Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/40—Casings; Connections of working fluid
  • F04D29/403—Casings; Connections of working fluid especially adapted for elastic fluid pumps
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D17/00—Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps
  • F04D17/08—Centrifugal pumps
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D19/00—Axial-flow pumps
  • F04D19/002—Axial flow fans
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D25/00—Pumping installations or systems
  • F04D25/02—Units comprising pumps and their driving means
  • F04D25/06—Units comprising pumps and their driving means the pump being electrically driven
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D25/00—Pumping installations or systems
  • F04D25/02—Units comprising pumps and their driving means
  • F04D25/08—Units comprising pumps and their driving means the working fluid being air, e.g. for ventilation
  • F04D25/12—Units comprising pumps and their driving means the working fluid being air, e.g. for ventilation the unit being adapted for mounting in apertures
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/02—Selection of particular materials
  • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/05—Shafts or bearings, or assemblies thereof, specially adapted for elastic fluid pumps
  • F04D29/053—Shafts
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
  • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
  • F04D29/00—Details, component parts, or accessories
  • F04D29/60—Mounting; Assembling; Disassembling
  • F04D29/601—Mounting; Assembling; Disassembling specially adapted for elastic fluid pumps
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
  • F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
  • F24F13/20—Casings or covers
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
  • F24F7/00—Ventilation
  • F24F7/007—Ventilation with forced flow
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2230/00—Manufacture
  • F05D2230/50—Building or constructing in particular ways
  • F05D2230/54—Building or constructing in particular ways by sheet metal manufacturing
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2300/00—Materials; Properties thereof
  • F05D2300/10—Metals, alloys or intermetallic compounds
  • F05D2300/12—Light metals
  • F05D2300/121—Aluminium
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2300/00—Materials; Properties thereof
  • F05D2300/10—Metals, alloys or intermetallic compounds
  • F05D2300/17—Alloys
  • F05D2300/171—Steel alloys
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
  • F24F13/00—Details common to, or for air-conditioning, air-humidification, ventilation or use of air currents for screening
  • F24F13/20—Casings or covers
  • F24F2013/205—Mounting a ventilator fan therein
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49229—Prime mover or fluid pump making
  • Y10T29/49236—Fluid pump or compressor making
  • Y10T29/49243—Centrifugal type
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49229—Prime mover or fluid pump making
  • Y10T29/49236—Fluid pump or compressor making
  • Y10T29/49245—Vane type or other rotary, e.g., fan

Definitions

• Embodiments described herein generally relate to fan assemblies.
• Specific examples may include industrial fan assemblies, such as plenum fans.
• Fan assemblies such as plenum fans are commonly used in a number of industrial and consumer applications.
• the fan structure provides positioning of the motor and impeller assembly with respect to an inlet plate and/or inlet funnel, whilst also supporting the whole fan, rigidly or sprung, with respect to a customer's equipment.
• plenum fan construction consist of heavy gauge steel channels/beams that in turn support a separate heavy gauge steel motor mounting pedestal and inlet plate.
• Improved fan assemblies are desired that use less metal, are lighter weight, and exhibit improved performance, such as higher stiffness and/or higher stiffness to weight ratio.
• FIG. 1 is a fan assembly in accordance with some embodiments of the invention.
• FIG. 2A is chart illustrating some example material specifications in accordance with the prior art.
• FIG. 2B is chart illustrating some example material specifications in accordance with some embodiments of the invention.
• FIG. 3 is chart illustrating some additional material specifications in accordance with some embodiments of the invention.
• FIG. 4 is a flow diagram of an example method in accordance with some embodiments of the invention.
• Figure 1 shows a fan assembly 100 according to an example of the invention.
• the fan assembly 100 includes a motor 110 and an impeller 112.
• motors 110 include electric motors such as DC or AC motors, however other motors such as hydraulic motors, etc, are within the scope of the invention.
• Figure 1 shows a centrifugal impeller, having a number of blades 114, the invention is not limited to centrifugal impellers. Examples of the invention may also be used with axial impellers, and/or mixed flow impellers.
• a plenum fan assembly 100 is shown as an example, configurations of the present invention may also be used with other types of fans.
• the fan assembly 100 includes a support frame 120 to hold the motor 110, which in turn holds the impeller 112.
• the support frame 120 further includes an inlet plate 130 that couples to an inlet funnel 134.
• Examples of the fan assembly 100 include features that allow the fan assembly 100 to be significantly lighter and stiffer than prior fan assemblies. Lighter fan assemblies are desirable for a number of reasons. A lighter fan assembly is cheaper to ship. A lighter fan assembly requires less structural support at installation, for example on a rooftop or other ceiling structure. A lighter fan assembly may also use less material, such as sheet metal, and as a result, will be less expensive to manufacture. A stiffer fan assembly may be quieter than a less stiff fan assembly. In one example, a stiffer assembly allows the use of less material, and thus a lighter assembly. Using configurations described in the present disclosure, a fan assembly is shown that may be stiffer than prior configurations. Using configurations described in the present disclosure, a fan assembly is shown that may be lighter than prior configurations. Using configurations described in the present disclosure, a fan assembly may be both lighter and stiffer than prior
• the example fan assembly 100 of Figure 1 shows a plurality of box section rails.
• a first pair of box section rails 122 are shown running parallel to an axis of rotation of the motor 110.
• the box section rails 122 are formed from box section stock material, such as extruded stock.
• the box section rails 122 are formed by joining more than one formed component, such as two "L" shaped sections together to form the box section.
• an L shaped section 123 is shown joined with a second L shaped section to form each box section rail 122.
• two L shaped components are used as an example, other shapes of sub-components are possible when forming box section rails.
• substantially all components of the support frame 120 are formed from sheet metal.
• the sheet metal includes steel.
• the sheet metal includes aluminum.
• Other metals, or alloys are also possible within the scope of the invention.
• One advantage of forming box section rails from L shaped sections is that the sub-components are more easily formed from sheet metal. In many instances, sheet metal is less expensive that other types of stock material. As noted above, in examples of the present invention, cost and weight are further reduced by using thinner gauge sheet metal that in prior configurations.
• a second pair of box section rails 124 are further shown coupled between the first pair of box section rails 122.
• the first and second pair of box section rails 122, 124 form a ladder base unit, although the invention is not so limited.
• Other configurations of box section rail base units may include out of plane sections, and/or angles between box section rails that are different than 90 degrees.
• An advantage of using box section rail components includes increased stiffness that allows reduced weight (higher stiffness to weight ratio).
• the ladder configuration shown in Figure 1 is particularly effective at providing a high stiffness to weight ratio.
• the support frame 120 of the Figure 1 example further shows a motor mount 126. The motor mount is shown coupled to the second pair of box section rails 124.
• At least one internal member 128 is included with the motor mount 126 to form a plurality of triangular units within the motor mount 126.
• the resulting motor mount 126 forms a truss to further increase stiffness of the support frame 120, and provide a higher stiffness to weight ratio.
• a number of formed features are also included in at least a portion of the support frame 120.
• One or more formed features may add stiffness to individual components, and further increase stiffness of the support frame 120 and/or provide a higher stiffness to weight ratio.
• the inlet plate 130 includes formed features 132.
• the motor mount 126 includes formed features 127.
• at least one internal member 128 includes formed features 129.
• the formed features are shown as stamped or otherwise formed from within a planar surface of a component of the support frame 120. In one example, such a configuration provides stiffness within larger planar portions of a thinner gauge sheet, providing an increased stiffness to weight ratio. Although selected components such as the inlet plate 130, motor mount 126, and internal member 128 are shown in Figure 1 with formed features, other examples of the invention may utilize formed features in fewer or greater numbers of individual components.
• Figure 1 further shows a number of fastening locations 102.
• fasteners such as rivets, swage locks, screws, bolts, etc. are used to join components of the support frame 120.
• the components are joined using other methods, such as adhesives, or welding.
• spot welding is used at fastening locations 102.
• a stiffer and/or lighter fan assembly 100 is possible. Although individual components may be too flexible on their own, when assembled as described and shown in the figures, the support frame 120 becomes stiff, even though a material, such as sheet metal, used to form the support frame 120 is thinner than in prior designs.
• the assembly functions as a monocoque structure, where only in the assembled state does the frame exhibit the stiffness and strength necessary for operation. As noted above, this provides an increased stiffness to weight ratio.
• Figure 2A shows some prior material lists for assembly of three fan assembly examples. The fan size column at the left of the chart shows a fan diameter in millimeters. The materials specifications in the chart are shown for steel sheet metal, with the numbers indicating gauge thickness.
• Figure 2B shows a material list for assembly of thee fan assemblies with the same fan diameters from Figure 2A, but using component designs as described in embodiments of the invention.
• the gauge thickness is significantly reduced using component designs as described in embodiments of the invention.
• the mass of the support frame is equal to or less than half of the mass used in prior designs.
• a stiffness of the support frame is equal to or greater than a stiffness from prior designs, while the mass is equal to or less than half of the mass used in prior designs.
• Figure 3 shows a material list for a selection of example fan assemblies formed according to examples described in the present disclosure. Using methods and configurations shown, the fan assemblies are lighter and/or stiffer than prior designs.
• the chart in Figure 3 illustrates sheet metal gauge thickness for example fan assembly configurations formed from galvanized mild steel sheet.
• the fan sizes indicated in column 1 show fan diameters given in millimeters.
• fan assemblies are often categorized into Air Movement and Control Association (AMCA) international standard classifications. Factors that affect a fan assembly's AMCA class include motor power, and fan size.
• AMCA Air Movement and Control Association
• class I indicates a fan assembly operating range between a low value of approximately 3,400 cubic feet per minute at a static pressure of approximately 2.5 inches water gauge (W.G.) and a high value of approximately 2,415 cubic feet per minute at a static pressure of
• Class II indicates a fan assembly operating range between a low value of approximately 3,400 cubic feet per minute at a static pressure of approximately 2.5 inches water gauge (W.G.) and a high value of approximately 2,415 cubic feet per minute at a static pressure of approximately 5.0 inches water gauge (W.G.).
• Class III indicates a fan assembly operating range between a low value of approximately 5,500 cubic feet per minute at a static pressure of approximately 6.6 inches water gauge (W.G.) and a high value of approximately 4,000 cubic feet per minute at a static pressure of approximately 13.5 inches water gauge (W.G.).
• Figure 4 shows a flow chart of one example method of forming a fan assembly.
• a number of box section rails are formed.
• the number of box section rails are coupled together to form a base unit.
• an inlet plate is coupled to the base unit.
• a motor mount is coupled to the base unit, and in operation 410 a motor is coupled to the motor mount.
• an impeller is coupled to a shaft of the motor.
• any of a number of coupling techniques or fasteners may be used to couple components together to form a support frame of the fan assembly.
• welding and/or adhesives may be used.
• box section rails are formed by joining multiple components, such as L shaped sections, together.
• formed features are further added to selected components of the fan assembly.
• the formed features are stamped.
• other forming techniques such as drawing, bending, forging, etc. are also within the scope of the invention.
• Example 1 includes a fan assembly.
• the fan assembly includes a motor, an impeller coupled to a shaft of the motor, a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components, and a number of formed features within a planar surface of at least one of the number of sheet metal components.
• Example 2 includes the fan assembly of example 1 , wherein the number of sheet metal components include steel sheet metal.
• Example 3 includes the fan assembly of any one of examples 1-2, wherein the number of sheet metal components include aluminum sheet metal.
• Example 4 includes the fan assembly of any one of examples 1-3, further including an inlet funnel coupled to an inlet plate, wherein the inlet plate includes a number of formed features within a planar surface.
• Example 5 includes the fan assembly of any one of examples 1-4, wherein the number of sheet metal components are joined together using a fastener chosen from a group consisting of rivets, swage locks, bolts, screws, and adhesives.
• a fastener chosen from a group consisting of rivets, swage locks, bolts, screws, and adhesives.
• Example 6 includes the fan assembly of any one of examples 1-5, wherein the number of sheet metal components are joined together using welding.
• Example 7 includes the fan assembly of any one of examples 1-6, wherein the impeller includes an axial impeller.
• Example 8 includes the fan assembly of any one of examples 1-7, wherein the impeller includes a centrifugal impeller.
• Example 9 includes a fan assembly that includes a motor, an impeller coupled to a shaft of the motor and a support frame coupled to the motor, wherein the support frame includes a plurality of box section rails coupled together to form a base unit, an inlet plate coupled to the base unit, and a motor mount coupled to the base unit.
• Example 10 includes the fan assembly of example 9, wherein the motor mount includes a plurality of diagonal cross members to form a truss.
• Example 11 includes the fan assembly of any one of examples 9-10, wherein the plurality of box section rails includes a first pair of box section rails parallel to a rotation axis of the motor, and at least two second box section rails coupled between the first pair of box section rails to form a ladder base unit.
• Example 12 includes the fan assembly of any one of examples 9-11, wherein the support frame includes a number of formed features within a planar surface of at least a portion of the support frame.
• Example 13 includes the fan assembly of any one of examples 9-12, wherein the number of formed features are formed within a portion of the motor mount.
• Example 14 includes the fan assembly of any one of examples 9-13, wherein the number of formed features are formed within a portion of the inlet plate.
• Example 15 includes the fan assembly of any one of examples 9-14, wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 14.
• Example 16 includes the fan assembly of any one of examples 9-15, wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 14 for a centrifugal impeller diameter of approximately 365mm.
• Example 17 includes the fan assembly of any one of examples 9-15, wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 16 for a centrifugal impeller diameter of approximately 270mm.
• Example 18 includes the fan assembly of any one of examples 9-15, wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 18 for a centrifugal impeller diameter of approximately 122mm.
• Example 19 includes a method of forming a fan assembly.
• the method includes forming a number of box section rails, coupling together the number of box section rails to form a base unit, coupling an inlet plate to the base unit, coupling a motor mount to the base unit, coupling a motor to the motor mount, and coupling an impeller to a shaft of the motor.
• Example 20 includes the method of example 19, wherein forming the number of box section rails includes bending a flat sheet of metal to form the number of box section rails.
• Example 21 includes the method of any one of examples 19-20, wherein forming the number of box section rails includes joining two L shaped sections of sheet metal together to form the number of box section rails.
• Example 22 includes the method of any one of examples 19-21, further including stamping a number of features within a planar surface of at one sheet metal component of the fan assembly.
• Example 23 includes the method of any one of examples 19-22, wherein stamping a number of features includes stamping a number of features into a portion of the inlet plate.
• Example 24 includes the method of any one of examples 19-23, wherein stamping a number of features includes stamping a number of features into a portion of the motor mount.
• Example 25 includes a fan assembly, including a motor, and an impeller coupled to a shaft of the motor, a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components with no component thicker than 14 gauge steel.
• the fan assembly is designed to operate in a range between a low value of approximately 5,500 cubic feet per minute at a static pressure of approximately 6.6 inches water gauge (W.G.) and a high value of approximately 4,000 cubic feet per minute at a static pressure of
• Example 26 includes a fan assembly, including a motor, and an impeller coupled to a shaft of the motor, a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components with no component thicker than 14 gauge steel.
• the fan assembly is designed to operate in a range between a low value of approximately 4,400 cubic feet per minute at a static pressure of approximately 4.3 inches water gauge (W.G.) and a high value of approximately 3,150 cubic feet per minute at a static pressure of
• Example 27 includes a fan assembly, including a motor, and an impeller coupled to a shaft of the motor, a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components with no component thicker than 14 gauge steel.
• the fan assembly is designed to operate in a range between a low value of approximately 3,400 cubic feet per minute at a static pressure of approximately 2.5 inches water gauge (W.G.) and a high value of approximately 2,415 cubic feet per minute at a static pressure of
• present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Structures Of Non-Positive Displacement Pumps (AREA)

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• 2014
  • 2014-03-20 US US14/220,540 patent/US20150267713A1/en not_active Abandoned
• 2015
  • 2015-03-19 WO PCT/US2015/021388 patent/WO2015143108A1/en active Application Filing
  • 2015-03-19 MX MX2016012212A patent/MX2016012212A/es unknown

Patent Citations (9)

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