Fan array control system

Abstract

A fan array fan section in an air-handling system includes a plurality of fan units arranged in a fan array and positioned within an air-handling compartment. One preferred embodiment may include an array controller programmed to operate the plurality of fan units at peak efficiency by computing the power consumed in various configurations and selecting the configuration requiring minimum power to operate.

1 - 10 . (canceled) 
     
     
         11 . A method for controlling an array of fan units in an air handling system that conditions air to be delivered to a building, the method comprising:
 providing a select level for an environmental parameter based on a building requirement, the environmental parameter representing at least one of static pressure or air flow;   setting a number of operative fan units to an initial number;   measuring, at a sensor, the environmental parameter to obtain a measured value representative of the at least one of the air flow or static pressure;   operating a controller in a feedback control loop to control the operative fan units based on the select level for the environmental parameter and the measured value from the sensor; and   varying the number of operative fan units to maintain the operative fan units within a desired range.   
     
     
         12 . The method of  claim 11 , further comprising utilizing the controller to vary at least one of the flow rate or static pressure continuously or periodically as a level of the environmental parameter for the building changes. 
     
     
         13 . The method of  claim 11 , wherein the controller varies at least one of the flow rate or static pressure by varying the number of operative fan units within the array. 
     
     
         14 . The method of  claim 11 , wherein the environmental parameter represents flow rate, the providing operation including providing a first level relative to a maximum fan-array flow rate capacity during a first time period and providing a second level relative to the maximum fan-array flow rate capacity during a second time period. 
     
     
         15 . The method of  claim 11 , wherein the sensor is connected to a feedback line that is connected to the controller to provide measured values for at least one of the flow rate or static pressure. 
     
     
         16 . The method of  claim 11 , further comprising providing information to the controller regarding a motor operational status through a feedback line that is connected between the controller and motors of the fan units. 
     
     
         17 . The method of  claim 11 , further comprising, when an RPM speed of at least one of the operative fan units reaches a maximum rated level of a motor of the at least one operative fan unit, incrementing the number of operative fans. 
     
     
         18 . The method of  claim 11 , wherein the incrementing operation includes, when incrementing the number of operative fan units, changing the RPM speed to an initial RPM speed. 
     
     
         19 . The method of  claim 11 , further comprising continuously selecting an efficient combination of the number of operative fan units and an RPM speed for the operative fan units to satisfy programmed constraints. 
     
     
         20 . The method of  claim 11 , wherein the desired range correspond to at least one of a desired fan efficiency range, motor efficiency range or a motor load range, the controller operating in the feedback control loop to maintain the fan units continuously operating in at least one of the desired fan efficiency range, motor efficiency range or the motor load range. 
     
     
         21 . The method of  claim 11 , wherein the desired range corresponds to power consumption of the operative fan units. 
     
     
         22 . The method of  claim 11 , further comprising measuring a power input to at least one of the operative fan units, the number of operative fan units being varied based on the power input measured. 
     
     
         23 . The method of  claim 11 , further comprising outputting at least one of a number of fan units or an RPM speed to achieve a desired level of power as a suggestion for an operator to implement the varying operation manually. 
     
     
         24 . The method of  claim 11 , wherein the feedback control loop continuously selects a number of operative fan units and RPM speed to satisfy the select level for the environmental parameter. 
     
     
         25 . The method of  claim 11 , wherein the varying operation increments the number of operative fan units when an RPM speed of the operative fan units reaches a maximum rated level. 
     
     
         26 . An air handling system comprising:
 a preselected number of fan units, said fan units arranged in a fan array, said array capable of operation with an initial number of operative fan units less than the preselected number of fan units to maintain a select level for an environmental parameter based on a building requirement, the environmental parameter representing at least one of static pressure or air flow;   a sensor to measure the environmental parameter to obtain a measured value representative of at least one of the air flow or static pressure; and   a controller configured to:   control the operative fan units based on the select level for the environmental parameter;   utilize the measured value and the select level in a feedback control loop to control the operative fan units; and   vary the number of operative fan units to maintain the operative fan units within a desired range.   
     
     
         27 . The system of  claim 26 , wherein the controller is configured to vary at least one of the flow rate or static pressure continuously or periodically as a level of the environmental parameter for the building changes. 
     
     
         28 . The system of  claim 26 , wherein the controller varies at least one of the flow rate or static pressure by varying the number of operative fan units within the array. 
     
     
         29 . The system of  claim 26 , wherein the environmental parameter represents flow rate, the controller maintains a first level relative to a maximum fan-array flow rate capacity during a first time period and maintains a second level relative to the maximum fan-array flow rate capacity during a second time period. 
     
     
         30 . The system of  claim 26 , wherein the controller receives information regarding a motor operational status through a feedback line that is connected between the controller and motors of the fan units and utilizes the information to vary the number of operative fan units. 
     
     
         31 . The system of  claim 26 , wherein the controller increments the number of operative fans when an RPM speed of at least one of the operative fan units reaches a maximum rated level of a motor of the at least one operative fan unit. 
     
     
         32 . The system of  claim 26 , wherein the controller changes the RPM speed to an initial RPM speed when incrementing the number of operative fan units. 
     
     
         33 . The system of  claim 26 , wherein the controller continuously selects an efficient combination of the number of operative fan units and an RPM speed for the operative fan units to satisfy programmed constraints. 
     
     
         34 . The system of  claim 26 , wherein the desired range correspond to at least one of a desired fan efficiency range, motor efficiency range or a motor load range, the controller operating in the feedback control loop to maintain the fan units continuously operating in at least one of the desired fan efficiency range, motor efficiency range or the motor load range. 
     
     
         35 . The system of  claim 26 , wherein the sensor is located in an air-handling system installed in a building. 
     
     
         36 . The system of  claim 26 , wherein the measured valves include power usage of the motor. 
     
     
         37 . The system of  claim 26 , wherein the controller calculates a power consumption of the operative fan units based upon RPM information, the controller identifies the number of fan units and a fan unit speed that will achieve power consumption within the desired range. 
     
     
         38 . A method for controlling an array of fan units in an air handling system that conditions air to be delivered to a building, the method comprising:
 providing a select level for an environmental parameter based on a building requirement, the environmental parameter representing at least one of static pressure or air flow;   measuring, at a sensor, the environmental parameter to obtain a measured value representative of at least one of the air flow or static pressure;   obtaining information regarding motor operation;   varying the number of operative fan units based on the information regarding motor operation in a feedback control loop to operate the operative fan units; and   controlling the operative fan units based on the measured value and the select level for the environmental parameter.   
     
     
         39 . The method of  claim 38 , wherein the operative fan units are maintained in a desired range corresponds to power consumption of the operative fan units. 
     
     
         40 . The method of  claim 38 , further comprising measuring a power input to at least one of the operative fan units, the number of operative fan units being varied based on the power input measured. 
     
     
         41 . The method of  claim 38 , further comprising outputting at least one of a number of fan units or an RPM speed to achieve a desired level of power as a suggestion for an operator to implement the varying operation manually. 
     
     
         42 . The method of  claim 38 , wherein the feedback control loop continuously selects a number of operative fan units and RPM speed to satisfy the select level for the environmental parameter. 
     
     
         43 . The method of  claim 38 , wherein the varying operation increments the number of operative fan units when an RPM speed of the operative fan units reaches a maximum rated level.