximately a quarter wavelength below the fan mounted to the outlet. The quarter wavelength may be calculated based on the dominant acoustic frequency (f) generated by the fan (208).
1003411 One of ordinary skill in the art would appreciate that embodiments herein provide for an improved heat exchanger unit of the present disclosure that need not have one or more baffles therein.
1003421 Referring now to Figures 4A, 4B, and 4C together, an isometric partial view of a radiator core, a close-up downward view of a tank welded to a core, and an isometric view or a core end welded to a tank end, respectively, in accordance with embodiments disclosed herein, are shown.
A radiator core 206 for an HX Unit (e.g., 200) may include a structure formed from stacked layers 270 a, b, etc. of corrugated fin elements. Each layer 270 may be mounted or otherwise arranged in manner so that channels 271a formed by the fins in one layer 270a lie in transverse (or albeit sometimes parallel) relation to the channels 271b formed by the fins in adjacent layers 270b, whereby fluid flow passing through the channels may be in cross-flow or counterflow relation in alternate layers.
1003431 While only some layers of the core 206 are shown, various numbers of finned layers may be similarly stacked for completing the core 206, the number of layers depending on the particular application.
1003441 A parting sheet 272 may be placed between adjacent layers to maintain separation between alternate fluid flow paths, and an outer cover bracket(s) 281 may also be used, including for structural support. The cover bracket 281 may be similar to the parting sheets 272, but of thicker stock for added strength. The cover brackets 281 may be brazed to the core 206 (or parts of core 206, such as sheets 272) on each respective side.
1003451 In aspects, the core 206 may be a structure in which a first fluid passes through alternate layers of the core in one direction and a second fluid passes through the remaining layers in a direction perpendicular to the first fluid.
1003461 The core 206 may include external fins 273, which may be associated with each layer where airflow passes therethrough. The core 206 may include internal fins 274, which may be associated with each layer where a HGD utility fluid F passes therethrough.
1003471 The fin elements of layers 270 a,b may be made of aluminum, or other material suitable for heat transfer, including copper, brass, steel, and composite. In aspects, the fins may be made of 3003 aluminum. Each layer 270 may have a fin density of about 4 to about 30 fins per inch.
in aspects, layers 270 of the external and internal fins 273, 274 may have in the range of about to about 15 fins per inch.
1003481 In manufacture, the layers 270 of fins may be laid alternatingly transverse to each other between parting sheets 272, and fitted with respective header bars 275 and face bars 276. A brazing material may be placed between respective sheets 272 and bars 275, 276. The brazing material may be 4004 aluminum, or other comparable material.
1003491 The layers are pressed and held together, and then placed into a brazing oven (or heating furnace, etc.). The brazing operation is finished by taking out the core from the oven, and then cooled. The brazing may be controlled with time and temperature. The assembled unit may be a 'core' 206.
1003501 The core 206 may be part of a cooler 204 (or cooling circuit). There may be an inlet tank 277 and an outlet tank (not shown here), which may be welded to a core end 206a of the core 206. The tank 277 may be welded in a manner whereby a HGD utility fluid F may flow therein, and into respective layers 270b of internal fins 274. Although not shown here, the inside of inlet tank 277 may be divided by one or more partition walls or plates, for which fluid may flow therein. The inlet tank may have one or more tank inlets 278. The tank inlets 278 may be configured in a manner whereby a fluid may be transferred into the tank 277 via the inlets 278.
Various piping, tubing, etc. may be connected to the tank inlets 278, as may be desired for a particular application, and as would be apparent to one of skill in the art.
Fluid may be generally evenly distributed through the respective channels 271 as a result of inherent resistance from the fin stack configuration.
1003511 With brief additional reference to Figure 2A, in operation, a utility fluid F from HGD 203 may be transferred into the HX unit 200. The transfer may be direct or indirect (such as from a holding tank). Within the unit 200, the fluid may flow into a tank chamber (not shown) via inlet 278 of inlet tank 277. The fluid then distributes into the various alternating layers 270 b, etc. and respective channels 271 b.
1003521 Similarly airflow 216 may be drawn into FIX unit 200, and into the various perpendicular and alternating layers 270 a, etc. and respective channels 271a. The HX unit 200 may be configured for passing atmospheric air through or in contact with the core 206, so as to reduce the temperature of the service fluid circulated through the core 206. In this respect, a fan (or fan system) 208 may be rotatable about a fan axis so as to draw in (or suction, etc.) atmospheric air inwardly through channels 271a, resulting in airflow through the core 206. The fan 208 may operate in a manner whereby airflow may move in a generally horizontal direction from external of the core 206, through the core 206, and into the interior of the HX unit 200, whereby the heated air then may transition to a generally vertical direction and out as exhaust 218.
1003531 The service fluid Fi_hot, having a temperature hotter than the airflow, may be cooled (and conversely, the airflow warms). Cooled service fluid Fi_coid leaves the cooling circuit via a fluid outlet 284. Various piping, tubing, etc. may be connected to the tank outlet 284, as may be desired for a particular application, and as would be apparent to one of skill in the art. In some aspects, the tank outlet 284 may be in fluid communication with an inlet of a subsequent cooling circuit also connected with the frame 202.
1003541 Cooled utility fluid may be returned from the FIX unit 200 to a source tank, or directly to the HGD 203. Thus, service fluid from the heat generation unit 203 may be circulated in a cooling circuit in a systematic and continuous manner. As will be appreciated, a suitable circulating pump (not shown) may be provided to circulate the service fluid through the core cooler 204.
1003551 Header bars 275 and face bars 276 may be mounted adjacent to the sides of fins 274 and 273, respectively, the bars being brazed between the extending ends of the parting sheets 272.
The face bars 276 may be coupled parallel to the channels 271b and serve to block the sides of the channels to prevent fluid leakage, add structural stability and strength to the core 206, and provide a structure to which the tanks may be welded.

1003561 To direct the fluid flow into the channels, tanks may be welded to the core 206 at the fluid inlet side 206a, or the fluid outlet side, or commonly both sides. Since the core 206 (including the fins), parting sheets, and bars are normally joined by brazing, welding the tanks directly to the core 206 may be of concern as the welding temperature may be about or in excess of 1200 F. These temps may leave the core 206 distorted, and promote flow and leaching of the braze alloy.
1003571 The bars 275, 276 may have a respective bar length 286, which may include pointed extension 283. Thus the bar 275 or 276 may have an effective brazing length 285. Accordingly, at least some or all of the brazing material between the bar and respective parting sheet may heat, and even partially melt during a weld process; however, the brazing length 285 is sufficient enough to prohibit or deter flow of the brazing material, and after weld heat is removed, the braze resolidfies in place.
1003581 In essence, the bars 275 and 276 are part of a core end 206a, which has an effective core end mass Mce approximately defined by the mass within region Mce. Mce may be determined by mass within a volume (e.g., brazing length 285 x fin stack height x core width). In a similar respect the tank (277, 280) has a tank end 277a, which has an effective tank end mass Mte within region Mte. Mte may be defined by a volume of material at the tank end (e.g., tank wall thickness x tank length x tank width). The effective core end mass Mce may be greater than the effective tank end mass Mte. This may provide the ability so that whereby when the tank is welded to the core there is a natural barrier within the core (as a result of its increased mass) that prevents leaching or flowing of the brazing material. And where maybe some of the brazing material becomes molten or gooey, this portion of material may be held in situ by the part of the brazing material that remains solid.
1003591 The tank end 277a may be welded to the core end 206a. The weld 293 may be any desired weld suitable and known to one of skill in the art for welding a tank to a core. In embodiments, the weld 293 may be a v-groove weld. Weld material 294 may be used to accomplish the weld.
1003601 Other coolers 204 (e.g., 204 b, c, d, etc.) may be generally similar in nature, and suitably configured for the cooling of various service fluids from the heat generation device 203.

1003611 Referring now to Figures 7A and 7B together, an isometric view of a monitored heat exchanger system that includes a monitoring module, a heat exchanger unit, and a heat generation device operably coupled together, and an isometric component breakout of a monitoring module associated with a heat exchanger unit, respectively, in accordance with embodiments disclosed herein, are shown. Embodiments herein apply to a heat exchanger unit that may be an inclusive assembly of a number of components, subcomponents, which may be further associated with operable systems, subsystems, assemblies, modules, and so forth that may overall be referred to as a system, such as heat exchanger monitoring system 701 (or monitored heat exchanger system).
1003621 The heat exchanger unit 700 may be part of an overall system 701 that may be monitored.
Monitored system 701 includes at least one monitoring module 1000, as described herein. While it need not be exactly the same, system 701 may include various features and components like that of other systems or units described herein, and thus components thereof may be duplicate or analogous 1003631 The heat exchanger unit (or HX unit) 700 may include a solid integral frame (or skeletal frame) or may be a frame 702 that includes a number of elements arranged and coupled together.
The simplified diagram of Figure 7B illustrates the HX unit 700 coupled with a heat generation device 703. As can be seen a hot service fluid Fhot may circulate from the HGD
703 to the HX
unit, be cooled via core 706 (also sometimes recognizes as a cooler or radiator, or part thereof), and recirculate as a cooled service fluid Fc001 back to the HGD 703. Other equipment including other piping, valves, nozzles, pumps, tanks, etc. need not be shown, as one of skill in the art would have an understanding of coupling the FIX unit 700 with the HGD 703 for operable transfer of one or more service fluids therefrom.
1003641 As shown system 701 may include the use of a monitoring module 1000.
The monitoring module 1000 may be usable for monitoring one or more conditions, properties, characteristics, etc. associated with the operation of the HX unit 700. As an example, the monitoring module 1000 may be configured and used for measuring fouling associated with the core 706.
1003651 The module 1000 may be a modular assembly having various components and subcomponents associated and operable together, and like that described herein. The module 1000 may be sized and optimized accordingly for operable coupling with any type of radiator, including that associated with the HX unit 700. One of skill in the art would appreciate the monitoring, module 1000 could be retrofitted to equipment already used in the field. Just the same the monitoring module 1000 could come associated and operably engaged with newly fabricated equipment. In aspects, a single 1-1X unit 700 may have multiple monitoring modules 1000 associated therewith.
1003661 The module 1000 may be coupled to the frame 702 on a respective side of the 1-1X unit 700 (including in place of a rock grate [not shown]). As shown, the module 1000 may include a mounting frame 1001. The mounting frame 1001 may be an integral piece having a first mounting frame side 1002, a second mounting frame side 1003, a mounting frame top 1004, and a mounting frame bottom (not shown here). The mounting frame may have a cover panel or guard 1007, which may be integral or coupled therewith. Analogous to the mounting frame 1001, the cover panel 1007 may have a first cover panel side 1008, a second cover panel side 1009, a cover panel top 1010a, and a cover panel bottom 1010b. Although quadrilateral in the general sense, it is within the scope of the disclosure that the mounting frame 1001 and/or the cover panel 1007 may have different shapes, including as might be necessary to be mounted with a different shape HX unit or radiator core.
1003671 As shown in Figure 7A, the cover panel 1007 may have a plurality of cover panel apertures 1012 configured to coincide with a respective plurality of mounting frame apertures 1014a. Likewise the mounting frame 1001 may have a plurality of other mounting frame apertures 1014b configured to coincide with a respective plurality of apertures 782 of the frame 702.
1003681 One of skill would appreciate the mounting frame 1001 may be connected to the frame 702 via insertion of a plurality of connectors (fasteners, etc.) 1013 through apertures 1014b and 782, which may be screws, nut/bolt, quick disconnect, etc. Similarly, the cover panel may be connected to the mounting frame 1001 via insertion of a plurality of cover connecters 1011 through apertures 1012 and 1014a. The use of a separable mounting frame 1001 and cover panel 1007 allows for simple connect and disconnect from each other, which may make it easier for tasks such as maintenance or cleaning. In this respect the panel 1007 may be easily attachable and removable from the HX unit 700.
1003691 There may be a dampener(s) 1018 disposed between various components.
For example, there may be one or more dampeners 1018 disposed between the frame 702 and the mounting frame 1001. Analogously, there may be one or more dampeners 1018 disposed between the cover panel 1007 and the mounting frame 1001. The dampener(s) 1018 may be suitable for reducing vibration stemming from operation of the heat exchanger unit 700 that may otherwise be induced into or received by the monitoring module 1000. The dampener 1018 may be one or more layers of a rubbery material, which may have one or more sides with an adhesive thereon.
1003701 The cover panel 1007 may have a front side 1019 and a back side 1020.
From a reference standpoint the front side 1019 may be that which tends to face outward or away from the HX unit 700. Or where the cover panel 1007 may be considered exposed or external to the surrounding environment. The back side 1020 of the cover panel 1007 may be associated with one or more sensors 1021. The monitoring module 1000 may have a number of different types of sensors associated therewith, including pressure, temperature, noise, etc. Sensor 1021 may be referred to as an airflow sensor, in that the operation of sensor 1021 may help measure, determine, or otherwise sense airflow 716 moving into (or out of) the HX unit 700. In aspects, there may be about 1 to about 26 sensors 1021 associated with module 1000. However, the number of sensors 1021 is not meant to be limited, and may change depending on desired monitoring requirements for a given type of heat exchanger.
1003711 The sensor 1021 may be mounted to the cover panel 1007, and operated in a manner to sense airflow into the HX unit 700 as a result of suction. However, the sensor 1021 may just as well be mounted and operated in a manner to sense airflow out of the HX unit 700 (as a result of blowing). The sensor 1021 may be operated and setup to detect airflow through the core 706 during a clean, unfouled state, which may then be used as a baseline. As the HX unit 700 fouls, airflow through the core 700 may be effected, and the electrical signal generated by the sensor 1021 will have a measurable, detectable change in signal strength.
1003721 In some embodiments, the configuration (including its size, type placement, etc.) and operation of the sensor 1021 is believed of significance. For example, the sensor 1021 may need to be robust and durable, yet not of any (or as minimal as possible) effect on the operation of the FIX
unit 700. For example, a sensor that has an orifice may be just as prone to fouling and plugging, and ultimately failure and inability to measure airflow. Other sensors that are large or bulky may be cost prohibitive and/or attribute to unacceptable pressure drop attributable to the monitoring module.
1003731 As shown the sensor 1021 may have a rotating member 1024 (rotatable around an axis) with a plurality of blade members 1023 extending radially therefrom. The blade members 1023 may be configured to induce movement of the rotating member 1024 (rotatable about an axis) much in the same way the blades of a windmill function. That is, upon movement of air thereby, at least a minor amount of force (the amount of force being dependent upon the amount of movement of air) will be felt by the blade members 1023, and as a result of being connected to the rotating member 1024, induce rotation of the member 1024.
1003741 The rotating member 1024 may be associated with one or more bearings, whereby the rotating member 1024 may be freely movable with respect to a sensor housing or chassis 1025. In aspects, the rotating member 1022 may have a shaft or rotor, and the housing 1025 may be configurable as a (pseudo) stator. The sensor 1021 may have various circuitry and hardware associated therewith, whereby rotation of the shaft may induce or generate an electric current (e.g., via inductive properties attributable to a rotor/stator configuration).
1003751 The sensor 1021 may thus be configured to generate an electric current (or in the analogous sense, a voltage) proportional to an amount of rotation. The current, or really, a signal, may then be communicated to a microcontroller (1006, Figure 1C), which may be part of a logic circuit of the monitoring module 1000. To be sure, sensor 1021 in other embodiments may be able to communicate other forms of sensed information, such as, for example, rpm related to the rotating member.
1003761 Referring briefly to Figure 7C, a component breakout view of a controller housing usable with a monitoring module, and having various internal components, according to embodiments of the disclosure, is shown. Equipment, such as hardware and software, pertaining to the logic circuit may be operably arranged within a controller housing 1016 (which may have a controller housing top 1016a).
1003771 The controller housing 1016 may be weatherproof and dustproof, and this may have an ability to protect internals from undesired environmental and harsh weather conditions. The housing 1016 may be mountable to housing mount 1015. The housing 1016 and housing mount 1015 may have corresponding openings 1017a, 1017b, respectively, for accommodating the passing of wires and other circuitry therethrough. The openings 1017 a,b may be sealed, such as with silicone.
1003781 The controller housing 1016 may be configured with suitable components and hardware for that accommodate or provide functionality of the monitoring system 201. Such components may include, for example, the microcontroller 1006 (in operable communication and connected with sensors 1021 via wiring, circuitry, and so forth), a regulator (such as a voltage regulator) (not shown here), a power supply or battery (or battery cell) 1027a, a charger (e.g., battery charger) (not shown here), solid data storage 1028, a Wi-Fi module 1029, a GSM module 1030, a CAN-Bus module 1031, and various indicators, such as audio or visual (e.g., RGB LEDs) 1032.
1003791 Referring now to Figures 7A, 7B, and 7C, together, the microcontroller 1006 may be readily useable and compatible with various hardware, including switches, LED's, and sensors.
The microcontroller 1006 may include HDMI output to a screen such as a TV or a monitor, as well as wirelessly communicating to smart phones or computers via Wifi or Bluetooth.
1003801 A signal from the microcontroller 1006 may generate a signal communicable as a message or other form of warning, including by way of one or more of audio, video/visual (e.g., Green, Yellow, Red LEDs), email, SMS/text, CAN Bus, such as J1939. Thus, the module 1000 may include a LED response interface. In embodiments, LED lights may be configured to provide varied warnings based on monitoring and detection. For example, and with respect to certain percentage of fouling, the LED lights may flash green (0-25% fouled), yellow (25-75%
fouled), or red (75-100% fouled). In a similar manner, a warning may be transmitted (e.g., text/SMS, push notification, email, JI939, etc.) based on a percentage of fouling.
1003811 Software herein may be able to read values from the SD card and create a look-up table.
1003821 Referring now to Figures 8A and 8B together, a logic circuit process flow diagram and a logic circuit decision tree operable as part of a monitoring module, respectively, according to the embodiments of the disclosure, are shown. As illustrated and previously touched on, the monitoring module 1000 may include various hardware and software operable together as an overall 'logic circuit' in which logic of the present disclosure may be implemented.
1003831 The logic circuit may be programmable and compatible to various computer devices that include, for example, PCs, workstations, laptops, mobile devices, cell phones, tablets, PDAs, palm devices, servers, storages, and the like. Generally, in terms of hardware and related architecture, the logic circuit may include one or more microcontrollers 1006, memory or data storage 1028, and one or more I/O devices (not shown), which may all be operatively communicatively coupled together, including such as circuitry, pins, and via a local interface (not shown).
1003841 As would be apparent to one of skill in the art the local interface may be understood to include, for example, one or more buses or other wired or wireless connections. The local interface may have additional elements, such as controllers, buffers (caches), drivers, repeaters, and receivers, to enable communications. Further, the local interface may include address, control, and/or data connections to enable appropriate communications among the aforementioned components.
1003851 The logic circuit may receive power from a source, such as (upwards of) a 5V supplier.
The power, which may be in the form of a voltage, may be regulated by regulator 1026. An example voltage regulator includes AC DC Converters_ Recom Power RAC03-05SE/277 (85 ¨
305 VAC TO V). Power from the regulator 1026 may be fed to a power supply or battery 1027a.
The battery 1027a may be a LiPo battery cell (1200mAh, 3.7V). The battery 1027a may be charged by a battery charger 1027b. An example battery charger includes LiPo Energy Shield.
1003861 The microcontroller (or sometimes just 'controller') 1006 may be a hardware device configured for execution of software (programming, computer readable instructions, etc.), which may be stored (programed thereinto) in a controller memory. The controller 1006 may be any custom made or commercially available processor, a central processing unit (CPU), a digital signal processor (DSP), or an auxiliary processor among several processors associated therewith.
As an example, the controller 1006 may be an Arduino MEGA 2560 microcontroller.
1003871 Microcontroller 1006 may be powered via the battery1027a. In an embodiment, the microcontroller 1006 may be powered, directly or indirectly, via operation of the sensor(s) 1021.
With power initiation, such as at startup of the monitoring module (1000), the controller 1006 may be in communicative operability with the SD storage 1028. An example SD
storage includes Yun Shield.
1003881 The microcontroller 1006 may be in communicative operability with Wi-Fi module 1029.
An example Wi-Fi module includes E5P8266 or particle photon.
1003891 The microcontroller 1006 may be in communicative operability with GSM
module 1030.
An example GSM module includes Arduino GSM Shield V2 or Particle Elctron.
1003901 The microcontroller 1006 may be in communicative operability with CAN-Bus module 1031. An example CAN-Bus module includes CAN-BUS shield with MCP2515 CAN bus controller.
1003911 The microcontroller 1006 may be in communicative operability with LEDs 1003921 The controller memory may include any one or combination of random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), ROM, erasable programmable read only memory (EPROM), electronically erasable programmable read only memory (EEPROM), programmable read only memory (PROM), tape, compact disc read only memory (CD-ROM), disk, diskette, cartridge, cassette or the like, and so forth. Moreover, the controller memory may incorporate electronic, magnetic, optical, and/or other types of storage media.
1003931 Software in the controller memory may include one or more separate programs, each of which may include an ordered listing of executable instructions for implementing logical functions. Software in the controller memory may include a suitable operating system (OS), compiler, source code, and/or one or more applications in accordance with embodiments herein.
Software may be an application ("app") that may include numerous functional components for implementing the features and operations of embodiments of the disclosure.
1003941 The OS may be configured for execution control of other computer programs, and provides scheduling, input-output, file and data management, memory management, and communication control and related services. In aspects, the app may be suitable for implementation of embodiments herein to all commercially available operating systems.
1003951 Software may include an executable program, script, object code, source program, or any other comparable set of instructions to be performed.
1003961 Software may be written as object oriented programming language, which may have classes of data and methods, or a procedure programming language, which has routines, subroutines, and/or functions. The programming language may include for example Python, HTML, XHTML, Java, ADA, XML, C, C++, C#, Pascal, BASIC, API calls, ASP
scripts, FORTRAN, COBOL, Perk .NET, Ruby, and the like.
1003971 The input/output (I/O) device(s) may include an input device such as, for example, a mobile device, a keyboard, a mouse, a touchscreen, a microphone, a camera, a scanner, and so forth. The I/O device(s) may include an output device such as, for example, a display, a printer, an email, a text message, and so forth. The I/0 device may include devices configurable to communicate both inputs and outputs, such as a router, a telephonic interface, a modulator/demodulator or NIC (that may be suitable to access remote devices, other files, devices, systems, or a network), a radio frequency (RF) or other transceiver, a bridge, and so forth. The I/O devices may include one or more components for communicating over various networks, such as the Internet or intranet.

1003981 In aspects, external computers (and respective programming) may be communicably operable with the logic circuit (and thus monitoring module 1000).
1003991 In operation of the logic circuit, the microcontroller may: execute software stored within the memory; communicate data to and from the memory; and/or generally control operations of the logic circuit pursuant to the software.
In Operation (with logic) 1004001 The operation of the logic circuit may be further understood with an explanation of the tree diagram of Figure 8B. The tasks are numbered in above the task name. Task 1 is to acquire data from the sensors 1021. Although sensor 1021 is referenced here, the logic circuit is not meant to be limited, and may be suitable for other sensors/sensor assemblies, such as sensor assembly 2000 discussed herein.
1004011 Tasks may include sampling the data from the sensors 1021 over a short time (e.g., 60 seconds) and taking an average and standard deviation. Task 2 compares the standard deviation of the new data with a predetermined acceptable limit saved on a memory of the system. This allows sporadic or outlier data to be excluded. This consequently ensures that, for example, windy conditions will not be interpreted as fouling, and thus preventing false alarms.
1004021 If the sampled data is sporadic and not acceptable, a delay (task 5) will be implemented to retry (or loop) for data acquisition. Either the data will be acceptable or will remain sporadic.
If the sporadic data is very consistent and the number of sporadic data occurrence exceeds a predefined value (task 3), the user is notified of an error (task 4) (typically an installation error).
1004031 Once the sampled data of task I has been accepted, it is checked with a lookup-table (LUT) flag (task 6), which is essentially a binary that allows for the completion of the fouling lookup-table. This flag indicates if the fouling lookup-table is already generated and exists or not (Initially and during installation, this flag is false, meaning that the table is not yet generated). If the LUT flag from task 6 is false, the programming uses an averaging method to create a fouling lookup-table containing the data output of the sensors 1021 (or sensor assemblies 2000) in a clean condition (tasks 7 and 8). After generating the LUT table through multiple iterations (averaging), the system turns the LUT flag true.
1004041 If the LUT flag is true, the overall fouling is then calculated in task 9. This consists of referencing acquired data from the sensors 1021 (or assemblies 2000) against the fouling lookup-table which represents a clean condition. If fouling is evident, a foul state is recorded (task 10).
In task II, the fouled state is evaluated. If consecutive data has determined that the radiator is in a severe (as defined by the user) fouling condition, then the user will be notified using one or more of the defined warning methods (task 10), e.g., LED, email, J1939 message, etc. If the foul count is not too high, a delay will occur (task 12), and the system will continue to collect data to proactively warn the user in case of any fouling.
1004051 Referring now to Figure 9, a side view of a monitored heat exchanger system that includes a monitoring module, a heat exchanger unit, and a heat generation device, operably coupled together, in accordance with embodiments disclosed herein, are shown. Embodiments herein apply to a heat exchanger unit that may be an inclusive assembly of a number of components and subcomponents. The heat exchanger unit 900 may be part of an overall system 901 that may be monitored. Monitored system 901 may include at least one monitoring module 1000, as described herein.
1004061 While it need not be exactly the same, system 901 may be, like that of system 701 of Figures 7A-7C (or other systems herein), and components thereof may be duplicate or analogous. Thus, only a brief discussion of system 701 is provided, recognizing that differences, if any, would be discernable by one of skill in the art, especially in view of the Applicant's co-pending US patent application S/1\I 15/477,097. Accordingly it would be further understood that aspects of system 901 may include various additional improvements related to airflow, noise reduction, cooling efficiency, structural integrity, and combinations thereof.
It is further noted that system 301 may include other sensor-type configurations, such as one or more sensor assemblies 2000 described herein.
1004071 The HX unit 900 may include one or more cores 906 being associated with respective monitoring module(s) 1000. It should be apparent that while HX unit 900 may have a plurality of sides (or side regions), each of the plurality of sides having respective coolers, not every side need have a monitoring module 1000. Still, it may every well be that every cooler is monitored via one or more modules 1000. Moreover, while the module 1000 may be particularly useful for monitoring fouling, other conditions of the HX unit 900 (or system 901) may be monitored.
1004081 One or more cores 906 may be associated with and proximate to a respective protective grate (not viewable), which may be useful for protecting fins of the core 906.
The monitoring module 1000 may be installed in place of the grate.

1004091 Although not shown in entire detail here, the fIX unit 900 may include a fan system.
Briefly, the fan system may include related subcomponents, such as a fan that may be understood to include a rotating member with a plurality of fan blades extending therefrom. The fan may be operable by way of a suitable driver, such as a fan motor, which may be hydraulic, electrical, gas-powered, etc. Conduits may be configured for the transfer of pressurized hydraulic fluid to and from the motor. As such, pressurized hydraulic fluid may be used to power the motor.
1004101 The fan system may include a fan shroud, which may be generally annular. The fan shroud may be coupled to the frame via connection with the top plate. The shroud may include one or more lateral openings 960 to accommodate the passing of the mount bar 909 therethrough.
The mount bar 909 may be a rigid bar or beam that extends from one side 959a of the HX unit 900 to another side 959b.
1004111 A fan rock guard 947 may be coupled to a shroud 913. The shroud 913 may be proximate to an aeroring (not shown). The aeroring may be annular in nature, and have a ring cross-section that may have a radius of curvature. Thus, the aeroring may have a rounded surface that may aid in improving airflow and reducing pressure in and around the fan system.
Without the aeroring, eddies and other undesired airflow may occur in corners of the top of the frame.
1004121 The configuration of the shroud and aeroring may provide added ability for further streamlining airflow, which may beneficially reduce overall power requirements.
1004131 The fan system can be operable to draw in and direct the flow of air 916. The air 916 may be drawn through the sides of the 11X unit 900 (and respective cores, which may then be used to cool one or more utility fluids F) and out as heated exhaust 918. The benefit of such a configuration is the ability to provide cooling in parallel, versus series. In a series configuration, the airflow becomes progressively hotter as it passes through each cooling circuit, resulting in a loss in cooling efficiency. This can be especially problematic where ambient air temperature is usually hotter, like Texas and Oklahoma.
1004141 Utility fluid F (or multiple F's) may include by way of example, lubc oil, jacket water, turbo (such as for an engine), transmission fluid (such as for a pump), and hydraulic fluid (such as for the fan drive).
1004151 One of skill in the art would appreciate that airflow through the core 906 may be generally in a path parallel to a horizontal axis. In an analogous manner, the fan 908 may have an axis of rotation generally parallel to a vertical axis. Accordingly, airflow through the FIX unit 900 may be transitioned from (approximately) horizontal to vertical as the airflow moves through the core 906 and out the fan exhaust 918.
1004161 As such, by way of example, utility fluid F1 may be transferred from a heat generating device 903 at a hot temperature into an HX unit inlet 978, cooled with airflow via core 906, and transferred out of an HX unit outlet 984 back to the HGD 903 at a cooler temperature. While not meant to be limited, HGD 903 may be an engine, a genset, a motor, a pump, or other comparable equipment that operates in a manner whereby a utility fluid is heated.
1004171 There may be one or more cores 906. A 'cooler' or 'cooling circuit' may include one or more cores 906. The HX unit 900 may have between about 1 to about 8 cooling circuits, which each may be configured for cooling in parallel to each other.
1004181 The HX unit 900 may include various sound reduction or integrity features like that as described in pending US patent application SN 15/477,097, such as various sound baffle configurations and/or flexible mount assemblies.
1004191 In operation, a utility fluid F from HGD 903 may be transferred into the HX unit 900.
Within the unit 900, the fluid may flow into a tank chamber (not shown) via inlets of inlet tank.
The fluid may then distribute into the various alternating layers and respective channels of the core 906.
1004201 Similarly airflow 916 may be drawn into HX unit 900, and into the various perpendicular and alternating layers and respective channels of the core 906. The HX unit 900 may be configured for passing atmospheric air through or in contact with the core 906, so as to reduce the temperature of the service fluid circulated through the core 906. In this respect, a fan (or fan system) may be rotatable about a fan axis so as to draw in (or suction, etc.) atmospheric air inwardly through channels (or fins), resulting in airflow through the core 306 may be connected to the tank outlet, as may be desired for a particular application, and in some aspects, the tank outlet may be in fluid communication with an inlet of a subsequent cooling circuit also connected with the frame 902.
1004211 Cooled utility fluid may be returned from the HX unit 900 to a source tank, or directly to the HGD 903. Thus, service fluid from the HGD 903 may be circulated in a cooling circuit in a systematic and continuous manner. As will be appreciated, a suitable circulating pump (not shown) may be provided to circulate the service fluid through the core cooler 306.

1004221 Other coolers of the HX unit 900 may be generally similar in nature, and suitably configured for the cooling of various service fluids from the HOD 903.
1004231 Referring now to Figures 10A, 10B, and 10C together, an isometric view of a monitored heat exchanger system that includes an airflow sensor assembly, a heat exchanger unit, and a heat generation device operably coupled together, an isometric component breakout of an airflow sensor assembly, and a longitudinal cross-sectional view of an airflow sensor assembly, respectively, in accordance with embodiments disclosed herein, are shown.
1004241 Embodiments herein apply to a heat exchanger unit that may be an inclusive assembly of a number of components and subcomponents, which may be further associated with operable systems, subsystems, assemblies, modules, and so forth that may overall be referred to as a system, such as heat exchanger monitoring system 401 (or monitored heat exchanger system).
System 401, and any components thereof, may be like that of other systems described herein or in the Applications. Thus, various discussion of system 401 may be provided in brevity, recognizing that differences, if any, would be discernable by one of skill in the art in accordance with the disclosure, as well as in view of the Applications. It would be further understood that aspects of system 401 may include various additional improvements related to airflow, noise reduction, cooling efficiency, structural integrity, cooler orientation or arrangement, and combinations thereof.
1004251 The heat exchanger unit (or HX unit) 400 may include a solid integral frame (or skeletal frame) or may be a frame 402 that includes a number of elements arranged and coupled together.
Figure 4A illustrates the HX unit 400 coupled with a heat generation device 403. HGD 403 is shown in 'box' form as a representation that the HGD 403 may be any such device suitable for heat exchange of a service fluid, as would be understood to one of skill in the art. Just the same the type of HX unit is not limited to the unit 400 depicted, as other types of units (such as multi-sided, vertical, etc.) are possible in accordance with embodiments herein and in the Applications.
1004261 As can be seen a hot service fluid F110, may circulate from the HGD
403 to the HX unit 400, be cooled via a core (also sometimes referred to as a cooler, cooling circuit, or radiator, or part thereof), and recirculate as a cooled service fluid Feoid back to the I
IGD 403. Other equipment including other piping, valves, nozzles, pumps, tanks, etc. need not be shown, as one of skill in the art would have an understanding of coupling the FIX unit 400 with the HGD 403 for operable transfer of one or more service fluids therefrom.

1004271 As shown system 401 may include the use of a sensor assembly 2000.
There may be a plurality of sensor assemblies 2000 operably coupled together via a bus network 2040. Thus, wiring 2022 from any applicable assembly 2000 may connect with the bus network 2040, which may be passive in nature. The bus network 2040 may be associated with a communications protocol subject to RS-485 Protocol. A main cable of network 2040 may be directly connected to the primary microcontroller (1006, as described herein). The sensor assembly 2000 may be usable for or in connection with monitoring one or more conditions, properties, characteristics, etc. associated with the operation of the HX unit 400. As an example, the sensor assembly 2000 may be configured and usable (in connection with other various equipment) for measuring or helping determine fouling associated with a core (not shown here) of the unit 400.
1004281 The sensor assembly 2000 (or assemblies) may be operably coupled with the components of controller housing 1016 (including primary microcontroller 1006, etc.), thus having the same monitoring logic and so forth, as described herein and which may be further referenced in Figures 7B-17 and 8A-8B. For the sake of brevity, the reader is directed to the accompanying text, recognizing that one of skill in the art would readily appreciate and understand how to wire the components of the controller housing 1016 with the sensor assembly 2000, including associated programming, and various communication protocol (data transfer) and power. The controller housing 1016 may be mounted to the HX unit 400, and may be operable for the monitoring of the system 401.
1004291 The sensor assembly 2000 may be a modular assembly having various components and subcomponents associated and operable together, and like that described herein. The sensor assembly 2000 may be sized and optimized accordingly for operable coupling with any type of radiator, including that of the HX unit 400. The sensor assembly 2000 may be retrofitted to equipment already used in the field, or the sensor assembly 2000 may come associated and operably engaged with newly fabricated equipment.
1004301 The sensor assembly 2000 may be coupled to FIX unit 400, including by direct coupling to a respective side/top thereof, such as, for example, to a rock guard 447.
Although not meant to be limited, in aspects, the sensor assembly 2000 may have an assembly diameter in the range of about 5 inches to about 15 inches. Generally it may be desirable to have an assembly size that is large enough to effectively sense a condition, such as airflow, but small enough to avoid having detrimental effect on the operational capability of the HX unit 400 (e.g., by blocking or impeding airflow or increasing pressure drop). As such, spacing between respective assemblies 2000 may be done in a manner to minimize impact by the presence thereof.
1004311 Figure 10B shows the sensor assembly 2000 may include a mounting frame 2001. The mounting frame 2001 may be made from a material suitable for rugged durability, such as metal.
Although shown as being separate from a casing 2007, the frame 2001 and casing components could just as easily be integral to each other.
1004321 The mounting frame 2001 need not be limited to any particular shape, but in general the mounting frame 2001 may be a unitary piece having a first mounting frame (top) side 2002 and a second mounting frame (bottom) side 2003. In assembly, the casing 2007 may be proximate to the first frame side 2002, and the FIX unit 400 may be proximate to the second side 2003. As shown, the frame 2001 may have a central segment 2041 joined with a ring-shape perimeter 2001a via one or more bridging members 2042. The mounting frame 2001 may thus have characteristics of being able to couple the assembly 2000 to the HX unit 400, support various components of the assembly 2000, and yet still have gaps 2043 for airflow to pass therethrough, thereby reducing the impact, if any, of the assembly 2000 on the operational capability of the HX
unit 400.
1004331 The mounting frame 2001 may have one or more mounting arms 2044, which may extend outward from the perimeter 2001a. The mounting aims 2044 may be configured to provide the assembly 2000 with universal connectivity to a respective HX unit, which may have connection points (such as a rock guard 447) with varied features. In this respect, one or more of the mounting arms may have a series of mounting frame apertures 2014. As one of skill would appreciate a nut and bolt or other suitable fastener may be used for coupling the mounting frame 2001 with the HX
unit, including to the rock grate.
1004341 Referring briefly to Figures 11A and 12B, which illustrates the universality of the mounting frame 2001 coupled with different shape rock grates 447 a, b. The sensor assembly 2000 may be connected to an FIX unit by way of coupling the frame 2001 to a respective rock guard 447 a, b.
Coupling may be via use of a plurality of fasteners 2050 (which may be nut-bolt or other suitable fastening type device) through apertures 2014, although one of skill in the art would appreciate there may be any number of ways to couple the assembly 2000 to the HX unit.
Moreover, the coupling need not be limited to a rock grate, as other structures may be suitable.

1004351 Referring again to Figures 10A-10C, the mounting frame 2001 may have one or more dog ears 2045 extending outward from the perimeter 2001a. In aspects there may be about four dog ears 2045 positioned generally symmetrically around the perimeter 2001a, and may be proximate to respective arms 2044. The ears 2045 provide additional support, and also have frame apertures 2012a that align with respective casing apertures 2012 for connection therewith. That is, an assembly screw 2020 may be inserted into the frame aperture 2012a as it is aligned with the casing aperture 2012, whereby a screw end 2020a may extend out of the casing 2007 and a fastener 2005 may then be screwed thereon.
1004361 In embodiments the assembly may also include a guard 2004. The guard 2004 may provide an additional layer of protection, including against inadvertent touching of assembly components, as well as preventing larger debris from entering into the assembly 2000.
Although shown as having a 'grill' configuration, the configuration of the guard 2004 is not meant to be limited. The guard 2004 may be of a shape suitable for not attributing to significant pressure drop or impeding airflow through the sensor assembly 2000. The guard 2004 may have one or more guard apertures 2004a that may align with respective apertures 2012, 2012a. The apertures 2004a may be disposed on ends of respective guard mount legs 2004b. The legs 2004b may be 'raised' in a manner where a slight clearance is provided between the guard 2004 and the blades 2023 of a rotating member 2024.
1004371 Accordingly, the screw end 2020a may be interested through the apertures 2004a, 2012, 2012a, and have the respective fastener 2005 tightened thereon. Although the Figures illustrate a grouping of four respective screws/apertures/fasteners, embodiments herein are not meant to be limited, as other configurations are possible.
1004381 The central segment 2041 may have one or more segment apertures 2014a.
The central segment may also have a segment wiring aperture 2017 suitable for wiring 2022 to pass therethrough. Wiring 2022 may having a bundle configuration whereby one or more wires are associated therewith, including for communication protocol (data/signal transfer) and power.
1004391 The casing 2007 may be an integral piece having a casing outer side 2008, a casing inside 2009, a casing topside 2010a, and a casing bottom side 2010b. The casing 2007 may have a shape corresponding to that of the mounting frame 2014, such as generally ring-shaped.
Although not meant to be limited, the height between the topside 2010a and the bottom side 2010b may be about 1 inch to about 5 inches.

1004401 Similarly, although not limited there may be a casing thickness of material between the outer side 2008 and the inside 2009 in the range of about 0.1 inches to about 0.5 inches. The casing thickness may be suitable for casing apertures 2012 to be disposed therein. As shown, there may be one or more casing ears 2007a extending outward from the outer side 2008, which may further correspond to respective frame ears 2045. The apertures 2012 may be formed in the respective ears 2007a.
1004411 One of skill would appreciate the mounting frame 2001 may be connected to the HX unit via insertion of a plurality of connectors (fasteners, etc.) through apertures 2014 and an applicable surface (or other feature) of the HX unit 400, such as the rock guard 447.
Moreover, although shown mounted external to the rock guard 447, the assemblies 2000 could just as well have an internal mounting (such as on the inner side of the rock guard 447). In this respect the assembly 2000 may be easily attachable and removable from the HX unit 400. This may be for example, by way of screws, nut/bolt, quick disconnect, etc. The sensor assembly 2000 may be mounted to the HX unit 400 in a vicinity of where airflow 416 may occur in sufficient amount to move the rotating member 2024.
1004421 The casing 2007 may be connected to the mounting frame 2001 via insertion of screws 2020 through respective apertures 2012 and 2012a. The use of a separable mounting frame 2001 and casing 2007 may provide for simple connect and disconnect from each other, which may make it easier for tasks such as maintenance or cleaning, as well as access to, and assembly of, inner components.
1004431 The sensor assembly 2000 may be referred to as an airflow sensor assembly, in that the operation of sensor assembly 2000 may help measure, determine, or otherwise sense airflow 416 moving into (or out of) the HX unit 400. In aspects, there may be about 1 to about 25 sensor assemblies 2000 associated with a respective side of the FIX unit 400.
However, the number of assemblies 2000 is not meant to be limited, and may change depending on desired monitoring requirements for a given type of heat exchanger.
1004441 Inner components of the sensor assembly 2000 may disposed within the casing 2007, and further supported by the central segment 2041. The assembly 2000 may be operated in a manner to sense airflow into the FIX unit 400, which may be as a result of suction or blowing. The sensor assembly 2000 may be operated and setup to detect airflow through the HX unit (or respective core) during a clean, unfoulcd state, which may then be used as a baseline. As the HX unit 400 fouls, airflow therethrough may bc effected, and the electrical signal generated by the sensor assembly 2000 will have a measurable, detectable change in signal strength.
1004451 The configuration (including its size, type placement, etc.) and operation of the sensor assembly 2000 is believed of significance, whereby the sensor assembly 2000 (and its components) may need to be robust and durable, yet not of any (or as minimal as possible) effect on the operation of the HX unit 400. For example, sensing airflow with an orifice-type sensor may result in plugging thereof, and ultimately failure and inability to measure airflow. Other sensors that are large or bulky may be cost prohibitive and/or attribute to unacceptable pressure drop attributable to the monitoring module. Still other sensors may be prone to breakage, or otherwise susceptible to conditions associated with the HX unit 400, which include the impact of airflow (sometimes in the range of 20-30 meters-per-second [nips]) on the sensor assembly 2000 and/or the hot temperatures. In aspects, during normal cooling operation, the speed of the airflow 416 may be in the range of about 20 to about 35 mps.
1004461 Figures 10B and 10C together show a durable and rugged sensor assembly 2000 that may include the rotating member 2024 (rotatable around an axis) with a plurality of blade members 2023 extending radially therefrom. The blade members 2023 may be configured to induce movement of the rotating member 2024 (rotatable about an axis) much in the same way the blades of a windmill function. That is, upon movement of air thereby and thereagainst, at least a minor amount of force (the amount of force being dependent upon the amount of movement (speed) of airflow) will be felt by the blade members 2023, and as a result of being connected to the rotating member 2024, induce rotation of the member 2024. In aspects the shape and design of the blade members 2023 may be that which is sensitive to airflow, including with various blade curvature and/or rounded surfaces, as well as the number of blades and spacing therebetween.
1004471 The rotating member 2024 may be disposed around a shaft 2030, which may be centrally positioned within the casing 2007. In a non-limiting example, the shaft 2030 may be a bolt with threaded and/or non-threaded regions, and a bolt head 2030a. As shown, other components of the assembly 2000 may be disposed around and in proximity to the shaft 2030. It would be apparent to one of skill that the shaft 2030 may be directly connected with other components that may move or are otherwise rotatable, but the shaft 2030 may not be directly connected with other components that are fixed in place. Thus, the shaft 2030 may rotate freely.

1004481 There may be a support platform 2033. While not meant to be limited, the platform 2033 may be made from a metal such as aluminum, which has the benefits of being economical, resistance to corrosion, and non-ferromagnetic. As will be described, the use of non-ferromagnetic material is of significance as the assembly 2000 uses properties of magnetism.
1004491 The support platform 2033 may shaped and sized in a manner to generally correspond to the size and shape of the central segment 2041. The support platform 2033 may be cylindrical in shape.
The support platform 2033 may have one or more platform apertures 2033a configured to align with segment apertures 2014a. Thus the support platform 2033 may be coupled to the central segment 2041, such as by way of one or more binding post 2028 and binding screw 2029 combinations. As shown, there may be about three binding posts 2028 with respective binding screws 2029 that may threadingly engage to each other. The posts 2028 and screws 2029 may be spaced apart generally equidistantly in order to distribute forces between the components as they are coupled together, and during operation of the assembly 2000.
1004501 The support platform 2033 may have a middle, hollowed region (or "platform hollow") 2051 that may accommodate for the positioning of the platform around the shaft 2030, as well as the proximate positioning of one or more bearings 2031, 2032 therein. Because of the tight tolerance fit of the bearings 2031, 2032 within the hollowed region (and tight tolerance fit of the shaft 2030 within an inner ring of the bearings), as well downward pressure from tightening of fastener 2027 (exerting a pressure against bolt head 2030a), the shaft 2030 may be freely rotatable, but otherwise prevented from moving or having undesired wobble or slippage.
1004511 While not limiting, it is generally thought that for size and performance two bearings 2031, 2032 may be optimal. Though the first bearing 2031 may be placed proximately above second bearing 2032, it may be useful to have a shim 2036 positioned therebetween.
The shim 2036 may help distribute pressure evenly. In aspects, the bearings 2031, 2032 may be ABEC rated between 1 and 9, and have an inner diameter of at least 0.1 inches and outer diameter of less than 0.8 inches.
in other aspects, the inner diameter is about 0.25 inches and the outer diameter is about 0.63 inches.
1004521 The support platform 2033 may have an additional platform aperture 2033b for which wiring 2022 can pass therethrough. As shown the support platfon-n 2033 may have a circuit board 2015 coupled therewith. The circuit board 2015 may be mounted or otherwise disposed on a top platform surface 2052 of the support platform 2033.

1004531 Referring briefly at Figure 11C a downward view of a circuit board with various components and circuitry, in accordance with embodiments disclosed herein, is shown. Although not limited, the circuit board 2015 may have a shape, to correspond with fitting onto the support platform 2033. As shown, the circuit board may have a half-moon or half-donut type shape, and generally configured to accommodate positioning at least partially around the shaft 2030.
1004541 The circuit board 2015 may have various conductivity paths 2022a and circuit components associated therewith, and may be powered by way of connectivity with network bus 2040. As seen on the top of the board 2015a, there may be a Hall sensor 2021 (with respective Hall element), a microcontroller 2006, and a transceiver (or transceiver IC) 2037, all in operable connectivity, and having associated computer instructions.
1004551 The Hall sensor 2021 may be akin to a magnetic switch latch like latch manufactured by Melexis Technologies NV. Although not limited, the sensor 2021 may be a thin piece of rectangular p-type semiconductor material such as gallium arsenide (GaAs), indium antimonide (InSb) or indium arsenide (InAs), subjected to passing of a continuous current therethrough.
1004561 The microcontroller 2006 may be, for example, an 8-bit AVR RISC-based microchip like the ATtiny167 microcontroller manufactured by Microchip. This microcontroller 2006, which may be referred to as a secondary microcontroller, may have the ability to provide some calculation, filtering, and so forth, as it pertains to the signal generated from the Hall sensor 2021. The resultant signal may then be communicated to the primary microcontroller 1006 for additional processing.
1004571 The transceiver 2037 may be accommodate operation of the communications protocol. For example, the transceiver 2037 may be suitable to function as a pseudo-translator to conform generated signals to be useable with the communications protocol. By way of example, the transceiver 2037 may be like that of a MAX3485AEASA+ manufactured by Maxim Integrated.
1004581 Referring again to Figures IA-1C, the circuit board 2015 may have one or more board apertures 2015b for respective posts 2028 and screws 2029 to pass therethrough. Thus upon sufficient tightening the circuit board 2015 may be held rigidly and securely in place on the support platform 2033. Fastener 2027 (which may be a lock nut or nut with lock washer) may also be used to provide sufficient pressure between the circuit board 2015, the bearings 2031, 2032, and the support platform 2033.

1004591 There may be an additional support plate 2035 disposed around the shaft 2030 and coupled with the support platform 2033. While not limited, the support plate 2035 may be made of corrosive-resistant, non-ferromagnetic metal, such as stainless steel. As various components of the assembly 2000 may be susceptible to expansion as a result of surrounding heat, while others are not, the support plate 2035 may help aid in keeping the effect of gaps resulting therefrom minimized.
1004601 The support plate 2035 may have support plate apertures 2035a for respective posts 2028 and screws 2029 to pass therethrough. Thus upon sufficient tightening, the plate 2035 may be held rigidly and securely in place, and further sandwich the circuit board 2015 on the support platform 2033. The use of the support plate 2035 may further help in preventing slippage within the assembly. It may be especially desired to prevent slippage between the shaft and the inner ring surfaces of the bearings 2031, 2032, as well as to prevent slippage between the outer ring surfaces of the bearings 2031, 2032.
1004611 Although not limited to any particular shape, the support plate 2035 may have a tri-wing configuration, as shown in Figure 10B.
1004621 As the circuit board 2015 and components proximate thereto may be sensitive to the surrounding environment, including dust or other particulate, the assembly 2000 may include a protective inner housing 2025. The inner housing 2025 may be generally cylindrical, and otherwise shaped in a manner for fitting around the shaft 2030, and at least partially down and around the support platform 2033 (and also surrounding components coupled with the support platform 2033).
Although they may be possibly located elsewhere, the inner housing 2025 may have one or more magnets fixedly attached therewith, such as magnets 2016a and 2016b. The magnets 2016 a,b may be attached to the inside (underside) of inner housing 2025 with a high temperature adhesive.
1004631 The magnets 2016 a,b may be attached to the insider upper surface of the inner housing 2025, and thus be oriented in a manner to come into proximity with the Hall sensor element 2021.
As they pass each other there may be a clearance between the sensor element 2021 and the magnets 2016 a,b in the range of about 1 mm to about 10 mm. However, the size of the clearance is not meant to be limited, and may be a suitable size to provide sufficient interaction between the magnets 2016 a,b and the sensor element 2021. The magnets 2016 a,b and the sensor element 2021 may be disposed and arranged in a manner whereby as the magnets 2016 a,b rotate, the magnets 2016 are sufficiently able to repeatedly (cyclically) effect the magnetic field of the sensor element 2021.

1004641 The rotating member 2024 may be disposed around the shaft 2030, and proximate to the inner housing 2025. The rotating member 2024 may have a rotating member ring 2024a that fits around the 2030, and provides sufficient amount of material whereby a set screw (or comparable) (not shown here) may be inserted therethrough and tightened against the shaft 2030. In addition to the downward pressure from tightened locknuts, the use of the set screw may help provide removably fixed connected between the rotating member 2024 and the shaft 2030.
Top fastener 2027a may be threadingly engaged onto shaft end 2030b in a manner to provide sufficiently desired pressure between the components disposed around the shaft 2030, including member ring 2024a and inner housing 2025.
1004651 The rotating member 2024 may be movingly associated with the bearings 2031, 2032, whereby the rotating member 2024 may be freely movable with respect to the support platform 2033 (and components coupled thereto). Although not shown here, it could be the case that the rotating member 2024 may be configured to rotate around the shaft 2030 while the shaft is held stationary. This could occur, for example, by configuring the rotating member 2024 with one or more bearings, and the inner ring of the bearings disposed around the shaft 2030.
1004661 Accordingly, as airflow (416) impacts the blades 2023, the rotating member 2024 may be urged to move (rotate). As the rotating member 2024 rotates, so does the shaft 2030 and any components fixedly connected thereto, including inner housing 2025. As the housing 2025 rotates, so too will the magnets 2016 a,b. Although not limited to any particular number of magnets, the use of two promotes efficiency in generating a true digital signal related to the rotation of the shaft 2030. Referring briefly to Figure 11D, an example of magnets having oppositely positioned poles, according to embodiments of the disclosure, is shown. As illustrated, one of the magnets 2016a may have a North/South pole 2018/2019 configuration, whereas the other magnet 2016b may have a South/North pole 2019/2018 configuration.
1004671 In an operational example, the magnet 2016a may pass the Hall sensor element 2021, thereby effecting the magnetic field of the element in a manner to generate therefrom a first digital signal akin to a '1'. Next, when the magnet 2016b passes the sensor element 2021, the magnetic field is effected in an opposite matter, thus resulting in the digital signal changing to a low or a '0'.
As the magnets 2016 a,b pass through the magnetic field of the Hall sensor element 2021, the field is disrupted, and a change in the current occurs, as would be known by one of skill in the art as the "Hall effect-. The circuitry associated with Hall sensor elements may be configured to generate the digital signal, which may then be processed by the secondary microcontroller 2006, and subsequently communicated to the primary microcontroller 1006. The frequency of the digital signal may be proportional the amount (i.e., speed) of rotation, and thus proportional the rate of airflow.
1004681 Although sensor assembly 2000 has been shown and described, embodiments herein are not meant to be limited as other ways of obtaining information about the operation of the HX unit 400 are possible.
1004691 Referring now to Figure 12, a cross-sectional view of an alternative sensor assembly according to embodiments of the disclosure, is shown.
1004701 Sensor assembly 2000a, and any components thereof, may be like that of other sensor assemblies described herein, such as assembly 2000. Thus, various discussion of assembly 2000a may be provided in brevity, recognizing that differences, if any, would be discernable by one of skill in the art in accordance with the disclosure, as well as in view of the Applications.
1004711 Briefly, assembly 2000a may have a shaft 2030 with various components disposed therearound, including support platform 2030, one or more bearings 2031, 2032, circuit board 2015, and so forth. As shown, the support plate 2035 may have a generally horizontal portion 2046. The horizontal portion 2046 may be tightened against a lower ridge 2048 of a retainer insert 2047 via binding post 2028 and screw 2029. The retainer insert 2047 may be useable to further constrain the bearings 2031 and/or 2032 from wobble or slippage. The retainer insert 2047 may have an upper ridge 2049, whereby as the support plate 2035 compresses against the lower ridge 2048, compression may also be incurred by upper ridge 2049 to the outer ring of the bearings 2031, 2032.
1004721 Referring again to Figures 10A-10C, although not shown in detail here, the HX unit 400 may include one or more cores being associated with one or more sensor assemblies 2000. It should be apparent that while FIX unit 400 may have a plurality of cooling regions (side, sides, topside, etc.), each having respective coolers, not every region need have sensor assembly 2000.
Still, it may every well be that every cooler is monitored via or otherwise operatively associated with one or more assemblies 2000. Moreover, while the sensor assembly 2000 may be particularly useful for monitoring fouling, other conditions of the HX unit 400 (or system 401) may be monitored.
1004731 One or more cores may be associated with and proximate to a respective protective grate, which may be useful for protecting fins a core.

1004741 Although not shown in entire detail here, the HX unit 400 may include a fan system.
Briefly, the fan system may include related subcomponents, such as a fan that may be understood to include a rotating member with a plurality of fan blades extending therefrom. The fan may be operable by way of a suitable driver, such as a fan motor, which may be hydraulic, electrical, gas-powered, etc. Conduits may be configured for the transfer of pressurized hydraulic fluid to and from the motor. As such, pressurized hydraulic fluid may be used to power the motor. The fan system may include a fan shroud, which may be generally annular. The fan system may have features and an operational configuration like that as described in pending US
patent application SN 15/477,097 1004751 The fan system can be operable to draw in and direct the flow of air 416. The air 416 may be drawn through the top or sides of the HX unit 400 (and respective cores, which may then be used to cool one or more utility fluids F) as may be applicable, and out as heated exhaust 418.
1004761 Utility fluid F (or multiple F's) may include by way of example, lube oil, jacket water, turbo (such as for an engine), transmission fluid (such as for a pump), and hydraulic fluid (such as for the fan drive).
1004771 While not meant to be limited, HGD 403 may be an engine, a genset, a motor, a pump, or other comparable equipment that operates in a manner whereby a utility fluid is heated.
1004781 Embodiments herein provide for a system (and related method of operating or using the system) using on or more components described herein. For example, such a system may include a wellbore and other wellbore and production equipment, as well as a frac trailer. The frac trailer may include a frac pump, a HGD, and a HX unit as pertaining to the disclosure.
1004791 Other embodiments herein provide for a method of doing business related to a monitored heat exchanger system. The method may include the steps of having a customer relationship between a provider and recipient (i.e., customer, client, etc.). The method may include charging a one-time or ongoing fee related to the monitored system. The provider may install the monitored heat exchanger system as a new standalone skid. Alternatively, the provider may retrofit existing equipment for operable communication with a monitoring module as described herein. Thus, in embodiments there may be a first transaction related to equipment purchase or use, followed by a second transaction related to installation.

1004801 Another part of transaction, or alternatively, a separate transaction, may pertain to a license for the use software (or programming) related to a logic circuit of the monitoring module, as the provider may own copyright in the respective software (or be an exclusive licensee).
1004811 The provider may provide services and equipment directly, or may use a subcontractor.
1004821 Once a recipient has completed its applicable transaction, and the system has been associated with monitoring functionality, the recipient may be provided with the capability to track and monitor one or more characteristics or properties respective to an individual heat exchanger unit performance. Reported information (or parameters) may include percentage of fouling, time between warnings, cleaning frequency, etc). This information may be groupable by location or region to see if one is performing better than another. The system may also indicate them how many units are in green, yellow or red, which may further help identify problem regions, operators etc.
1004831 The method may further include a field service component. That is, the provider, or affiliated field service business, may be able to offer (give, etc.) a solution, whereby the monitored system sends out an alarm of some variation, such as SMS/text, email, etc. In this respect the recipient has the option to address the alarm, or have the provider tend to. In other words, in the event the monitored system provides a warning about, for example, a dirty radiator, the recipient is prompted to find a remedy that can alleviate or mitigate process downtime.
1004841 The business method may thus include steps pertaining to receiving a warning via the monitoring module, and selecting a remediation option, such as cleaning with dry ice or a pressure washer or in their yard when the pump comes back in from the field. In aspects, these steps may be handled remotely and/or off the jobsitc. Accordingly, the recipient need not even have to take any action, as the provider may handle all steps.
1004851 The business method may include providing an incentivized transaction if the monitoring module is used with a HX unit that is sold by the provider. The monitoring module may have components as described herein, and the HX unit may likewise have components of any HX unit described herein.
Advantages.
1004861 Embodiments of the disclosure advantageously provide for an improved heat exchanger unit useable with a wide array of heat generating devices.

1004871 Embodiments of the disclosure advantageously provide for new and innovative systems, hardware, software, and related methods, for monitoring a heat exchanger unit.
An associated monitoring module may beneficially be retrofitted to existing equipment.
Sensors of the module are configured for precision, and in conjunction with a microcontroller, are able together to accurately measure characteristics of a heat exchanger in real-time. In particular, the characteristic may be fouling. The ability to accurately warn of fouling alleviates the need for conventional and cumbersome remediation methods.
1004881 Embodiments of the disclosure advantageously provide for a new and durable sensor assembly useable in a wide range of external environments where heat exchanger units are often used.
1004891 The heat exchanger unit of the disclosure may provide for the ability to reduce sound attributable to a point source, such as a fan. The fan may have a dominant acoustic frequency that may be reduced by at least 10 decibels. The heat exchanger unit may be configured with a particular baffle configuration that helps reduce sound. The baffles may be configured to have or contain a sound absorbing material. At the same time the baffle configuration may help drastically improve streamlined airflow, which further helps reduce sound emission and improves overall efficiency of the heat exchanger unit because of lowered power requirements.
1004901 The heat exchanger unit may advantageously provide for the ability to simultaneously cool multiple utility fluids in parallel.
1004911 Advantages of the disclosure provide for a compact design with more heat transfer area in limited space, more heat transfer capability, reduced overall height by arranging heat exchanger cores at all four sides in general cube shape.
1004921 Embodiments of the disclosure advantageously provide for the ability to improve structural integrity of a heat exchanger unit. A radiator core of the unit may have an increased mass on a core end that may substantially prohibit or eliminate runoff of brazing material during a welding process.
1004931 The heat exchanger unit may provide for the ability to provide an 'absorber' effect with any thermal expansion. That is, one or more components may be coupled together via the use of a flex amount assembly, the assembly having a deformable member associated therewith.
As thermal expansion occurs, the deformable member may defon-n resulting to absorb the expansion motion or stress.

1004941 Advantages herein may provide for a more convenient and realizable welding practice for core and tank, and a more convenient and flexible mount assembly.
1004951 While embodiments of the disclosure have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the disclosure presented herein are possible and are within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations. The use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of any claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, and the like.
1004961 Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present disclosure.

Claims (44)

1. An airflow sensor assembly for a monitored heat exchanger system, the sensor comprising:
a casing comprising a casing outer surface, a casing inner surface, a casing topside, a casing bottom side, and a casing opening;
a mounting frame disposed proximate to the casing bottom side, the mounting frame further comprising a central segment;
a guard disposed proximate to the casing topside;
a support platform coupled with the central segment, and further comprising: a platform hollow; and a top platform surface;
a shaft centrally positioned within the casing opening and further disposed in the platform hollow;
a plurality of assembly screws disposed through the casing, the mounting frame, and the guard;
a plurality of fasteners configured for connecting with the plurality of assembly screws;
a first bearing disposed around the shaft and proximate the support platform;
a second bearing disposed around the shaft and on top of the first bearing, and proximate the support platform;
a circuit board positioned onto the top platform surface, the circuit board being configured with an operable logic circuit further comprising a secondary microcontroller, a Hall effect sensor, and a transceiver;
a first lock nut threadingly engaged around the shaft in an amount sufficient to engage the second bearing;
an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform;
at least one magnet coupled with the inner sensor housing;
a rotating member comprising a plurality of blades, and the rotating member being disposed around the shaft;
a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member.

2. The airflow sensor assembly of claim 1, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, and thus causes the shaft to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

3. An airflow sensor assembly for a monitored heat exchanger system, the sensor comprising:
a mounting frame configured for coupling the assembly with the heat exchanger unit, the mounting frame further comprising a central segment;
a support platform coupled with the central segment, and further comprising: a platform hollow; and a top platform surface;
a shaft disposed in the platform hollow;
a first bearing disposed around the shaft and proximate the support platform;
a circuit board positioned onto the top platform surface, the circuit board being configured with an operable logic circuit further comprising a secondary microcontroller and a Hall effect sensor;
a rotating member comprising a plurality of blades, the rotating member being disposed around the shaft;
a lock nut threadingly engaged around the shaft sufficiently enough to engage a rotating member mounting ring.

4. The airflow sensor assembly of claim 3, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, and thus causes the shaft to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

5. A sensor assembly comprising:
a mounting frame further comprising a central segment;
a support platform coupled with the central segment, and further comprising:
a platform hollow; and a top platform surface;

a shaft disposed in the platform hollow;
a first bearing disposed around the shaft, and also disposed at least partially in the platform hollow;
a circuit board positioned onto the top platform surface, the circuit board being configured with a secondary microcontroller and a Hall effect sensor;
a first lock nut threadingly engaged around the shaft sufficiently enough to exert a holding pressure against the first bearing;
an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform;
a rotating member comprising a plurality of blades and a rotating member mounting ring, the rotating member being disposed around the shaft and on top of the inner sensor housing;
a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring.

6. The sensor assembly of claim 5, the assembly further comprising:
a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening;
a guard disposed proximate to the casing topside;
a plurality of assembly screws disposed through the casing, the mounting frame, and the guard;
a plurality of fasteners configured for connecting with the plurality of assembly screws; and a second bearing disposed around the shaft and on top of the first bearing.

7. The sensor assembly of claim 6, wherein the assembly further comprises:
a shim disposed around the shaft and between the first bearing and the second bearing;
a tri-wing shaped support plate disposed on top of the second bearing;
at least one binding screw mated with a respective binding post coupled together, whereby the tri-wing shaped support plate, the circuit board, the support platform, and the central segment are resultantly coupled together.

8. The sensor assembly of claim 7, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shall rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

9. A sensor assembly comprising:
a mounting frame;
a cylindrical support platform coupled with the mounting frame, and further comprising: a platform hollow; and a top platform surface;
a circuit board positioned onto the top platform surface, the circuit board being configured with a secondary microcontroller and a Hall effect sensor;
an inner sensor housing configured to extend out and around the circuit board and the support platform;
a first magnet coupled to an underside of the inner sensor housing;
a rotating member comprising a plurality of blades and a rotating member mounting ring, the rotating member being disposed on top of the inner sensor housing;
a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring.

10. The sensor assembly of claim 9 further comprising:
a shaft disposed in the platform hollow;
a first bearing disposed around the shaft, and also disposed at least partially in the platform hollow;
a first lock nut threadingly engaged around the shaft sufficiently enough to exert a holding pressure against the first bearing;
a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring, wherein rotating member is disposed around the shaft.

11. The sensor assembly of claim 10, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

12. The sensor assembly of claim 9, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

13. The sensor assembly of claim 9, the assembly further comprising:
a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening;
a guard disposed proximate to the casing topside;
a plurality of assembly screws disposed through the casing, the mounting frame, and the guard;
a plurality of fasteners configured for connecting with the plurality of assembly screws; and a second bearing disposed around the shaft and on top of the first bearing;
and a second magnet coupled to the underside of the inner sensor housing.

14. The sensor assembly of claim 9, wherein the assembly further comprises:
a shim disposed around the shaft and between the first bearing and the second bearing;
a tri-wing shaped support plate disposed on top of the second bearing;
at least one binding screw mated with a respective binding post coupled together, whereby the tri-wing shaped support plate, the circuit board, the support platform, and the central segment are resultantly coupled together.

15. The sensor assembly of claim 9, the assembly further comprising a second magnet coupled to the underside of the inner sensor housing, wherein the first magnet is oriented in a N/S pole orientation, and wherein the second magnet is oriented in a S/N pole orientation.

16. The sensor assembly of claim 15, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shaft rotates the at first magnet periodically comes into proximity with the Hall effect sensor, wherein a first digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the first magnet, and wherein a second digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the second magnet.

17. An airflow sensor assembly for a monitored heat exchanger system, the sensor comprising:
a casing comprising: a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening;
a mounting frame disposed proximate to the casing bottom side;
a guard disposed proximate to the casing topside;
a shaft centrally positioned within the casing opening;
a support platform disposed around the shaft;
a plurality of assembly screws disposed through the casing, the mounting frame, and the guard;
a plurality of fasteners configured for connecting with the plurality of assembly screws;
a first bearing disposed around the shaft in a bearing annulus between the shaft and the support platform;
a second bearing disposed around the shaft in a bearing annulus between the shaft and the support platform;
a shim disposed around the shaft and between the first bearing and the second bearing;
a circuit board coupled to the support platform, the circuit board being configured with an operable logic circuit further comprising a microcontroller, a Hall effect sensor, and a transceiver;
a first lock nut threadingly engaged around the shaft to in an amount sufficient to engage the second bearing;
an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform;
at least one magnet coupled with the inner sensor housing;
a rotating member comprising a plurality of blades disposed around the shaft;
and a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member.

18. The airflow sensor assembly of claim 17, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, and the shaft is also thus caused to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

19. The sensor assembly of claim 17, the assembly further comprising a second magnet coupled to the underside of the inner sensor housing, wherein the at least one magnet is oriented in a N/S pole orientation, and wherein the second magnet is oriented in a S/N
pole orientation.

20. The sensor assembly of claim 19, wherein in operation, as airflow impacts the plurality of blades, the rotating member rotates, which resultantly causes the shaft to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, wherein a first digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet, and wherein a second digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the second magnet.

21. A sensor assembly comprising:
a mounting frame;
a cylindrical support platform coupled with the mounting frame, and further comprising: a platform hollow; and a top platform surface;
a circuit board positioned onto the top platform surface, the circuit board being configured with a secondary microcontroller and a Hall effect sensor;
an inner sensor housing configured to extend out and around the circuit board and the support platform;
a first magnet coupled to an underside of the inner sensor housing; and a rotating member comprising a plurality of blades and a rotating member mounting ring, the rotating member being disposed on top of the inner sensor housing.

22. The sensor assembly of claim 21 further comprising:
a shaft disposed in the platform hollow;
a first bearing disposed around the shaft, and also disposed at least partially in the platform hollow;
a first lock nut threadingly engaged around the shaft sufficiently enough to exert a holding pressure against the first bearing; and a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring, wherein the rotating member is disposed around the shaft.

23. The sensor assembly of claim 22, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, resultantly causing the shaft to rotate, wherein as the shaft rotates the first magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by first magnet passing thereby.

24. The sensor assembly of claim 22, the assembly further comprising:
a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening;
a guard disposed proximate to the casing topside;
a plurality of assembly screws disposed through the casing, the mounting frame, and the guard;
a plurality of fasteners configured for connecting with the plurality of assembly screws; and a second bearing disposed around the shaft and on top of the first bearing;
and a second magnet coupled to the underside of the inner sensor housing.

25. The sensor assembly of claim 24, wherein the assembly further comprises:
a shim disposed around the shaft and between the first bearing and the second bearing;
a tri-wing shaped support plate disposed on top of the second bearing;
at least one binding screw mated with a respective binding post coupled together, whereby the tri-wing shaped support plate, the circuit board, the support platform, and the central segment are resultantly coupled together.

26. The sensor assembly of claim 25, the assembly further comprising a second magnet coupled to the underside of the inner sensor housing, wherein the first magnet is oriented in a N/S pole orientation, and wherein the second magnet is oriented in a S/N
pole orientation.

27. The sensor assembly of claim 26, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shall to rotate, wherein as the shaft rotates the at first magnet periodically comes into proximity with the Hall effect sensor, wherein a first digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the first magnet passing thereby, and wherein a second digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the second magnet passing thereby.

28. The sensor assembly of claim 25, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shaft rotates the at first magnet periodically comes into proximity with the Hall effect sensor, wherein a first digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the first magnet, and wherein a second digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the second magnet.

29. The sensor assembly of claim 21, the assembly further comprising a second magnet coupled to the underside of the inner sensor housing, wherein the first magnet is oriented in a N/S pole orientation, and wherein the second magnet is oriented in a S/N
pole orientation.

30. The sensor assembly of claim 29, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shall rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

31. The sensor assembly of claim 21, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shaft rotates the at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

32. A sensor assembly comprising:
a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening;
a mounting frame disposed proximate to the casing bottom side, the mounting frame further comprising a central segment;
a guard disposed proximate to the casing topside;
a support platform coupled with the central segment, and further comprising:
a platform hollow; and a top platform surface;
a shaft centrally positioned within the casing opening and further disposed in the platform hollow;
a plurality of assembly screws disposed through the casing, the mounting frame, and the guard;
a plurality of fasteners configured for connecting with the plurality of assembly screws;
and a first bearing disposed around the shaft and the proximate the support platform.

33. The sensor assembly of claim 32, the assembly further comprising: a circuit board positioned onto the top platform surface;
an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform; and a rotating member comprising a plurality of blades, and the rotating member being disposed around the shaft.

34. The sensor assembly of claim 33, the assembly further comprising:
at least one magnet coupled with the inner sensor housing, wherein the circuit board is configured with an operable logic circuit further comprising a secondary microcontroller, a Hall effect sensor, and a transceiver;

35. The sensor assembly of claim 34, the assembly further comprising:
a second bearing disposed around the shaft and on top of the first bearing, and proximate the support platform;
a first lock nut threadingly engaged around the shaft in an amount sufficient to engage the second bearing; and a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member.

36. The sensor assembly of claim 34, wherein in operation as the shaft rotates the at least one magnet periodically comes into close proximity with the Hall effect sensor, and wherein a digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.

37. The sensor assembly of claim 32, the assembly further comprising:
a second bearing disposed around the shaft and on top of the first bearing, and proximate the support platform;
a first lock nut threadingly engaged around the shaft in an amount sufficient to engage the second bearing; and a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member.

38. A sensor assembly comprising:
a mounting frame further comprising a central segment;
a support platform coupled with the central segment, and further comprising: a platform hollow; and a top platform surface;
a shaft disposed in the platform hollow;
a first bearing disposed around the shall, and also disposed at least partially in the platform hollow;
a circuit board positioned onto the top platform surface, the circuit board being configured with a secondary microcontroller and a Hall effect sensor;

a first lock nut threadingly engaged around the shaft sufficiently enough to exert a holding pressure against the first bearing;
an inner sensor housing disposed around the shaft, the inner sensor housing configured to extend out and around the circuit board and the support platform; and a rotating member comprising a plurality of blades and a rotating member mounting ring, the rotating member being disposed around the shaft and on top of the inner sensor housing.

39. The sensor assembly of claim 38, the assembly further comprising:
a second lock nut threadingly engaged around the shaft sufficiently enough to engage the rotating member mounting ring.

40. The sensor assembly of claim 39, the assembly further comprising:
a casing comprising a casing outer surface, a casing inner surface, a casing topside, and a casing bottom side, and a casing opening;
a guard disposed proximate to the casing topside; and a plurality of assembly screws disposed through the casing, the mounting frame, and the guard.

41. The sensor assembly of claim 40, the assembly further comprising: at least one magnet coupled with the inner sensor housing;
a plurality of fasteners configured for connecting with the plurality of assembly screws;
and a second bearing disposed around the shaft and on top of the first bearing.

42. The sensor assembly of claim 41, wherein the assembly further comprises:
a shim disposed around the shaft and between the first bearing and the second bearing;
a tri-wing shaped support plate disposed on top of the second bearing;
at least one binding screw mated with a respective binding post coupled together, whereby the tri-wing shaped support plate, the circuit board, the support platform, and the central segment are resultantly coupled together.

43. The sensor assembly of claim 41, the assembly further comprising a second magnet coupled to the underside of the inner sensor housing, wherein the first magnet is oriented in a N/S pole orientation, and wherein the second magnet is oriented in a S/N pole orientation.

44. The sensor assembly of claim 38, wherein in operation, as airflow impacts the plurality of blades the rotating member rotates, thus causing the shaft to rotate, wherein as the shaft rotates at least one magnet periodically comes into proximity with the Hall effect sensor, and wherein a first digital signal is generated based on a change in a magnetic field of the Hall effect sensor caused by the at least one magnet.