Embodiments described herein generally relate to fans having electronic control circuitry and methods.
Industrial fans for HVAC, venting, or other uses typically utilize a local electronic module to control one or more motor function. It is desired to provide fan assembly configurations that provide high efficiency and reliability to the assemblies. In one example, specifically improving efficiency and reducing stress on the electronic module is desired. Improved fan assembly configurations and methods are desired that address these concerns, and other technical challenges.
The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.
An impeller 110 is further illustrated in
The impeller 110 is coupled to a shaft 114 of an electric motor 112.
In one example, the motor controller 116 is located partially or completely outside the airflow pathway 104 to facilitate easier electrical connection to an external power source (not shown). In one example, the motor controller 116 is located partially or completely outside the airflow pathway 104 to reduce bulky circuitry that may impede air flow. In one example, motor controller 116 is located partially or completely outside the airflow pathway 104 to improve access for maintenance or service to the motor controller 116.
In the example of
In one example, the heat exchanger 122 is located within the inlet airflow 106. In one example, the heat exchanger 122 is located within the outlet airflow 108. In the examples of
The heat exchanger 200 of
In one example, one or more of the regions 202, 204, 206 are formed from heat conducting materials, such as metal or metal alloy. Other heat conducting materials may include carbon or carbon fiber composites. In one example, the second region 204 includes one or more fins 220. The inclusion of fins on the second region 204 increases a surface area of the second region 204, and provides increased heat transfer from the second region 204. Fins may be integrally formed into the second region 204, or may be attached in contact with the second region 204 to provide a thermal pathway. In one example, the fins 220 are oriented parallel to an airflow pathway to improve laminar airflow while providing a heat transfer function. In one example, the fins 220 are oriented vertically. Other orientations of fins 220 are also within the scope of the invention. Other surface area increasing features are also within the scope of the invention. For example, dimples or protrusions of any shape may be added to the second region 204 to increase heat transfer ability.
In one example heat exchanger 300 includes one or more fins 310 separated from one another by spaces 312, located on the second region 304. Similar to the example of
To better illustrate the fans and methods disclosed herein, a non-limiting list of embodiments is provided here:
Example 1 includes a fan assembly. The fan assembly includes a fan housing, defining an airflow pathway, an impeller located within the airflow pathway of the fan housing, wherein the impeller is coupled to a shaft of an electric motor, a motor controller mounted outside the airflow pathway, the motor controller electrically coupled to the electric motor, and a heat exchanger located at least partially within the airflow pathway, and coupled between the airflow pathway and the motor controller, wherein the heat exchanger is configured to move heat from the motor controller to the airflow pathway when the fan assembly is in operation.
Example 2 includes the fan assembly of example 1, wherein the heat exchanger includes one or more cooling fins.
Example 3 includes the fan assembly of any one of examples 1-2, wherein the heat exchanger includes a cooling medium configured to circulate between the motor controller and the heat exchanger.
Example 4 includes the fan assembly of any one of examples 1-3, wherein the cooling medium includes a liquid cooling medium.
Example 5 includes the fan assembly of any one of examples 1-4, wherein the impeller is an axial flow impeller.
Example 6 includes the fan assembly of any one of examples 1-5, wherein the impeller is a radial flow impeller.
Example 7 includes the fan assembly of any one of examples 1-6, wherein the heat exchanger is incorporated into an electric motor support structure.
Example 8 includes the fan assembly of any one of examples 1-7, wherein the heat exchanger is incorporated into an electrical connection conduit.
Example 9 includes a fan assembly. The fan assembly includes a fan housing, defining an airflow pathway, an electric motor located within the fan housing, an impeller coupled to a shaft of the electric motor, a motor controller mounted outside the airflow pathway, and one or more metal fins located at least partially within the airflow pathway, and physically contacting the motor controller, wherein the one or more metal fins are configured to move heat from the motor controller to the airflow pathway when the fan assembly is in operation.
Example 10 includes the fan assembly of example 9, wherein the impeller is an axial flow impeller.
Example 11 includes the fan assembly of any one of examples 9-10, wherein the impeller is a radial flow impeller.
Example 12 includes the fan assembly of any one of examples 9-11, wherein the one or more metal fins are incorporated into an electric motor support structure.
Example 13 includes the fan assembly of any one of examples 9-12, wherein the one or more metal fins are incorporated into an electrical connection conduit between the electric motor and the motor controller.
Example 14 includes a method of cooling, including controlling an electric motor within an airflow pathway of a fan housing using a motor controller, wherein the motor controller is located outside the airflow pathway, rotating an impeller driven by the electric motor within the airflow pathway, and drawing heat from the motor controller through a heat exchanger coupled to the motor controller, and transferring the heat to air flowing within the airflow pathway using the heat exchanger.
Example 15 includes the method of example 14, wherein drawing heat from the motor controller through a heat exchanger includes transferring heat to a cooling medium and circulating the cooling medium through the airflow pathway.
Example 16 includes the method of any one of examples 14-15, wherein drawing heat from the motor controller through a heat exchanger includes conducting heat from the motor controller into one or more metallic fins, wherein the one or more metallic fins are located within the airflow pathway.
Example 17 includes the method of any one of examples 14-16, wherein rotating the impeller includes rotating an axial impeller.
Example 18 includes the method of any one of examples 14-17, wherein rotating the impeller includes rotating a radial impeller.
Throughout this specification, plural instances may implement components, operations, or structures described as a single instance. Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as separate components in example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of the subject matter herein.
Although an overview of the inventive subject matter has been described with reference to specific example embodiments, various modifications and changes may be made to these embodiments without departing from the broader scope of embodiments of the present disclosure. Such embodiments of the inventive subject matter may be referred to herein, individually or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single disclosure or inventive concept if more than one is, in fact, disclosed.
The embodiments illustrated herein are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed. Other embodiments may be used and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. The Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.
As used herein, the term “or” may be construed in either an inclusive or exclusive sense. Moreover, plural instances may be provided for resources, operations, or structures described herein as a single instance. Additionally, boundaries between various resources, operations, modules, engines, and data stores are somewhat arbitrary, and particular operations are illustrated in a context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within a scope of various embodiments of the present disclosure. In general, structures and functionality presented as separate resources in the example configurations may be implemented as a combined structure or resource. Similarly, structures and functionality presented as a single resource may be implemented as separate resources. These and other variations, modifications, additions, and improvements fall within a scope of embodiments of the present disclosure as represented by the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
The foregoing description, for the purpose of explanation, has been described with reference to specific example embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the possible example embodiments to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The example embodiments were chosen and described in order to best explain the principles involved and their practical applications, to thereby enable others skilled in the art to best utilize the various example embodiments with various modifications as are suited to the particular use contemplated.
It will also be understood that, although the terms “first,” “second,” and so forth may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the present example embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the example embodiments herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used in the description of the example embodiments and the appended examples, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of 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, components, and/or groups thereof.
As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” may be construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62/819,730, filed on Mar. 18, 2019, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | |
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62819730 | Mar 2019 | US |