MANUFACTURING FIXTURES INCLUDING AN INTEGRATED DIFFUSER FOR DIFFUSING CONDITIONED AIR
20230168002 · 2023-06-01
Inventors
- Daryl Van Zee (Pella, IA, US)
- Travis Strunk (Eddyville, IA, US)
- Eric Roggatz (West Melbourne, FL, US)
- Vanessa Chapman (Pella, IA, US)
- Matt Paschal (Pella, IA, US)
Cpc classification
F24F13/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F13/081
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F13/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F24F13/062
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A manufacturing fixture having an integrated diffuser for diffusing conditioned air into an industrial workspace is disclosed. The fixture includes an elevated platform having an air inlet and a diffuser deck mounted below the platform and disposed below the air inlet. The diffuser deck includes a set of louver plates arranged in a vertical stack. Each of the louver plates of the set has a top surface and an opening wherein the opening of each subsequent louver plate below the uppermost louver plate has an area less than the area of the louver plate directly above. The top surface of each louver plate is angled downward from the opening.
Claims
1. A manufacturing fixture having an integrated diffuser for diffusing conditioned air into an industrial workspace, the fixture comprising: an elevated platform supported by frame members, the elevated platform having an air inlet formed therein having an air inlet area; a diffuser deck mounted below the elevated platform and disposed directly below the air inlet, the diffuser deck being disposed within the frame members, the diffuser deck comprising a set of louver plates arranged in a vertical stack, each of the louver plates of the set having: an opening having a centroid and defining an opening plane, wherein: the opening of each subsequent louver plate below an uppermost louver plate has an area less than the area of the louver plate directly above; and the centroids of each opening of the louver plates are positioned at a generally vertical louver axis, the opening planes being generally perpendicular to the louver axis; and a top surface, the top surface of each louver plate being angled downward from the opening.
2. The manufacturing fixture as set forth in claim 1, wherein the diffuser deck comprises a louver base plate arranged at a bottom of the vertical stack, the louver base plate not having an opening formed therein through which cool air passes.
3. The manufacturing fixture as set forth in claim 1, wherein the each of the top surfaces of the louver plates includes an outer perimeter, the outer perimeters being aligned when viewed from above.
4. The manufacturing fixture as set forth in claim 1, wherein the each of the top surfaces of the louver plates includes an outer perimeter, at least a portion of the outer perimeters being asymmetrical to other outer perimeters.
5. The manufacturing fixture as set forth in claim 1, wherein each of the plurality of louver plates is frustoconical.
6. The manufacturing fixture as set forth in claim 1, wherein the top surface and opening plane of each louver plate form an angle from 10 to 20 degrees.
7. The manufacturing fixture as set forth in claim 1, wherein the top surface and opening plane of each louver plate form an angle from 14 to 16 degrees.
8. (canceled)
9. The manufacturing fixture as set forth in claim 1, wherein each louver plates is spaced at least 3 inches from each adjacent louver plate.
10. The manufacturing fixture as set forth in claim 1, wherein the diffuser deck does not exceed a footprint of the elevated platform.
11. A vertical displacement ventilation system for diffusing conditioned air into an industrial workspace, the system comprising: a supply duct; and the manufacturing fixture of claim 1 disposed below the supply duct.
12. The vertical displacement system as set forth in claim 11 wherein the supply duct forms the air inlet formed in the elevated platform.
13. The vertical displacement system as set forth in claim 11 wherein the supply duct passes through the air inlet formed in the elevated platform.
14. The vertical displacement system as set forth in claim 11 wherein the supply duct has an outlet separate from and disposed above the air inlet formed in the elevated platform.
15. The vertical displacement system as set forth in claim 11 comprising an air blower fluidly connected to the supply duct.
16. The vertical displacement ventilation system as set forth in claim 11 comprising an exhaust disposed above the diffuser deck for removing ambient air and fumes from the industrial workspace, the exhaust having an inlet disposed above the diffuser deck.
17. (canceled)
18. The vertical displacement ventilation system as set forth in claim 11, the elevated platform being connected to a supporting structure of an industrial edifice in which the manufacturing fixture is disposed.
19. A method of dispelling ambient air containing fumes in an industrial workspace arranged within an open factory, the industrial workspace including a floor and a roof disposed above the floor, the method comprising: directing a conditioned air stream from a supply duct to a vertical diffuser having a plurality of louver plates arranged in proximity to the floor; introducing the conditioned air stream at a velocity less than 150 feet per minute at a distance of 12 inches away from the diffuser by laminar flow into the ambient air containing fumes; displacing ambient air containing fumes by the laminar conditioned air flow such that the ambient air containing fumes is displaced in a vertical direction towards the roof; and exhausting ambient air containing fumes through an exhaust system arranged in proximity to the roof.
20. The method set forth in claim 19, wherein the conditioned air stream from the vertical diffuser is at a lower temperature and a higher density than the ambient air containing fumes in the industrial workspace, such that the cool air stream displaces the ambient air containing fumes and forces the ambient air containing fumes in a vertical direction.
21. The method as set forth in claim 19, wherein the conditioned air stream from the vertical diffuser is introduced into the industrial workspace at temperature at least 5° F. less than the temperature of the ambient air containing fumes.
22. The method as set forth in wherein the conditioned air stream is contaminated and heated by a welding process to become ambient air containing fumes.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0024] Corresponding reference characters indicate corresponding parts throughout the drawings.
DETAILED DESCRIPTION
[0025] Provisions of the present disclosure relate to manufacturing fixtures having a diffuser integrated therein for diffusing conditioned air into an industrial workspace such as a generally open factory layout in which one or more industrial operations are performed. An example industrial workspace 10 in which the fixture may be used is shown in
[0026] During a welding operation, the ambient air adjacent the welding zone 12 is heated and contaminated with welding fumes. In accordance with embodiments of the present disclosure, the welding station 16 is in proximity to a manufacturing fixture 100 (e.g., a welding platform adapted for storing and securing welding equipment). The manufacturing fixture 100 includes a diffuser 102 (
[0027] Referring now to
[0028] The ventilation system 120 includes a supply duct 122 which is in flow communication with the diffuser deck 106. In some embodiments, the supply duct 122 forms the air inlet 112 in the elevated platform 104. In other embodiments, the supply duct 122 passes through the air inlet 112 formed in the elevated platform 104. In yet other embodiments, the supply duct 122 has an outlet separate from and disposed above the air inlet 112 formed in the elevated platform 104. In some embodiments, the supply duct 122 is connected to the elevated platform 104.
[0029] The supply duct 122 may be spaced a distance from the diffuser deck 106 (i.e., the uppermost plate 148 thereof) while maintaining flow communication (e.g., laminar flow) between the duct 122 and diffuser deck 106 (e.g., at least 1 inch, 2 inches, 6 inches, or 18 inches or more of spacing between a lower end of the supply duct 122 and the uppermost plate 148 of the diffuser deck 106). In other embodiments, the supply duct 122 is connected to the diffuser deck (i.e., without spacing between the supply duct 122 and diffuser deck 106). The supply duct 122 may have a length sufficient to create laminar air flow within the duct 122.
[0030] The supply duct 122 may be fluidly connected with components associated with a heating, ventilation, and air conditioning system (HVAC) system that may be supported by the industrial workspace 10. The vertical displacement ventilation system 120 includes an air blower 124 (
[0031] The manufacturing fixture 100 may be any suitable fixture used for an industrial operation, particularly for operations which generate heat and/or release fumes or contaminates polluting the surrounding ambient air. In addition, the manufacturing fixture 100 which integrates the diffuser 102 may be utilized for industrial workspaces 10 where there is limited available space on a floor 18 (
[0032] In the illustrated embodiment, the elevated platform 104 is used to support industrial equipment 110 pertinent to an industrial operation. For example, the elevated platform 104 may support a welding unit, a welding boom arm, shelves, and/or welding cables. In some embodiments, the equipment 110 may include hand and power tools, personal protective equipment, tool box, small fixtures, and/or welding wire storage.
[0033] The manufacturing fixture 100 may be in proximity to a welding station 16 that includes a welding work surface, such as a welding table 22 as shown in
[0034] Referring now to
[0035] In some embodiments, the elevated platform 104 is connected to a supporting structure 131 of the industrial edifice in which the manufacturing fixture 100 is disposed (e.g., an I-beam). The supporting structure 131 may also include a baffle 132 used to deflect conditioned air exiting the diffuser deck 106. The baffle 132 is used to reduce or prevent turbulence created as the conditioned air interacts with the supporting structure 131. The baffle 132 may be tent like in shape including a first panel 134 and second panel 136 angled relative to the first panel 134. In some embodiments, the baffle 132 is not mounted to the supporting structure 131, such that the baffle 132 is free standing and is placed in proximity to an obstruction to deflect airflow in a smooth manner around the obstruction.
[0036] The diffuser deck 106 is mounted below the elevated platform 104. The diffuser deck 106 includes a set of louver plates 140 arranged in a vertical stack 142. In this illustrated embodiment, the louver plates 140 are generally frustoconical in shape. Each of the louver plates 140 of the set includes an opening 144 (
[0037] Each of the louver plates 140 includes a top surface 150. The top surface 150 of each louver plate 140 is angled downward from its opening 144. The top surface 150 and the opening plane P.sub.144 of each louver plate 140 form an angle α from 10° to about 20° (e.g., from about 14° to about 16°). In some embodiments, the angle α is 15°.
[0038] Referring now to
[0039] In some other example embodiments, the louver plates 140 are frustum in shape and the outer perimeter 152 is rectangular (e.g., square) in shape. Additionally, in some embodiments, the openings 144 of each louver plate may have a shape other than circular (e.g., rectangular).
[0040] Each of the louver plates 140 are spaced apart a distance L.sub.140 (
[0041] The louver plates 140 are supported by a plurality of struts 154 (
[0042] Generally, a portion of conditioned air is introduced to each louver plate 140 via the opening 144 and/or openings 144 formed on the louver plates 140 arranged above in the vertical stack 142 of the diffuser deck 106. The top surface 150 of each louver plate 140 deflects a portion of the conditioned air outwards towards the surrounding ambient air and the opening 144 allows a portion of the conditioned air to pass to the louver plate 140 arranged below.
[0043] The diffuser deck 106 includes a louver base plate 160 arranged at the bottom of the vertical stack 142. The louver base plate 160 does not have an opening 144 formed therein through which cool air passes. The louver base plate 160 includes a base plate surface 162 (
[0044] The deflected conditioned air exits the diffuser deck 106 at the outer perimeter 152 (
[0045] In accordance with embodiments of the present disclosure, the conditioned air exits the diffuser deck 106 and may be introduced into the surrounding ambient air using laminar flow. The conditioned air does not substantially mix with the ambient air creating stratification between the conditioned air and the ambient air. The diffuser deck 106 may be configured to deliver conditioned air at laminar flow in about a region having a radius of about 20 feet from the diffuser deck 106.
[0046] In the illustrated embodiment, the diffuser deck 106 has a throw angle of 360° about the louver axis Y.sub.140. More specifically, the integrated diffuser 102 introduces the conditioned air into the ambient air, in all directions surrounding the diffuser deck 106 (excluding obstructions).
[0047] The conditioned air exits the diffuser deck 106 and is introduced into the ambient air in a direction generally along the angled top surface 150 of the louver plates 140 such that the introduced conditioned air is directed substantially downwards towards the floor 18 of the industrial workspace 10. In some example embodiments, the conditioned air is introduced to the ambient air in a direction that is generally parallel to the opening planes P.sub.144 and/or generally perpendicular to the louver plate axis Y.sub.140.
[0048] The manufacturing fixture 100 is configured to be relatively simple to manufacture and install. For example, the diffuser deck 106 may lack components used for acoustic damping.
[0049] The manufacturing fixture 100 may be incorporated a vertical displacement ventilation system 120 (
[0050] The manufacturing fixture 100 is arranged within an industrial edifice, also referred to as an industrial plant, having external walls (not shown). The exhaust system 126 includes an exhaust outlet 130 that is external to the industrial edifice. The exhaust system 126 removes ambient air and fumes from within the industrial workspace 10 by drawing in ambient air through the exhaust duct inlets 128 by an exhaust fan (not shown) and expelling the ambient air through the exhaust outlet 130. In some example embodiments, a portion of the exhausted air may be vented to an exterior of the industrial workspace and another portion may be filtered and then used for recirculation, i.e., re-supplied to AC system 125.
[0051] The conditioned air is introduced in proximity to the floor 18 such that the ambient air is displaced in a vertical direction toward the roof 20. More specifically, the conditioned air is cooler in temperature than the ambient air in the industrial workspace 10. The conditioned air may be at least 5° F., at least 10° F., or at least 15° F. cooler than the ambient air. Likewise, the conditioned air is denser than the ambient air containing fumes. The cooler, denser conditioned air displaces the hotter and less dense ambient air forcing the ambient air to rise in a vertical direction upward toward the roof 20. The vertically displaced ambient air is subsequently exhausted through the exhaust system 126. In other example embodiment, the conditioned air may be any suitable temperature such that the conditioned air is denser than the ambient air.
[0052] Accordingly, the vertical ventilation system 120 reduces or eliminates recirculation of the ambient air containing fumes with the conditioned air introduced into the work zone 12. In some example embodiments, the work zone 12 may have a slightly lower pressure, compared to the pressure of the surrounding industrial workspace 10, such that fumes created in the welding zone 12 are further contained within the welding zone 12 and prevented from mixing and contaminating the surrounding ambient air outside of the designated work zone 12. The lower pressure of the designated works zone 12 may also draw in fumes and ambient air from surrounding zones which will subsequently be displaced and expelled by the vertical displacement ventilation system 120.
[0053] The introduced conditioned air is subsequently contaminated and heated by additional welding processes or other industrial operations workspace and accordingly, the conditioned air becomes the ambient air containing fumes. New conditioned air introduced by the vertical displacement ventilation system 120 will continue to displace the contaminated air from within the welding zone. In this illustrated embodiment, the ventilation system 120 is capable of performing at least two air exchanges per hour, at an exchange rate of 2000 cubic feet per min (CFM). In some example embodiments, the exchange rate is 4000 CFM. The ventilation system 120 has the capacity to perform 4 to 5 air exchanges per hour.
[0054] Another embodiment of the manufacturing fixture 200 is shown in
[0055] Compared to conventional conditioning systems used for industrial workspaces, the conditioning systems of embodiments of the present disclosure have several advantages. By integrating the diffuser into a manufacturing fixture such as a welding station (e.g. elevated platform that supports the welding units), the integrated diffuser requires less space and does not create an obstruction within an industrial workspace. In addition, the manufacturing fixture may be used to perform an industrial operation that generates heat and/or contaminates which pollute the air surrounding the manufacturing fixture. The integrated system is capable of providing conditioned air, using laminar flow, in proximity to the floor, displacing the hot contaminated air localized near the integrated system without combining with the contaminated air and/or circulating the contaminated air throughout the rest of the industrial workspace. In embodiments wherein the integrated diffuser includes a plurality of louver plates each having an angled top surface, the diffuser is able to introduce conditioned air into the surrounding ambient air using laminar flow, i.e., with limited to no turbulence, creating stratification between conditioned air and contaminated ambient air. More specifically the conditioned air introduced by the integrated diffuser does not mix with the contaminated ambient air. The top surface of each of the louver plates may be angled (e.g., 10° to 20°) such that the conditioned air is deflected by the top surface and introduced into the surrounding contaminated ambient air at low velocities, preventing the conditioned air from displacing contaminated ambient air outward into surrounding zones of the industrial workspace. The angled top surfaces of the louver plates are arranged such that the conditioned air is introduced in proximity to the floor, displacing the contaminated air in a substantially vertical direction towards an exhaust inlet. Furthermore, the embodiments of the present disclosure include a robust design capable of withstanding environmental hazards, such as impacts and/or interaction with debris, common in an industrial workspace (e.g., impact with industrial mobile equipment such as lift truck or automated guide vehicles which may maneuver around the integrated diffuser). By incorporating the diffuser into the manufacturing fixture, conditioned air is introduced into the workspace in proximity to operators working within the industrial workspace.
[0056] As used herein, the terms “about,” “substantially,” “essentially” and “approximately” when used in conjunction with ranges of dimensions, concentrations, temperatures or other physical or chemical properties or characteristics is meant to cover variations that may exist in the upper and/or lower limits of the ranges of the properties or characteristics, including, for example, variations resulting from rounding, measurement methodology or other statistical variation.
[0057] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” “containing” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of terms indicating a particular orientation (e.g., “top”, “bottom”, “side”, etc.) is for convenience of description and does not require any particular orientation of the item described.
[0058] As various changes could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawing[s] shall be interpreted as illustrative and not in a limiting sense.