This disclosure relates generally to an axial fan diffuser. More specifically, the disclosure relates to an axial fan diffuser for use in a heating, ventilation, and air conditioning (HVAC) system.
A heating, ventilation, and air conditioning (HVAC) system typically includes a compressor, a condenser, an expansion device, and an evaporator, combined to form a refrigeration circuit. The HVAC system can include a condenser fan configured to draw air over the condenser. A condenser fan is often placed within a duct. The outlet of the duct generally includes a grille, which serves to prevent anything from reaching the moving parts of the condenser fan (e.g., a body part such as a finger, foreign substances such as leaves and sticks, or the like).
This disclosure relates generally to an axial fan diffuser. More specifically, the disclosure relates to an axial fan diffuser for use in an HVAC system.
In some embodiments, an axial fan can be a condenser fan in a refrigeration unit. A refrigeration unit can, for example, include an air-cooled water chiller (e.g., a compressor, condenser, expansion device, and evaporator), an air-cooled condenser unit (e.g., a compressor, condenser, expansion device, and evaporator), or other similar unit in an HVAC system including one or more axial fans. The axial fan can be installed within a duct. The duct can include a diffuser collar. The diffuser collar can control an expansion of an outflow from the axial fan from an outflow side of the axial fan to the duct exit.
In some embodiments, an axial fan including a diffuser collar can have an improved static efficiency over an axial fan without a diffuser collar. Fan performance can, for example, be measured on a wind tunnel to obtain fan pressure rise and flow rate, which along with input power can be used to calculate static efficiency. In one embodiment, a static efficiency of an axial fan including a diffuser collar tested in a wind tunnel can be between about 5 and about 10 percent higher than an axial fan without a diffuser collar tested in a wind tunnel. It is to be appreciated that the stated range is exemplary and that efficiency improvements can vary beyond the stated range.
In one embodiment, a fan assembly can include an impeller having a plurality of blades, a duct configured to receive an outflow provided by the impeller, and a diffuser collar extending from the impeller toward a duct exit. The diffuser collar has a variable diameter and can be configured to radially expand the outflow provided by the impeller.
In one embodiment, a diffuser collar can have a smaller diameter at the outflow side of an axial fan than a diameter of a duct in which the axial fan is installed. The diffuser collar can expand the outflow from the axial fan to a slower rate than the duct alone. In some embodiments, modifying the expansion rate of the outflow can improve the efficiency of the axial fan by, for example, increasing pressure rise through diffusion of the outflow.
In another embodiment, a plurality of diffuser collars are concentrically arranged to control an expansion of an outflow from an axial fan. The plurality of diffuser collars can include a plurality of vane diffusers. In some embodiments, a plurality of diffuser collars and a plurality of vane diffusers can reduce an amount of the outflow recirculating to the inlet side of the axial fan. In some embodiments, reducing recirculation of the outflow can improve the efficiency of the axial fan. For example, the plurality of vane diffusers can increase the axial velocity of the outflow provided by the axial fan, thereby allowing more air to be drawn without increasing the speed of the axial fan. The plurality of vane diffusers can also decrease a circumferential velocity of the outflow. Reducing recirculation of the outflow can also reduce a sound level (e.g., audible volume) of the axial fan.
In another embodiment, a diffuser collar can be installed in a duct including a grille. In some embodiments, a plurality of concentrically arranged diffuser collars can be installed in a duct including a grille. In other embodiments, a plurality of diffuser collars and a plurality of vane diffusers can be installed in a duct in place of a grille.
A fan assembly and a method of assembling a diffuser collar in the fan assembly are disclosed. The fan assembly includes an impeller including a plurality of blades. The impeller has an impeller diameter. A duct is configured to receive an outflow provided by the impeller. The duct has a duct exit diameter that is larger than the impeller diameter. The fan assembly further includes a diffuser collar extending from the impeller toward a duct exit. The diffuser collar is configured and arranged to radially expand the outflow provided by the impeller. The diffuser collar has a first diameter at a first edge disposed a first distance from the impeller. A contour extends from the first edge toward a second edge having a second diameter. The second edge is disposed a second distance from the impeller. The first distance is smaller than the second distance, the first diameter is smaller than the second diameter, and the first and second diameters are smaller than the duct exit diameter.
A method of assembling a diffuser collar apparatus in a fan system is described. The method includes providing an axial fan having a duct with a duct exit of a larger diameter than an impeller of the axial fan; and providing a diffuser collar at a duct exit having a variable diameter for radially expanding an outflow from the impeller of the axial fan to the duct exit.
A method of controlling an outflow of an axial fan is described. The method includes providing an axial fan having a duct with a duct exit of a larger diameter than an impeller of the axial fan; and providing a plurality of concentrically spaced diffuser collars having variable diameters at the duct exit for radially expanding an outflow from the impeller of the axial fan out of the duct exit.
References are made to the accompanying drawings that form a part of this disclosure, and which illustrate embodiments in which the systems and methods described in this specification may be practiced.
Like reference numbers represent like parts throughout.
This disclosure relates generally to an axial fan diffuser. More specifically, the disclosure relates to an axial fan diffuser for use in an HVAC system.
A refrigeration unit in an HVAC system generally includes a compressor, a condenser, an expansion device, an evaporator, and a condenser fan (e.g., an axial fan installed within a duct). The refrigeration unit can, for example, be an air-cooled water chiller, an air-cooled condenser unit, or other similar unit in an HVAC system including one or more axial fans. The condenser fan is configured to draw airflow over the condenser in the refrigeration unit.
In some embodiments, a refrigeration unit can include a plurality of condenser fans. The condenser fan is generally installed within a duct. The duct modifies the outflow from the condenser fan. The configuration of the duct (e.g., height, diameter, or the like), at least in part, determines the efficiency of the condenser fan. A grille is typically installed at the duct exit. The grille serves as a guard, preventing contact with the condenser fan and its rotating parts (e.g., for safety, to prevent damage to the condenser fan, or the like). The duct is typically of a larger diameter than an impeller of the condenser fan, which can cause the outflow to decelerate as it expands from the outflow side of the impeller to the duct exit. A portion of the outflow can recirculate because of the larger diameter of the duct. Recirculation of the outflow can increase the sound level of the condenser fan. In some embodiments, the audible volume of the condenser fan can particularly be an issue if the refrigeration unit is operating on or near a building having a maximum sound level limit (e.g., a sound ordinance, a user preference, or the like). Recirculation of the outflow can also adversely impact the efficiency of the condenser fan.
Embodiments of this disclosure are directed to a diffuser collar to modify an outflow from an axial fan. Some embodiments include a plurality of diffuser collars and a plurality of vane diffusers to modify the outflow from the axial fan. Modifying the outflow from the axial fan can increase the efficiency of the axial fan as compared to a system not including the diffuser collar and/or vane diffusers. In some embodiments, an axial fan including a diffuser collar can have an improved static efficiency over an axial fan without a diffuser collar. In some embodiments, fan performance can be measured on a wind tunnel to obtain fan pressure rise and flow rate, which along with input power can be used to determine static efficiency. In one embodiment, a static efficiency of an axial fan including a diffuser collar tested in a wind tunnel can be between about 5 and about 10 percent higher than an axial fan without a diffuser collar tested in a wind tunnel. It is to be appreciated that the stated range is exemplary and that efficiency improvements can vary beyond the stated range. In some embodiments, the diffuser collar can reduce the sound level of the axial fan during operation.
A condenser fan in a refrigeration unit is discussed by way of example in this specification. The embodiments, aspects, and concepts described within this specification may apply to axial fans other than a condenser fan in a refrigeration unit. Examples of additional applications include, but are not limited to, exhaust fans, circulation fans, radiator fans, cooling fans (e.g., for electronics or the like), or the like.
In one embodiment, a fan assembly can include an impeller having a plurality of blades, a duct configured to receive an outflow provided by the impeller, and a diffuser collar extending from the impeller toward a duct exit. The diffuser collar has a variable diameter and can be configured to radially expand the outflow provided by the impeller.
The impeller 105 includes a plurality of blades installed on a central hub. The impeller 105 can also include a band at the outer periphery of the blades. This band is represented as a dashed box around the impeller 105 in
The impeller 105 has a diameter d1 and a height h. The diameter d1 can, for example, be measured from blade tip to blade tip in a straight line that is perpendicular to the axis R-R. If the impeller 105 includes a band at the outer periphery of the blades, the diameter d1 can be the diameter of the band in such an embodiment. The diameter d1 is smaller than the diameter of the duct 110 on the inflow side 120A. The diameter d1 can be smaller than the diameter of the duct 110 on the outflow side 120B as well. The diameter d1 is smaller than the diameter of the duct 110 at the location of the impeller 105 corresponding to the outflow side 120B. Because the diameter of the duct 110 is larger than the diameter d1 of the impeller 105, the outflow from the impeller 105 can expand rapidly. The rapid expansion can cause recirculation of a portion of the outflow to the inflow side 120A of the impeller 105. The recirculation can reduce the efficiency of the axial fan system 100 and increase a sound level of the axial fan system 100.
The duct 110 duct has a diameter d2 on the inlet side 120A. The outlet side 120B of the duct 110 has a diameter d2′. The diameter d2 is greater than the diameter d1 of the impeller 105. Because the diameter d2 is greater than the diameter d1 of the impeller 105, the outflow may expand rapidly, which can cause recirculation of the outflow and can reduce the efficiency of the axial fan system 100.
Disposed near the outflow side 120B of the impeller 105 is the diffuser collar 115. A diameter d3 of the diffuser collar 115 disposed near the outflow side 120B of the impeller 105 is about the same as the diameter d1 of the impeller 105. In some embodiments, the diameter d3 can be slightly smaller than the diameter d1 of the impeller 105 such that when the impeller 105 spins it rubs away a portion of the diffuser collar 115. This can, for example, provide a tighter fit between the diffuser collar 115 and the impeller 105. The diffuser collar 115 can be made of, for example, plastic. It is to be appreciated that the diffuser collar 115 can be made of materials other than plastic, such as, but not limited to, sheet metal or the like.
The diffuser collar 115 has a height h3 and a diameter d3′ on the exit side of the duct 110. The diameter d3′ is generally larger than the diameter d3. The contour of the diffuser collar 115 varies from the outflow side 120B of the impeller to the exit of the duct 110. In some embodiments, the contour is linear. In other embodiments, the contour can be non-linear. The variation in diameter is generally designed to expand the outflow of the impeller 105 at a desired rate to control an axial component and a circumferential component of the outflow velocity. The height h3 of the diffuser collar 115 is about the same as the distance from the outflow side 120B of the impeller 105 to the exit of the duct 110. The variation of the diameter of the diffuser collar 115 can be determined based on the height h3. For example, as the height h3 increases, the effectiveness of varying the diameter may increase. Similarly, as the height h3 increases, the variation between the diameters d3, d3′ of the diffuser collar 115 may be such that the contour of the diffuser collar 115 is increasingly non-linear.
A grille (not shown in
The axial fan system 200 includes the impeller 105 as described in accordance with
Each of the plurality of diffuser collars 115 has a first diameter disposed near the outflow side of the impeller 105 and a second diameter disposed near the exit of the duct 110 (as shown and described for the diffuser collar 115 in accordance with
As described in accordance with
The plurality of vane diffusers 305 is disposed between the concentrically arranged plurality of diffuser collars 115. The plurality of vane diffusers 305 extend substantially radially from the hub of the impeller 105 toward the duct (e.g., the duct 110 of
The vane diffusers 305 are configured to decrease a circumferential component of the velocity of the outflow and increase an axial component of the velocity of the outflow. As a result, the vane diffusers 305 can increase the outflow of the impeller 105 without increasing the speed of the impeller 105. In some embodiments, the vane diffusers 305 allow the axial fan speed to be decreased without affecting the cooling capacity of the refrigeration unit. Accordingly, the speed of the impeller 105 can be reduced, which can, in some embodiments, decrease the sound level of the axial fan system 300.
The contour of the vane diffusers 305 can be designed to control the expansion of the outflow in the axial direction. The number and/or spacing of the vane diffusers 305 can be varied based on the location as well. For example, there may be more vane diffusers 305 at the peripheral region of the impeller 105 than there are in the central region of the impeller 105 (e.g., near the axis of rotation of the impeller 105).
The plurality of vane diffusers 305 and the plurality of concentrically arranged diffuser collars 115 can take the place of the grille at the exit of the duct 110. Accordingly, the arrangement of the vane diffusers 305 and the diffuser collars 115 is such that body parts and other foreign substances are prevented from coming into contact with the impeller 105. The arrangement may also be designed to withstand a load directed toward the impeller (e.g., if an object is placed on the vane diffuser 305 and diffuser collar 115 arrangement, the object does not cause either the vane diffusers 305 or the diffuser collars 115 to come into contact with the impeller 105).
It is noted that any of aspects 1-12 below can be combined with any of aspects 13-14, 15-16, and 17-18. It is also to be noted that any of aspects 13-14 can be combined with any of aspects 1-12, 15-16, or 17-18. Further, any of aspects 15-16 can be combined with any of aspects 1-12, 13-14, or 17-18 and any of aspects 17-18 can be combined with any of aspects 1-12, 13-14, or 15-16.
The terminology used in this Specification is intended to describe particular embodiments and is not intended to be limiting. The terms “a,” “an,” and “the” include the plural forms as well, unless clearly indicated otherwise. The terms “comprises” and/or “comprising,” when used in this Specification, specify the presence of the stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or components.
With regard to the preceding description, it is to be understood that changes may be made in detail, especially in matters of the construction materials employed and the shape, size, and arrangement of parts without departing from the scope of the present disclosure. The word “embodiment” as used within this Specification may, but does not necessarily, refer to the same embodiment. This Specification and the embodiments described are exemplary only. Other and further embodiments may be devised without departing from the basic scope thereof, with the true scope and spirit of the disclosure being indicated by the claims that follow.
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