Reduced weight rigid hvac fan construction

Abstract

A fan assembly and associated methods are shown. Examples shown include components such as box section rails, truss structures, formed features and thinner gauge material that used in prior configurations. These and other features shown provide a lighter and/or stiffer fan assembly.

1 . A fan assembly, comprising:
 a motor;   an impeller coupled to a shaft of the motor;   a support frame coupled to the motor, wherein the support frame includes;
 a number of sheet metal components; and 
 a number of formed features within a planar surface of at least one of the number of sheet metal components. 
   
     
     
         2 . The fan assembly of  claim 1 , wherein the number of sheet metal components include steel sheet metal. 
     
     
         3 . The fan assembly of  claim 1 , wherein the number of sheet metal components include aluminum sheet metal. 
     
     
         4 . The fan assembly of  claim 1 , further including an inlet funnel coupled to an inlet plate, wherein the inlet plate includes a number of formed features within a planar surface. 
     
     
         5 . The fan assembly of  claim 1 , wherein the number of sheet metal components are joined together using a fastener chosen from a group consisting of rivets, swage locks, bolts, screws, and adhesives. 
     
     
         6 . The fan assembly of  claim 1 , wherein the number of sheet metal components are joined together using welding. 
     
     
         7 . The fan assembly of  claim 1 , wherein the impeller is an axial impeller. 
     
     
         8 . The fan assembly of  claim 1 , wherein the impeller is a centrifugal impeller. 
     
     
         9 . A fan assembly, comprising:
 a motor;   an impeller coupled to a shaft of the motor;   a support frame coupled to the motor, wherein the support frame includes;
 a plurality of box section rails coupled together to form a base unit; 
 an inlet plate coupled to the base unit; and 
 a motor mount coupled to the base unit. 
   
     
     
         10 . The fan assembly of  claim 9 , wherein the motor mount includes a plurality of diagonal cross members to form a truss. 
     
     
         11 . The fan assembly of  claim 9 , wherein the plurality of box section rails includes a first pair of box section rails parallel to a rotation axis of the motor, and at least two second box section rails coupled between the first pair of box section rails to form a ladder base unit. 
     
     
         12 . The fan assembly of  claim 9 , wherein the support frame includes a number of formed features within a planar surface of at least a portion of the support frame. 
     
     
         13 . The fan assembly of  claim 12 , wherein the number of formed features are formed within a portion of the motor mount. 
     
     
         14 . The fan assembly of  claim 12 , wherein the number of formed features are formed within a portion of the inlet plate. 
     
     
         15 . The fan assembly of  claim 9 , wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 14. 
     
     
         16 . The fan assembly of  claim 9 , wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 14 for a centrifugal impeller diameter of approximately 365 mm. 
     
     
         17 . The fan assembly of  claim 9 , wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 16 for a centrifugal impeller diameter of approximately 270 mm. 
     
     
         18 . The fan assembly of  claim 9 , wherein the support frame is formed from steel sheet metal having a gauge thickness equal to or less than 18 for a centrifugal impeller diameter of approximately 122 mm. 
     
     
         19 . A method of forming a fan assembly, comprising:
 forming a number of box section rails;   coupling together the number of box section rails to form a base unit;   coupling an inlet plate to the base unit;   coupling a motor mount to the base unit;   coupling a motor to the motor mount; and   coupling an impeller to a shaft of the motor.   
     
     
         20 . The method of  claim 19 , wherein forming the number of box section rails includes bending a flat sheet of metal to form the number of box section rails. 
     
     
         21 . The method of  claim 19 , wherein forming the number of box section rails includes joining two L shaped sections of sheet metal together to form the number of box section rails. 
     
     
         22 . The method of  claim 19 , further including stamping a number of features within a planar surface of at one sheet metal component of the fan assembly. 
     
     
         23 . The method of  claim 22 , wherein stamping a number of features includes stamping a number of features into a portion of the inlet plate. 
     
     
         24 . The method of  claim 23 , wherein stamping a number of features includes stamping a number of features into a portion of the motor mount. 
     
     
         25 . A fan assembly, comprising:
 a motor;   an impeller coupled to a shaft of the motor;   a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components with no component thicker than 14 gauge steel; and   wherein the fan assembly is designed to operate in a range between a low value of approximately 5,500 cubic feet per minute at a static pressure of approximately 6.6 inches water gauge (W.G.) and a high value of approximately 4,000 cubic feet per minute at a static pressure of approximately 13.5 inches water gauge (W.G.).   
     
     
         26 . A fan assembly, comprising:
 a motor;   an impeller coupled to a shaft of the motor;   a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components with no component thicker than 14 gauge steel; and   wherein the fan assembly is designed to operate in a range between a low value of approximately 4,400 cubic feet per minute at a static pressure of approximately 4.3 inches water gauge (W.G.) and a high value of approximately 3,150 cubic feet per minute at a static pressure of approximately 8.5 inches water gauge (W.G.).   
     
     
         27 . A fan assembly, comprising:
 a motor;   an impeller coupled to a shaft of the motor;   a support frame coupled to the motor, wherein the support frame includes a number of sheet metal components with no component thicker than 14 gauge steel; and   wherein the fan assembly is designed to operate in a range between a low value of approximately 3,400 cubic feet per minute at a static pressure of approximately 2.5 inches water gauge (W.G.) and a high value of approximately 2,415 cubic feet per minute at a static pressure of approximately 5.0 inches water gauge (W.G.).