Intelligent air mover apparatus

Abstract

A system for cooling an electronics enclosure comprises a plurality of fan modules. Each fan module comprises, a motor for driving a fan at a variable rotational speed, a microcontroller for controlling the rotational speed of the motor, an interface for electronically communicating between the microcontroller and an infrastructure controller external to the fan module, the infrastructure controller providing a target speed to the microcontroller, a memory for storing data including speed avoidance zones, wherein when the target speed falls within one of the speed avoidance zones, the microcontroller controls the motor speed to be slightly outside the speed avoidance zone.

1 . A system for cooling an electronics enclosure, comprising:
 a plurality of fan modules, each fan module comprising:
 a motor for driving a fan at a variable rotational speed; 
 a microcontroller for controlling the rotational speed of the motor; 
 an interface for electronically communicating between the microcontroller and an infrastructure controller external to the fan module, the infrastructure controller providing a target speed to the microcontroller; 
 a memory for storing data including speed avoidance zones; and 
 wherein when the target speed falls within one of the speed avoidance zones, the microcontroller controls the motor speed to be slightly outside the speed avoidance zone. 
   
     
     
         2 . The system of  claim 1 , the microcontroller comprising a speed sensor for detecting the rotational speed, wherein when the rotational speed sensed by the speed sensor falls below a target speed by at least a threshold amount, the microcontroller detects a locked rotor condition and initiates a sequence to shut down and restart the motor. 
     
     
         3 . The system of  claim 1 , the microcontroller comprising a voltage sensor, wherein when the voltage sensor senses a drop in voltage indicative of removal of power from the motor, the microcontroller simultaneously energizes one or more motor phases to stop the motor from rotating. 
     
     
         4 . The system of  claim 1 , wherein when the interface indicates a loss of communication with the infrastructure controller, the microcontroller maintains the rotational speed at a default speed. 
     
     
         5 . The system of  claim 1 , the fan module further comprising a crystal oscillator to ensure an accurate time base for motor speed measurements. 
     
     
         6 . The system of  claim 1 , the microcontroller further comprising memory for storing static data and an interface for electronically communicating between the microcontroller and an infrastructure controller external to the system, wherein the microcontroller communicates the static data to the infrastructure controller via the interface. 
     
     
         7 . The system of  claim 1 , the microcontroller further comprising a memory for storing dynamic data and an interface for electronically communicating between the microcontroller and an infrastructure controller external to the system, wherein the microcontroller communicates the dynamic data to the infrastructure controller via the interface. 
     
     
         8 . The system of  claim 1 , wherein the interface having redundant communication channels for electronically communicating between the microcontroller and an infrastructure controller external to the system, the infrastructure controller being adapted to switch between channels when one of the channels fails. 
     
     
         9 . The system of  claim 1 , further comprising at least one light emitting diode in electronic communication with the microcontroller to indicate at least one status condition of the system. 
     
     
         10 . The system of  claim 1 , wherein the microcontroller further provides a failure alert when a locked rotor condition is detected. 
     
     
         11 . The system of  claim 1 , wherein the microcontroller further provides an alert indicating that inspection of the fan is needed after a predetermined number of shut down and restart sequences. 
     
     
         12 . The system of  claim 1 , wherein the microcontroller further measures power to the motor, and wherein the microcontroller provides a pre-failure alert when a deviation is detected from an expected relationship between a motor rotational speed and the motor power. 
     
     
         13 . The system of  claim 1 , further comprising a temperature sensor for measuring motor temperature, wherein the microcontroller provides a pre-failure alert when the motor temperature deviates from an expected normal operating temperature. 
     
     
         14 . The system of  claim 1 , further comprising a temperature sensor for measuring fan air inlet temperature, wherein the microcontroller controls a motor rotational speed based on the fan inlet temperature. 
     
     
         15 . The system of  claim 1 , further comprising an overcurrent protector for shutting down and restarting the motor upon a detection of a high current condition.