Description:TECHNICAL FIELD
[001] This disclosure relates generally to heat exchangers, and more particularly to fan assembly in heat exchangers used in the automobiles.
BACKGROUND
[002] Noise, vibration, and harshness (NVH) is the study and measurement of aural and tactile feedback in an object. In automobiles, automotive sounds are designed, identified and optimized by engineers to enhance beneficial sounds — such as the signature rumble of a motorcycle. Engineers may reduce or eliminate unwanted noises, by analyzing NVH to identify where a sound is coming from and why. NVH is currently a key performance indicator in the automotive industry, particularly for electric vehicle due to the lack of engine noises. Various components of an automobile account for NVH in vehicles such as aerodynamics system that may include HVAC fans, wind against the car body; mechanical systems may include brake friction, engine operations, tire contact with the road; and electrical systems such as driver alerts, inverters in electric cars, etc. In vehicles with IC engines, the noise component of the engines being substantial often dampened noise coming from other components of the vehicle. However, in electric vehicle (EVs), due to absence of IC engine, noise from other components contributes mainly to the NVH targets. Therefore in EVs, the absence of engine noise emphasizes other noises such as condenser fan noise, radiator fan noise, cabin AC blower noise, wind resistance noise, tire noise, vibrations, etc. The various components that generate noise make a major impact on meeting NVH targets. Based on study and analysis of NVH in various EVs, one of the major contributor of audible noises are fans attached with heat exchangers.
[003] Heat exchangers in EVs play a crucial role in regulating the temperature of various vehicle components, including the engine and transmission. Fans are incorporated into heat exchanger systems to enhance airflow and facilitate the exchange of heat with the surroundings. The operation of these fans introduces an acoustic element which accounts for the NVH. Thus, to overcome this issue various noise reduction technologies may be used such as active noise control (ANC), soundproof materials, etc. which add to the cost and is not very efficient. Therefore, there is a need to operate of the fans of the heat exchangers in a manner to meet NVH targets in a cost effective and efficient manner.
SUMMARY OF THE INVENTION
[004] In an embodiment, an axial fan assembly for a finned tube heat exchanger may be disclosed. The axial fan assembly for the finned tube heat exchanger may include a motor shaft configured to axially pass through an opening configured in the finned tube heat exchanger. In an embodiment, the motor shaft may include a first end and a second end on opposite sides of the finned tube heat exchanger. The axial fan assembly for the finned tube heat exchanger may include a first fan mechanically coupled to the motor shaft at the first end. Further, the axial fan assembly for the finned tube heat exchanger may include a second fan mechanically coupled to the motor shaft at the second end.
[005] In another embodiment, an axial fan assembly for a finned tube heat exchanger may be disclosed. The axial fan assembly for the finned tube heat exchanger may include a first fan disposed on a first side of the finned tube heat exchanger and a second fan disposed on a second side of the finned tube heat exchanger. In same embodiment, the first side and the second side may be opposite sides of the finned tube heat exchanger. Further, the first fan and the second fan may be configured to throw air in same direction.
[006] In yet another embodiment, a system may be disclosed. The system may include a finned tube heat exchanger and an axial fan assembly for the finned tube heat exchanger. Further, the axial fan assembly for the finned tube heat exchanger may include a first fan disposed on a first side of the finned tube heat exchanger and a second fan disposed on a second side of the finned tube heat exchanger. In an embodiment, the first side and the second side may be opposite sides of the finned tube heat exchanger. Further, in an embodiment, the first fan and the second fan may be configured to throw air in same direction.
[007] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[008] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
[009] FIG. 1 illustrates a block diagram of the system comprising one or more subsystems each including an axial fan assembly for the finned tube heat exchanger, in accordance with the embodiments of the present disclosure.
[010] FIG. 2A illustrates a perspective view of the axial fan assembly for the finned tube heat exchanger, in accordance with an embodiment of the present disclosure.
[011] FIG. 2B illustrates an exploded view of the axial fan assembly for the finned tube heat exchanger of FIG. 2A.
[012] FIG. 3 illustrates an exploded view of an axial fan assembly for the finned tube heat exchanger with gear arrangement, in accordance with an embodiment of the present disclosure.
[013] FIG. 4 illustrates an exploded view of an axial fan assembly for the finned tube heat exchanger using two motors, in accordance with some embodiments of the present disclosure.
DETAILED DESCRIPTION
[014] The foregoing description has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which forms the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, systems, assemblies, and mechanisms for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that, such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its device or system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.
[015] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a system or a device that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
[016] Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals have been used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to FIGs. 1-4.
[017] As explained earlier, finned tube heat exchangers generally use air to cool or heat fluids such as air, water, oil or gas, or they can be used to capture or recover waste heat. These heat exchangers can used in a broad range of industries including oil & gas, power generation, marine and HVAC&R. In order to allow air exchange, the finned tube heat exchangers employ fans. Fan size, fan speed, and a number of fans used account for effectiveness of the finned tube heat exchangers. In an embodiment, multiple fans may be employed in finned tube heat exchangers to increase effectiveness of heat exchange, however, it may add to design cost. Further, in case of EVs fans of the heat-exchanger may account substantially to the NVH target of the vehicle. In order to modulate the NVH target of the vehicle, various fan assembly may be used that are also cost-effective and efficient.
[018] To this end, an axial fan assembly for a finned tube heat exchanger is illustrated. The axial fan assembly may be used in finned tube heat exchanger. Referring now to FIG. 1, a block diagram 100 of a system 102 comprising one or more subsystems 104 each including an axial fan assembly 112 in finned tube heat exchanger 110 is illustrated, in accordance with the embodiments of the present disclosure.
[019] In an embodiment, the system 102 may include a plurality of subsystems (subsystem-1 to subsystem-n 102-1 to 102-N) each including a finned tube heat exchanger 110A-N (individually referred to as finned tube heat exchanger 110 and cumulatively referred to as finned tube heat exchangers 110) and an axial fan assembly 112A-N (individually referred to as axial fan assembly 112 and cumulatively referred to as axial fan assemblies 112). In an embodiment, each of the axial fan assembly 112 may include a first fan (not shown) and a second fan (not shown). Each of the axial fan assembly 112 may be configured to sandwich a finned tube heat exchanger 110 in between the first fan (not shown) and the second fan (not shown).
[020] Further, the axial fan assembly 112 of one subsystem 102 may be configured to throw air in same direction passing through the finned tube heat exchanger 110 of that corresponding subsystem. The first fan and the second fan may throw the air in the same direction at a same or different duty cycle to cool the finned tube heat exchanger 110. The axial fan assembly 112 including the first fan and the second fan throwing air in same direction may enable the fans to be operated at a reduced speed as compared to a heat-exchanger having a single fan. Further, the axial fan assembly 112 including the first fan and the second fan may have less NVH as compared to NVH of a heat-exchanger having a single fan running at a high speed. Further, the axial fan assembly 112 including the first fan and the second fan may reduce an RPM of each fan by 25 percent at a given duty cycle as compared to a heat exchanger with one fan.
[021] In one embodiment, the system 102 may be a vehicle and may include Heating, Ventilation, and Air conditioning (HVAC) system as subsystem-1 102-1, a radiator of a traction cooling system as subsystem-2 102-2, and a condenser of a battery cooling system as a subsystem-3 in the vehicle. Each of the subsystems 102-1-N may include the axial fan assembly as provided by the embodiments of the present disclosure.
[022] In another embodiment, the system 102 may be a warehouse or a commercial building including an HVAC system as subsystem-1 102-1, power generator system as subsystem-2 102-2, a drier system as subsystem 102-3 and so on. Each of the subsystems 102 may employ the finned tube heat exchanger 110 with the axial fan assembly 112 as provided by the embodiments of the current disclosure.
[023] Referring now to FIG. 2A, a perspective view 200A of the axial fan assembly 112 for the finned tube heat exchanger 110 is illustrated, in accordance with an embodiment of the present disclosure. In an embodiment, the axial fan assembly 112 may include a first fan 202 provided on a front side 201A of the finned tube heat exchanger 110. The axial fan assembly 112 further includes a second fan 204 on the back side 201B of the finned tube heat exchanger 110. It is to be noted that the first fan 202 and the second fan 204 may be configured to throw air in same direction. In an embodiment, each of the first fan 202 and the second fan 204 may be fastened to the finned tube heat exchanger 110 using a fastening mechanism such as, but not limited to, screws, etc.
[024] Referring now to FIG. 2B, an exploded view 200B of the axial fan assembly 112 for the finned tube heat exchanger 110 is illustrated, in accordance with an embodiment of the present disclosure. The view 200B depicts the axial fan assembly 112 that includes the first fan 202 and the second fan 204 disposed on either sides of the finned tube heat exchanger 110. The axial fan assembly 112 may include a motor shaft 206 rotatably coupled to a motor 208. The motor shaft 206 may axially pass through an opening 210 provided in the finned tube heat exchanger 110. It is to be noted that the motor shaft 206 is mechanically coupled to the finned tube heat exchanger 110 via a bearing assembly (not shown) disposed within the opening 210. In an embodiment, the opening 210 may be provided at a center of the finned tube heat exchanger 110.
[025] In one embodiment, the motor 208 may be disposed in a fan hub 212 of the second fan 204. As shown in FIG. 2A, the motor shaft 206 may include a first end 216 and a second end 218 on opposite sides of the finned tube heat exchanger 110. Accordingly, the second fan 204 may be coupled to the second end 218 of the motor shaft 206. Further, the first end 216 of the motor shaft 206 may pass through the opening 210 in the finned tube heat exchanger 110 and the first fan 202 may be coupled on the first end 216 of the motor shaft 206. It is to be noted that the operation of the motor 208 may rotate the motor shaft 206 which in turn may rotate the first fan 202 and the second fan 204. Accordingly, the first fan 202 and the second fan 204 are configured to throw air in the same direction.
[026] The first fan 202 and the second fan 204 may be configured to throw the air in the same direction passing via the finned tube heat exchanger 110. Accordingly, the axial fan assembly 112, based on the operation of the first fan 202 and the second fan 204 disposed on opposite sides of the finned tube heat exchanger 110, may be configured to exchange heat. The finned tube heat exchanger 110 being sandwiched between the axial fan assembly 112 enhances the heat exchange based on the operation of the first fan 202 and the second fan 204. Accordingly, the present embodiment advantageously utilizes only one motor 208 to run both the fans 202 and 204, thus reducing the power requirement. Further, use of one motor 208 may reduce the contribution to the NVH and may allow meeting the NVH targets.
[027] Referring now to FIG. 3, an exploded view 300 of an axial fan assembly 112 for the finned tube heat exchanger 110 with a gear assembly is illustrated, in accordance with an embodiment of the present disclosure. The axial fan assembly 112 may include a first fan 202 and a second fan 204 rotatably coupled to each other through a gear assembly. As can be seen in FIG. 3, the first fan 202 and the second fan 204 may be disposed on opposite sides of the finned tube heat exchanger 110. Further, the second fan 204 is rotatably coupled to a motor 302 via a motor shaft 306. In an embodiment, any one of the first fan 202 or the second fan 204 may be coupled to the motor 302 via the gear assembly. The gear assembly may include a plurality of helical gears 304A-H coupled to a plurality of shafts (306, 308A, 310, 308B, 312) in a manner to rotatably couple the motor 302 with the first fan 202 and the second fan 204 in a synchronized manner.
[028] The motor shaft 306 may include the motor 302 at one end and may be rotatably coupled to the second fan 204 at another end. Further, the motor shaft 306 may include a first helical gear 304A rotatably coupled to the motor shaft 306 in between the second fan 204 and the motor 302. The gear assembly may further include a first vertical shaft 308A that may include a second helical gear 304B rotatably coupled to the first helical gear 304A. Further, the first vertical shaft 308 may include a third helical gear 304C on opposite end of the second helical gear 304B. The gear assembly may further include a vertical shaft 310 that may include a fourth helical gear 304D at one end and a fifth helical gear 304E at another end. The fourth helical gear 304D is rotatably coupled to the third helical gear 304C of the first vertical shaft 308A. Further, the vertical shaft 310 may include a fifth helical gear 304E at opposite end of the vertical shaft 310.
[029] Further, the second vertical shaft 308B may include the sixth helical gear 304F rotatably coupled to the fifth helical gear 304E. The second vertical shaft 308B may include a seventh helical gear 304G at opposite end of the end including the sixth helical gear 304F. Further, the first fan 202, disposed on the front side 201A of the finned tube heat exchanger 110, may be rotatably coupled to one end of a fan shaft 312. The fan shaft 312 may include an eighth helical gear at an opposite end of the end coupled to the first fan 202. The eighth helical gear 304H may be rotatably coupled to the seventh helical gear 304G coupled at one end of the second vertical shaft 308B.
[030] Accordingly, the gear coupling assembly rotatably couples the motor shaft 306 with the first vertical shaft 308A which in turn is rotatably coupled to the horizontal shaft 310 which in turn is rotatably coupled to the second vertical shaft 308B which is turn is rotatably coupled to the fan shaft 312. Thus, the rotation of the actuation of the motor 302 may lead to rotation of the second fan 204 and the first helical gear 304A that may rotate the second helical gear 304B that may in turn rotate the first vertical shaft 308A. The rotation of the first vertical shaft 308A may rotate the third helical gear 304C which in turn may rotate the fourth helical gear 304D. The rotation of the fourth helical gear 304D may rotate the horizontal shaft 310 that may rotate the fifth helical gear 304E. The rotation of the fifth helical gear 304E may rotate the sixth helical gear 304F that may rotate the second vertical shaft 308B. The rotation of the second vertical shaft 308B may rotate the seventh helical gear 304G which in turn may rotate the eighth helical gear 304H. Finally, the rotation of the eighth helical gear 304H may rotate the first fan 204. Accordingly, the first fan 202 and the second fan 204 may rotate together based on the actuation of the motor 302 in same direction and with same RPM. Further, the rotation of the first fan 202 and the second fan 204 may throw air in the same direction of the finned tube heat exchanger 110. It should be noted that based on the rotation of the first fan 202 and the second fan 204 in the same direction and being disposed on the opposite sides of the finned tube heat exchanger 110 may allow for an efficient heat exchange from the finned tube heat exchanger 110. It is to be noted that any of the shafts 308A, 310, 308B and 312 may be coupled to the motor 302. Accordingly, the present embodiment may utilize only one motor 302 to run both the fans 202 and 204 reducing the power requirement. Further, use of one motor 302 may reduce the NVH component as well.
[031] Referring now to FIG. 4, an exploded view 400 of an axial fan assembly 112 for the finned tube heat exchanger 110 using two motors is illustrated, in accordance with an embodiment of the present disclosure. The axial fan assembly 112 including the first fan 202 and the second fan 204 may be provided on opposite sides of the finned tube heat exchanger 110. Accordingly, the finned tube heat exchanger 110 may be sandwiched between the first fan 202 and the second fan 204. Further, the first fan 202 may be rotatably coupled to a first motor 402 via a first motor shaft 404A. Further, the second fan 204 may be rotatably coupled to a second motor 406 via a second motor shaft 404B.
[032] The first motor shaft 404A may be rotatably coupled to the first fan 202 at an end towards the front side 201A of the finned tube heat exchanger 110. Further, the first motor shaft 404A may be coupled to the first motor 402 at the opposite end of the end coupled to the first fan 202. Similarly, second motor shaft 404B may be rotatably coupled to the second fan 204 at an end towards the back side 201B of the finned tube heat exchanger 110. Further, the second motor shaft 404B may include the second motor 406 at the opposite end of end coupled to the second fan 204. It is to be noted that that the first motor 402 and the second motor 406 may be configured to be operated synchronously by being connected through same power supply line (not shown). Accordingly, based on transmission of power to both the first motor 402 and the second motor 406 by the same power supply line, both the first motor 402 and the second motor 406 may rotate in same direction at the same time. Accordingly, the first motor shaft 404A and the first fan 202 and the second motor shaft 404B and the second fan 204 may rotate in the same direction. In an embodiment, rotational speed of the first motor 402 and the second motor 406 may be same, thus the first fan 202 and the second fan 204 may rotate with same RPM in same direction. Accordingly, based on the synchronous operation of the first motor 402 and the second motor 406, the first fan 202 and the second fan 204 may be configured to throw the air in the same direction passing via the finned tube heat exchanger 110.
[033] Accordingly, the first motor shaft 404A of the first motor 402 and the second motor shaft 404B of the second motor 406 may be configured to rotate the first fan 202 and the second fan 204 in such a way that the first fan 202 and the second fan 204 may throw the air in the same direction passing via the finned tube heat exchanger 110. The embodiments 300 and 400 of the axial fan assembly 112, do not require alteration of the design of the finned tube heat exchanger 110. Thus, the the axial fan assembly 112 of the embodiments 300 and 400 of can be retrofitted to an already existing finned tube heat exchanger 110 without requiring any design change in the finned tube heat exchanger 110.
[034] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[035] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[036] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
[037] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
, Claims:1. An axial fan assembly (112) for a finned tube heat exchanger (110), comprising:
a motor shaft (206) configured to axially pass through an opening (210) configured in the finned tube heat exchanger (110), wherein the motor shaft (206) comprises a first end (216) and a second end (218) on opposite sides of the finned tube heat exchanger (110);
a first fan (202) mechanically coupled to the motor shaft (206) at the first end (216); and
a second fan (204) mechanically coupled to the motor shaft (206) at the second end (218).

2. The axial fan assembly (112) as claimed in claim 1, wherein the motor shaft (206) is mechanically coupled to the finned tube heat exchanger (110) via a bearing assembly disposed within the opening (210).

3. The axial fan assembly (112) as claimed in claim 1, wherein the motor shaft (206) is mechanically coupled to a motor (208), and wherein the motor (208) is disposed in a hub (212) of one of the first fan (202) and the second fan (204).

4. The axial fan assembly (112) as claimed in claim 1, wherein the opening (210) is provided at about center of the finned tube heat exchanger (110).

5. The axial fan assembly (112) as claimed in claim 1, wherein the first fan (202) and the second fan (204) are configured to throw air in the same direction.

6. An axial fan assembly (112) for a finned tube heat exchanger (110), comprising:
a first fan (202) disposed on a first side of the finned tube heat exchanger (110); and
a second fan (204) disposed on a second side of the finned tube heat exchanger (110),
wherein the first side and the second side are opposite sides of the finned tube heat exchanger (110), and
wherein the first fan (202) and the second fan (204) are configured to throw air in a same direction.

7. The axial fan assembly (112) as claimed in claim 6, wherein each of the first fan (202) and the second fan (204) are mechanically coupled to a motor via a motor shaft (206).

8. A system comprising:
a finned tube heat exchanger (110); and
an axial fan assembly (112) for the finned tube heat exchanger (110), the axial fan assembly (112) comprising:
a first fan (202) disposed on a first side of the finned tube heat exchanger (110);
a second fan (204) disposed on a second side of the finned tube heat exchanger (110),
wherein the first side (201A) and the second side (201B) are opposite sides of the finned tube heat exchanger (110), and
wherein the first fan (202) and the second fan (204) are configured to throw air in a same direction.

9. The system of claim 8, wherein each of the first fan (202) and the second fan (204) are mechanically coupled to a motor via a motor shaft (206).

10. The system of claim 8, wherein the finned tube heat exchanger (110) is one of a condenser of a heating, ventilation, and air conditioning (HVAC) subsystem, a radiator of a traction cooling subsystem, or a condenser of battery cooling subsystem.