ELECTRIC AIR HANDLING UNIT

Abstract

An electric air handling unit for a vehicle manufacturing facility includes an electric heating coil assembly including at least one electric heating coil, an electric heating control panel configured to receive electrical power from a power distribution panel of the air handling unit and supply the electrical power to the electric heating coil assembly, and a first disconnect switch coupled between the power distribution panel and the electric heating control panel. The first disconnect switch is located external to a housing of the electric heating control panel, and the first disconnect switch is configured to selectively enable flow of the electrical power from the power distribution panel to the electric heating control panel and electrically isolate the electric heating control panel from the electric heating control panel.

Description

FIELD OF THE DISCLOSURE

The present disclosure generally relates to an electric air handling unit, and more specifically to an electric air handling unit for automotive manufacturing facilities.

BACKGROUND OF THE INVENTION

The section provides a general summary of background information and the comments and examples provided in this section are not necessarily prior art to the present disclosure.

Vehicle manufacturers are transitioning from producing vehicles with combustion engines to electric vehicles to reduce emissions associated with operating vehicles. With this transition, vehicle manufacturers are also looking at transforming the manufacturing process to reduce emissions associated with the production of vehicles. Traditional air handling units for manufacturing facilities rely on fossil fuels for providing heat to the unit. Accordingly, a need exists for an air handling unit for manufacturing facilities that operate solely on electricity, without the need for fossil fuels.

SUMMARY OF THE INVENTION

An aspect of the disclosed embodiments includes an electric air handling unit for a vehicle manufacturing facility. The electric air handling unit includes an electric heating coil assembly including at least one electric heating coil, an electric heating control panel configured to receive electrical power from a power distribution panel of the air handling unit and supply the electrical power to the electric heating coil assembly, and a first disconnect switch coupled between the power distribution panel and the electric heating control panel. The first disconnect switch is located external to a housing of the electric heating control panel, and the first disconnect switch is configured to selectively enable flow of the electrical power from the power distribution panel to the electric heating control panel and electrically isolate the electric heating control panel from the electric heating control panel.

In another aspect, the air handling unit includes a housing with a plurality of compartments including an electric heating compartment and a maintenance compartment, an electric heating coil assembly comprising at least one electric heating coil located in the electric heating compartment, an electric heating control panel located in the maintenance compartment and configured to receive electrical power from a power distribution panel of the air handling unit and supply the electrical power to the electric heating coil assembly, and a first disconnect switch coupled between the power distribution panel and the electric heating control panel. The first disconnect switch is located in the maintenance compartment and external to a housing of the electric heating control panel, and the first disconnect switch is configured to selectively enable flow of the electrical power from the power distribution panel to the electric heating control panel and electrically isolate the electric heating control panel from the electric heating control panel.

These and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims, and the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

These and additional features provided by the electric air handling unit described herein will be more fully understood in view of the following detailed description, when considered in conjunction with the drawings in which:

FIG. 1 is a perspective view of an electric air handling unit for a manufacturing facility;

FIG. 2 is a top view of the electric air handling unit of FIG. 1;

FIG. 3 is a cross-sectional side view of the electric air handling unit taken along lines 1-1 of FIG. 2;

FIGS. 4A-4E depict various views of an electric heater of the air handling unit of FIG. 1;

FIG. 5 depicts an example schematic or block diagram of an air handling unit;

FIG. 6 is a functional block diagram of an example air handling unit; and

FIGS. 7A and 7B depict a front and side view of an example disconnect switch.

DETAILED DESCRIPTION OF THE ENABLING EMBODIMENTS

Exemplary embodiments and aspects of the electric air handling unit will now be more fully described with reference to the accompanying drawings. Each of these example embodiments are provided so that this disclosure is thorough and fully conveys the scope of the inventive concepts, features and advantages to those skilled in the art. To this end, numerous specific details are set forth such as examples of specific components, devices, mechanisms, assemblies and manufacturing or assembly steps to provide a thorough understanding of each of the embodiments associated with the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the subject disclosure.

Referring to FIGS. 1-3, wherein like numerals indicate corresponding parts throughout the several views, an electric air handling unit (AHU) 1 is generally illustrated. The AHU 1 includes a housing 3 that encloses a service vestibule 12 (or maintenance compartment), and an air plenum 5 having a plurality of rooms, an electric heating unit 7, a cooling unit 9, and a filtration system (including filters 21, 23, such as a pleated filter 21 and a box filter 23). The rooms of the air plenum 5 may be provided in sequence for air to flow from one room to the next, with each room including a door 13 (shown in FIG. 2) for entrance into the room (e.g., from the service vestibule 12) by a technician to monitor and/or repair the components within the room. Any of the heating unit 7, the cooling unit 9, and components of the filtration system may be positioned within the rooms of the air plenum 5.

The AHU 1 may include an outdoor air (OA) damper 15, an OA louver 17, a return air damper 19, the pleated filter 21, the box filter 23, a backdraft damper 11 and one or more supply fans 25, and a vestibule damper 27. The OA damper 15, the OA louver 17, and the return air damper 19 are provided at an end of the housing 3 to facilitate airflow from inside the housing 3 to outside the housing 3 and vice versa. A backdraft damper may be attached to the supply fans 25 to control airflow from the supply fans 25 by isolating one of the fans 25 when one or more fans 25 fail, thereby preventing back-cycling of air. The pleated filter 21 and the box filter 23 are positioned between the supply fans 25 and both the OA damper 15 and the OA louver 17 to filter the air flowing through and out of the air plenum 5.

The cooling unit 9 may be a direct exchange (DX) cooling unit 9, and includes a condensing unit 29, a DX cooling coil 31, and a flange mounted main disconnect. The cooling unit main disconnect is in series with the condensing unit 29 and the DX cooling coil 31, where the main disconnect can be activated to cut off power to the condensing unit 29. The main disconnect may be attached to a control panel that provides power to the DX cooling unit 9. The control panel may provide power to the DX cooling unit 9 with a separation of voltages, such that the control panel includes, for example, 24 volt (V), 120V, and 480V connections. The control panel providing power to the DX cooling unit 9 may be touch safe (National Electrical Manufacturers Association NEMA rated) to permit a technician to contact the control panel without risk of electrocution.

The heating unit 7 may include an electric heating coil assembly for providing heat that includes at least one electric heating coil 39 and a coil access panel 41. The electric heating coil 39 is positioned within one of the rooms of the air plenum 5, and the coil access panel 41 is positioned outside of the air plenum 5, within the vestibule 12 to be capable of being maintained without a technician entering the air plenum 5. The coil access panel 41 may include a flange mounted main disconnect that is in series with the electric heating coil 39, where the disconnect can be activated to cut off power to the electric heating coil 39.

As shown in FIGS. 4A-4E, at least one electric heating coil 39 is positioned within a coil housing that extends from the coil access panel 41 (FIG. 3) to allow the electric coil 39 to be positioned in the housing 3 with the coil access panel 41 positioned outside of the air plenum 5. The coil access panel 41 includes an enclosure 43 and a cover 45 hingedly coupled to the enclosure 43. As shown in FIGS. 4C and 4E, the cover 45 is attached to the enclosure by one or more hinges 47, and the enclosure 43 includes a gasket 49 on each side to be positioned between the cover 45 and the enclosure 43 to provide a buffer between the two. When closed, the cover 45 may cover one or more controls of the coil panel 41, including a power terminal block 51 of the coil panel 41, and may be opened to provide access to the controls. Referring to FIGS. 4A, 4B, and 4D, the coil access panel 41 includes a controller 53, wire hubs 55, and manual reset buttons 57 positioned on the outside of the enclosure 43, where the wire hubs 55 permit wires to be routed into and out of the enclosure 43 for wired connection of the various electrical components. The manual reset pushbuttons 57 allow for the coil access panel 41 to be reset.

Referring to FIGS. 2 and 3, the supply fans 25 may draw air flow through the air plenum 5 and across the various components of the AHU 1. Air flow may move from left to right in FIGS. 2 and 3, such that air is drawn through the AHU 1 by the supply fans 25. Air enters the AHU 1 through the OA louver 17 and OA damper 15, the RA damper 19, or a combination of OA and RA. The air then passes through the filters 21, 23, followed by the electric heating coil 39, the DX cooling coil 31, and then through the backdraft dampers 11. Air is discharged from the supply fans 25, and exits the AHU 1 through a supply air opening.

FIG. 5 shows (e.g., in a side view) an example schematic or block diagram of an air handling unit (AHU) 100 according to the principles of the present disclosure. The AHU 100 may have a configuration similar to the AHU 1 described above. As shown, the AHU 100 includes an housing or air plenum 102 having a plurality of rooms or compartments 104-1, 104-2, 104-3, 104-4, and 104-5, referred to collectively as compartments 104, and a condensing unit 106). Each of the compartments 104 may include (e.g., house) one or more unit, modules, components, etc. configured to perform respective functions of the AHU 100.

Various terms may be used to describe the compartments 104 and respective functions or components interchangeably. For example, compartment 104-1 may house filtration system components such as the damper 15 and louver 17, and may be referred to as a first filtration compartment, room, or unit. Compartment 104-2 may house additional filtration components (e.g., the pleated filter 21 and the box filter 23) and may be referred to as a second filtration compartment, room, or unit. Compartment 104-3 may house electric heating components (e.g., the electric heating unit 7 and coil 39) and may be referred to as an electric heating compartment, room, or unit. Compartment 104-4 may house cooling components (e.g., the cooling unit 9 and the DX cooling coil 31) and may be referred to as a cooling compartment, room, or unit. The compartment 104-5 may house air supply components (e.g., the filtration system 21, 23, the supply fans 25, etc.) and may be referred to as an air supply compartment, room, or unit. Air flows into the AHU 100 to be heated (e.g., within the electric heating compartment 104-3) and/or cooled (e.g., within the cooling compartment 104-4) to a desired temperature as described above.

FIG. 6 is a functional block diagram of an example AHU system 600 according to the present disclosure. For example, various components of the system 600 may be arranged/housed within the AHU 1, the AHU 100, or a similar AHU as described above. The system 600 includes a power distribution system or panel 604 configured to receive and distribute electrical power to various electric power and control panels of the system 600. For example, the power distribution panel 604 receives and distributes power, such as 480V power, from a manufacturing facility.

As shown, the power distribution panel 604 supplies 480V power to a main control panel 608, which in turn supplies 480V power to an electric heating control panel 612 and a condensing unit power panel 616. The electric heating control panel 612 supplies 480V power to an electric heating unit/coil 620. Conversely, the condensing unit power panel 616 supplies 480V power to a condensing unit 624 coupled to a cooling unit/coil 628. In an example, as shown, the condensing unit power panel 616 separately supplies power to a condensing unit control panel 632. For example, the condensing unit power panel 616 may contain a step down transformer to supply a lower voltage (e.g., 24V) to power to the condensing unit control panel 632. In this manner, the lower voltage condensing unit control panel 632 can be accessed without opening the condensing unit power panel 616.

In an example, the power distribution panel 604, the main control panel 608, and the electric heating control panel 612 are located in one or more rooms or compartments external and adjacent to the compartments 104 shown in FIG. 5, such as in a maintenance room or compartment 12 as shown in FIGS. 1 and 2. The electric heating unit/coil 620 is located within the electric heating compartment 104-3. The cooling unit/coil 628 is located within the cooling compartment 104-4. Conversely, the condensing unit power panel 616 and the condensing unit control panel 632 may be located adjacent to (e.g. mounted on a surface of) a condensing unit 620.

The system 600 may include a secondary power distribution system, unit, or panel, such as a mini power-zone (MPZ) 636. The MPZ 636 may be located in the maintenance compartment 12. For example, the MPZ 636 is configured to receive 480V power from the power distribution panel 604, supply 120V to various 120V components (e.g., power receptacles, lighting, etc.), and supply 240V power to various 240V components (e.g., a unit heater located in the maintenance compartment 12). The various 120V and 240V components are schematically represented, collectively, at 640.

The main control panel 608 may further supply 480V power to one or more supply fans 644. For example, the supply fans 644 may correspond to the supply fans 25 housed in the air supply compartment 104-5. The system 600 may include various other components that are supplied 480V, 240V, 120V, 24V, and/or other types of power. For simplicity, not all of such components are shown in FIG. 6.

The system 600 includes a plurality of power disconnect switches coupled between respective power supplies/sources and loads. For example, the system 600 includes power disconnect switches 644-1, 644-2, 644-3, and 644-4, referred to collectively as disconnect switches 644. The disconnect switches 644 are arranged electrically upstream of respective loads in the system 600 and are configured to selectively isolate/disconnect the loads from the respective power supplies. As shown, the disconnect switches 644-1 and 644-2 are arranged between (i) the main control panel 608 and (ii) the electric heating control panel 612 and the condensing unit power panel 616, respectively. The disconnect switch 644-3 is arranged between the power distribution panel 604 and the MPZ 636. The disconnect switches 644-4 are arranged between the main control panel 608 and the supply fans 640.

In each example, the disconnect switches 644 are located proximate to respective electrical loads, such as in a same one of the compartments 104, within arm's reach of the respective electrical loads, mounted on a surface of or a surface adjacent to the respective loads, etc. In some examples, the disconnect switches 644 may be mounted directly adjacent to (e.g., abutting) or integrated on a surface of the respective electrical loads.

In the case of the electric heating control panel 612, the disconnect switch 644-1 is located external to the electric heating control panel 612 but in a same compartment as the electric heating control panel 612 (e.g., within the maintenance compartment 12). Conventionally, disconnect switches or mechanisms are located within a corresponding power or electrical panel. In contrast, the disconnect switch 644-1 is located electrically upstream of the electric heating control panel 612 and is accessible when the electric heating control panel 612 is closed. Further, a tool is required to open the electric heating control panel 612 subsequent to the disconnect switch 644-1 being turned off to disconnect power from the electric heating control panel 612 (e.g., the electric heating control panel 612 has a “touch safe” configuration).

Similarly, in the case of the condensing unit power panel 616, the disconnect switch 644-2 is located external to the condensing unit power panel 616 (and the condensing unit control panel 632) but proximate to (e.g., mounted on a surface of or adjacent to) the condensing unit power panel 616. The disconnect switch 644-2 is located electrically upstream of the condensing unit power panel 616 and is accessible when the condensing unit power panel 616 is closed. Further, a tool is required to open the condensing unit power panel 616 subsequent to the disconnect switch 644-2 being turned off to disconnect power from the condensing unit power panel 616 (e.g., the condensing unit power panel 616 has a “touch safe” configuration). Since the condensing unit power panel 616 supplies power to the condensing unit control panel 632, shutting off power to the condensing unit power panel 616 by actuating the disconnect switch 644-2 also shuts off power to the condensing unit control panel 632.

FIGS. 7A and 7B show a front and side view of an example disconnect switch 700 according to the present disclosure. For example, at least the disconnect switches 644-1 and 644-2 may have a configuration similar to the disconnect switch 700. As shown, the disconnect switch 700 is a flanged disconnect switch, enabling the disconnect switch 700 to be mounted to a planar surface, such as on a surface or wall of one of the compartments 104, on a surface or side of one of the components of the system 600 (e.g., on a surface of the condensing unit 624), etc. For example, as used herein, a “flanged” disconnect switch refers to a disconnect switch having one or more flanges 704, plates, etc. that enable the disconnect switch to be mounted on a flat surface (e.g., using one or more fasteners). In some examples, the disconnect switch 700 is fusible. In other examples, the disconnect switch 700 is not fusible.

The disconnect switch 700 includes a housing or enclosure 708. The housing 708 encloses electrical connections (e.g., lugs, contacts, etc.) that couple wiring from a power supply or source (e.g., the main control panel 608) to wiring of a respective electrical load (e.g., the electric heating control panel 612, the condensing unit power panel 616, etc.). A hinged door 712 provides access to an interior of the housing 708. The flanges 704 extend from one or more sides or ends of the housing 708 (e.g., as shown, from top and bottom ends of the housing 708).

The disconnect switch 700 includes an actuator, such as a handle or lever 716, as shown. Actuating the lever 716 physically separates (or connects) input and output contacts within the housing 708 to isolate the electrical load from the power supply. For example, when the lever 716 is in a first position (e.g., up, as shown), input and output contacts of the disconnect switch 700 are electrically coupled together, allowing electrical power to flow from the power supply to the electrical load via the disconnect switch. For example, when the lever 716 is in a first position (e.g., up, as shown), input and output contacts of the disconnect switch 700 are electrically separated (e.g., with an air gap therebetween), preventing flow of electrical power from the power supply to the electrical load via the disconnect switch 700. Conversely, when the lever 716 is in a second position (e.g., down), input and output contacts of the disconnect switch 700 are electrically coupled together, allowing electrical power to flow from the power supply to the electrical load via the disconnect switch 700.

While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

Claims

1. An electric air handling unit for a vehicle manufacturing facility, the air handling unit comprising: an electric heating coil assembly comprising at least one electric heating coil;an electric heating control panel configured to receive electrical power from a power distribution panel of the air handling unit and supply the electrical power to the electric heating coil assembly; anda first disconnect switch coupled between the power distribution panel and the electric heating control panel, wherein the first disconnect switch is located external to a housing of the electric heating control panel, and wherein the first disconnect switch is configured to selectively (i) enable flow of the electrical power from the power distribution panel to the electric heating control panel and (ii) electrically isolate the electric heating control panel from the electric heating control panel.

2. The electric air handling unit of claim 1, further comprising: a direct exchange cooling unit;a condensing unit power panel configured to receive the electrical power from the power distribution panel and supply the electrical power to the direct exchange cooling unit; anda second disconnect switch coupled between the power distribution panel and the condensing unit power panel, wherein the second disconnect switch is located external to a housing of the condensing unit power panel, and wherein the second disconnect switch is configured to selectively (i) enable flow of the electrical power from the power distribution panel to the condensing unit power panel and (ii) electrically isolate the condensing unit power panel from the electric heating control panel.

3. The electric air handling unit of claim 2, wherein the first disconnect switch and the second disconnect switch are flanged disconnect switches.

4. The electric air handling unit of claim 3, wherein the electrical power is 480 volt power.

5. The electric air handling unit of claim 3, further comprising a main control panel arranged between the power distribution panel and the first and second disconnect switches.

6. The electric air handling unit of claim 5, further comprising a secondary power distribution system coupled between the power distribution panel and a plurality of electrical loads, wherein the secondary power distribution system is configured to convert the electrical power from a first voltage to a second voltage and supply the electric power to the plurality of electrical loads at the second voltage.

7. The electric air handling unit of claim 6, further comprising a third disconnect switch coupled between the power distribution panel and the secondary power distribution system.

8. The electric air handling unit of claim 6, wherein the secondary power distribution system includes a mini power-zone.

9. The electric air handling unit of claim 2, further comprising: a housing with a plurality of compartments including an electric heating compartment and a maintenance compartment, whereinthe at least one electric heating coil is located within the electric heating compartment, andthe electric heating control panel and the first disconnect switch are located within the maintenance compartment.

10. The electric air handling unit of claim 9, further comprising the power distribution panel, wherein the power distribution panel is located within the maintenance compartment.

11. The electric air handling unit of claim 2, further comprising a condensing unit coupled to the direct exchange cooling unit.

12. The electric air handling unit of claim 2, further comprising a condensing unit control panel, wherein the condensing unit power panel is configured to supply the electrical power to the direct exchange cooling unit at a first voltage, convert the electrical power from the first voltage to a second voltage, and supply the electrical power to the condensing unit control panel at the second voltage.

13. An electric air handling unit for a vehicle manufacturing facility, the air handling unit comprising: a housing with a plurality of compartments including an electric heating compartment and a maintenance compartment;an electric heating coil assembly comprising at least one electric heating coil located in the electric heating compartment;an electric heating control panel located in the maintenance compartment and configured to receive electrical power from a power distribution panel of the air handling unit and supply the electrical power to the electric heating coil assembly; anda first disconnect switch coupled between the power distribution panel and the electric heating control panel, wherein the first disconnect switch is located in the maintenance compartment and external to a housing of the electric heating control panel, and wherein the first disconnect switch is configured to selectively (i) enable flow of the electrical power from the power distribution panel to the electric heating control panel and (ii) electrically isolate the electric heating control panel from the electric heating control panel.

14. The electric air handling unit of claim 13, further comprising a direct exchange cooling unit;a condensing unit power panel configured to receive the electrical power from the power distribution panel and supply the electrical power to the direct exchange cooling unit; anda second disconnect switch coupled between the power distribution panel and the condensing unit power panel, wherein the second disconnect switch is located external to a housing of the condensing unit power panel, and wherein the second disconnect switch is configured to selectively (i) enable flow of the electrical power from the power distribution panel to the condensing unit power panel and (ii) electrically isolate the condensing unit power panel from the electric heating control panel.

15. The electric air handling unit of claim 14, wherein the first disconnect switch and the second disconnect switch are flanged disconnect switches.

16. The electric air handling unit of claim 14, further comprising a main control panel arranged, in the maintenance compartment, between the power distribution panel and the first and second disconnect switches.

17. The electric air handling unit of claim 14, further comprising, in the maintenance compartment, a mini power-zone coupled between the power distribution panel and a plurality of electrical loads, wherein the mini power-zone is configured to convert the electrical power from a first voltage to a second voltage and supply the electric power to the plurality of electrical loads at the second voltage.

18. The electric air handling unit of claim 17, further comprising a third disconnect switch coupled between the power distribution panel and the mini power-zone.

19. The electric air handling unit of claim 14, further comprising a condensing unit coupled to the direct exchange cooling unit.

20. The electric air handling unit of claim 19, further comprising a condensing unit control panel, wherein the condensing unit power panel is configured to supply the electrical power to the direct exchange cooling unit at a first voltage, convert the electrical power from the first voltage to a second voltage, and supply the electrical power to the condensing unit control panel at the second voltage.