The present invention generally relates to air moving assemblies, more particularly, to plenum/plug fan assemblies which boost static pressure/dynamic efficiency, and further provide noise reduction, both broadband and tone components thereof.
Relatively inexpensive plenum or plug-type fans are well known in the industrial and commercial fan industry. They are commonly sold as an unhoused fan unit by the manufacturers although they are mounted in a suitable support structure that can include a front wall with an air inlet opening formed therein. These fans are used instead of, or to replace, centrifugal type fans which are commonly used in the air handling industry. The wheel of the plenum fan is used to pressurize a surrounding air plenum or housing in which the fan is installed. A number of air ducts can be connected to the housing and these can extend from any direction. In addition to being a reasonably inexpensive fan structure, a plenum or plug fan unit can save space by eliminating a special fan housing, transitions and diffusers commonly characterizing centrifugal air handling system. When required, two or more of these fans can be mounted side-by-side on common or separate support frames.
A common and well known difficulty of plug or plenum fans is that they can be inefficient in their operation and noisy compared to other types of fans. Furthermore, such assemblies are known to require considerably more electrical power for operation of the one or more fans than more efficient units that produce the same amount of or more air flow. With respect to the noise problem, it is noted that with many known plug type fans, low frequency noises are generally produced, and there is no currently available and practical solution to the noise problem. Traditionally, noise reduction in air moving assemblies has been achieved at the cost of dynamic performance, via the inclusion of dissipative silencers. Such silencers typically comprise acoustically lined fan housings, ducting, etc. In an air handling system, such structures create a static pressure drop which results in a lowered static efficiency. Furthermore, dissipative silencers are ill suited to reduce or eliminate the tone component of sound, namely, blade pass frequency tone.
U.S. Pat. No. 5,749,702 (Datta et al.) describes, among other things, a fixed center body for axially directing air flow to and within a bladed fan wheel having an annular air outlet. The center body extends through the axial air intake, and radially expands rearwardly, terminating at an end at the back of the fan wheel, close to the rear plate thereof. Both inlet and outlet structures, including the center body, incorporate sound attenuating material for broadband noise reduction. Increased fan wheel efficiency is alleged as attributable to a solid curved rear end section of the center body, which redirects air flow in a radial direction towards the annular outlet of the fan wheel. Furthermore, a wall, spaced from a fixed sidewall or front wall of a fan support structure so as to be positioned behind the fan wheel, is further provided. The additional wall is preferably filled with sound attenuating material, and more preferably still, has a perforated front surface facing the back plate of the fan wheel.
U.S. Pat. No. 5,426,268 (Yazici et al.) describes combined utilization of air duct inlet and outlet silencer apparatuses for an air handling system. Both apparatuses include interior walls, arranged between interior and exterior walls thereof, comprised of sound attenuating material, with at least portions of the interior walls constructed of perforated metal sheets. In the outlet duct apparatus, the main passageway is substantially straight and increases in transverse cross-section from the inlet to the outlet. The transverse cross-section changes from circular at the end of the passageway adjacent the fan to rectangular at the opposite end.
U.S. Pat. No. 5,066,194 (Amr et al.) describes a fan orifice structure intended for use in conjunction with an outside enclosure, usually containing a heat exchanger and compressor of an air conditioner. The orifice is defined by an annular curved surface that extends downwardly from a top wall of the cover. The curved surface is generated by rotating a planar and curvilinear line about a coplanar axis of generation. It is said that the contour of the orifice enhances fan efficiency and reduces radiated noise. The orifice cover is made from plastic materials by a molding process.
U.S. Pat. No. 4,576,549 (Lanier) is generally directed to a centrifugal fan having a plurality of vortex generators fixed onto the outer wall of an annular member leading into an air inlet of the fan wheel. An inlet cone is shown as a concave annular form tapered inwardly from the larger diameter air inlet in the fan wheel plate. Vortex generators are shown as formed plates having lateral edges contoured to fit the curved annular wall of the inlet cone. It is believed that such structures, so arranged, permit merger of skin friction induced air current with the lower velocity air being discharged from the rotating fan wheel blades
As is readily appreciated, it remains advantageous to provide a fan unit which is simple to build and construct which employs a bladed fan wheel having an axial air intake and an annular air outlet, and at least one outlet diffuser for directing airflow from the fan wheel such that static efficiency is improved, and noise is greatly reduced. It is further advantageous to enhance the noise reduction capabilities of fan assemblies for air handling systems, more particularly, both the broadband and tone aspects thereof.
Fan silencers have traditionally achieved noise reduction at the expense of a static pressure drop resulting in an increase in power input to the fan, and consequently lowering its static efficiency. The subject invention achieves noise reduction by boosting the static pressure and static efficiency. Principles of dissipative silencer design have been employed for both the fan wheel inlet and outlet. Outlet or discharge considerations included principles of aerodynamic vane-less diffuser design.
In a first embodiment, a rear (hub) diffuser element, e.g., ring, is utilized adjacent the back plate of the fan wheel. The subject rear diffuser ring, as well as structures of the further embodiments, are readily, and preferably, but not necessarily, adapted for enhanced sound attenuation as will later be discussed.
In a further embodiment, a specially configured front (shroud) diffuser element, e.g., ring, is utilized, more generally, a structure which slows the air discharge velocity from the fan wheel/fan unit, is provided. In yet a further embodiment, an inlet diffuser is provide to selectively guide air flow into the fan wheel, preferably, but not necessarily, the inlet diffuser incorporates a blade pass frequency (BPF) tuned resonator. More specific features and advantages obtained in view of those features will become apparent with reference to the drawing figures and
As a preliminary matter, fan assemblies 10 of the subject invention are generally shown in
With reference now to
The assembly 10 further includes rear or hub diffusing structure 12, i.e., a first air outlet diffusing structure or element (e.g., a ring, or fractions thereof, i.e., halves, thirds, quarters, etc. as will later be described), depending or otherwise supported by the frame 24, or a portion thereof, adjacent the back plate 34 of the fan wheel 32, and front or shroud diffusing structure 14 i.e., a second air outlet diffusing element (e.g., a ring, or fractions thereof, i.e., halves, thirds, quarters, etc. as will later be described), depending or otherwise supported by the frame 24, or portion thereof, adjacent the front plate 36 of the fan wheel 32. As will later be detailed, each of the first and second air outlet diffusing structures include a peripheral region or segment 40, air exiting the annular air outlet 32 of the fan wheel 32 passing between the peripheral regions 40 of the diffusing elements 12, 14.
With particular reference to
The air inlet diffusing assembly 18 (
Prior to a further or more developed discussion of the air outlet diffusing structures, it is to be appreciated that in addition to prospective air handling applications, select structures of the assembly described herein (e.g., one or more of the air outlet diffusing elements, and or variants of the air inlet diffusing structure) may advantageously be supplied as a “kit” for after-market conversion of in-place, operational air handling assemblies. In furtherance of retrofitting such systems, select structures, e.g., first, second, and/or third air outlet diffusing elements may be fractionally supplied, preferably, but not necessarily, in halves (see e.g.,
Referring now generally to
Advantageously, as shown in
With regard to the sound insulating material 50, the density thereof is preferably within the range of about 0.5 to 8.0 pounds per cubic foot, with the preferred material thickness within the range of about 0.05 to 0.1 times the diameter (D) of a the fan wheel, i.e., 1D=fan wheel outside diameter (OD). One suitably known combination of thickness/density, wherein 1D=18.25 inches, is 1.5 inch thick insulation having a density of about 6.3 pounds per cubic foot, such material being commercially available and well known.
In connection to the air contacting surfaces of the insulated portions of the one or more air outlet diffusing elements, and/or air inlet diffusing structure, as has been heretofore described, perforated surfaces are especially advantageous. Although a variety of perforated surface configuration have, or are likely to have utility, those characterized by a transparency index (TI), defined by Theodore J. Schultz, “Acoustic Uses for Perforated Metals,” within a range of about 1,000 to 20,000 are desirable. The perforated steel plate used for the diffuser prototype is 20 GA cold rolled steel, with 0.060 diameter holes spaced on 3/32 inch staggered centers. The material has approximately one hundred twenty six holes per square inch, and a TI value of 13,887.
With reference again to FIGS. 1/4, the hub diffusing structure 12 is generally configured within the assembly of the subject invention, in all its contemplated embodiments, to be orthogonally disposed with respect to axial centerline 26 of the fan wheel 32, i.e., substantially parallel to the back plate 34, and spaced apart therefrom. Preferably configured as an annular element, the structure has an interior circumferential edge 62 opposite its outer circumferential edge 44, or the sidewall 52 associated therewith, and an intermediate circumferential edge 64 therebetween, namely, that associated with the interior sidewall 52a of the insulation retaining compartment 51.
Dimensionally, the diffuser outside diameter (Do), i.e., maximum dimension from opposing sites on the outer circumferential edge 44, is within the range of about 1.3-1.6D, and typically substantially equivalent to the frame size; the diffuser inside diameter (Di), i.e., maximum dimension from opposing sites on the interior circumferential edge 62, being within the range of about 0.6-0.7D; and, the diameter associated with the commencement of the peripheral region 40 (Dpr), i.e., maximum dimension from opposing sites on the intermediate circumferential edge 64 or interior sidewall 52a of the insulation retaining compartment 51, is within the range of about 1.01-1.02D. With such configuration, the perforated surface 56 of the peripheral region 40 of the hub diffusing structure 12 radial extends from the back plate 34, with clearance as noted (i.e., (Dpr−Dbp {˜1D})/2), so as to be substantially coplanar therewith, and in all cases, delimits a “rear” boundary or guide for air exiting from the annular air outlet 32.
With continued reference to FIGS. 1/4, the shroud diffusing structure 14, like the hub diffusing structure 12, is preferably configured as an annular element, the structure having interior circumferential edge 60 opposite its outer circumferential edge 44 or the sidewall 52a associated therewith, and an intermediate circumferential edge 66 therebetween, namely, that associated with the interior sidewall 52a of the insulation retaining compartment 51 coextensive with the peripheral region 40 as previously discussed. Although dimensionally similar to/with the hub diffusing structure, at least with respect to the configuration of
Advantageously, as shown in
The shroud diffusing structure 14 is generally segmented, a shroud segment 68 depending from the peripheral region thereof, more particularly, extending radially inward therefrom. With regard to the segmentation of the shroud diffusing structure of
With particular reference to
As noted in connection to the one or more outlet diffusing structures, the air inlet diffusing structure 18 is likewise adapted so as to include/incorporated insulative material 50. As shown in
The resonator assembly of
With reference now to
Noise reduction using both the outlet and inlet diffuser elements is indicated in
With reference now to Table 1, inlet and outlet diffuser performance is indicated for an 18.25″ OD bare fan wheel, no bearing support on inlet, having 9 blades (i.e., 182 EPFN), with and without the diffuser elements of the subject invention. The outlet sound power level (dB), indicated by Lw, is for the following frequencies (i.e., 1-8), respectively: 63 hz, 125, 250, 500, 1000, 2000, 4000, and 8000. Furthermore, LwA indicates an inlet A weighting. As can be seen, static efficiency improves dramatically for higher pressures where the vane less diffuser works best and, sound quality improves by various levels across all bands consistently, and may be further improved with selective perforation of the air contacting wall surface of the diffuser element, and further still, via utilization of a resonator to tune out BPF tone.
There are other variations of the subject invention, some of which will become obvious to those skilled in the art. It will be understood that this disclosure, in many respects, is only illustrative. Changes may be made in details, particularly in matters of shape, size, material, and arrangement of parts, as the case may be, without exceeding the scope of the invention.
This is an international regular application filed under 35 U.S.C. §363 claiming priority under 35 U.S.C. §119(e)(1), of provisional application Ser. No. 60/604,571 having a filing date of Aug. 26, 2004.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US05/30082 | 8/24/2005 | WO | 00 | 9/24/2007 |
Number | Date | Country | |
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60604571 | Aug 2004 | US |