AXIAL FLOW FUN
The invention is directed to dual purposes of increasing air volume and reducing noises of an inline axial flow fan. In the inline axial flow fan including a first axial flow fan unit 100-1, a first honeycomb 200-2, a second axial flow fan unit 100-2 and a second honeycomb 200-2 which are arranged in the order starting from an upstream side in an air flow direction, the first honeycomb includes a stator vane configured to be warped in a “U” shape against a rotation direction of the first axial flow fan unit, while the second honeycomb includes a stator vane configured to direct a trailing edge thereof in parallel to the air flow direction.
The present application claims priority from Japanese patent application serial no. 2010-163007 filed on Jul. 20, 2010, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates to an axial flow fan including axial flow fan units serially arranged in a direction of rotary shafts thereof.
2. Description of Related Art
Home electric appliances and OA/IT apparatuses are equipped with a cooling fan for cooling heat-generating electronic components. More recently, the market has been meeting demands for the downsizing and sophistication of these home electric appliances and OA/IT apparatuses. Along with the downsizing and sophistication efforts, the appliances and apparatuses tend to have an internal structure more densely mounted with the electronic components. This results in the increase in the amount of heat generation.
A compact, high volume axial flow fan is generally employed as a cooling fan to deal with the increased amount of heat generated by the electronic components.
However, in a case where the compact axial flow fan is employed for cooling the electronic components, the fan must be rotated at high speeds to provide a required volume of cooling air. Unfortunately, this entails a problem of noise increase although the air volume is increased by rotating the fan at high speeds.
On the other hand, a structure having the axial flow fan units serially arranged in the direction of rotary shafts thereof is adopted to deal with the increase in pressure loss as a consequence of the high-density mounting of electronic components.
As particularly exemplified by server apparatuses at data centers, machines and equipment designed on the assumption of long hours of continuous operation adopt a structure having a plurality of axial flow fan units operatively arranged in series from the standpoint of ensuring redundancy for preventing the total breakdown of a cooling function associated with the failure of the cooling fan.
In the structure wherein the axial flow fan units are serially arranged and operated, therefore, emphasis is placed on a technique for reducing noises during the operation of outputting the increased volume of cooling air.
U.S. Pat. No. 4,167,861 discloses a structure wherein two axial flow fan units are serially arranged in the direction of rotary shafts thereof. Interposed between the upstream axial flow fan unit and the downstream axial flow fan unit is a device (hereinafter, referred to as “honeycomb”) including a frame and vanes. The frame is called a stator and includes an inside surface and an outside surface. The vanes extend radially from the center of the frame. This honeycomb removes a swirling flow produced in an airflow by the axial flow fan unit, thus suppressing the noise generation.
However, the honeycomb of the U.S. Pat. No. 4,167,861 does not work on the air flow discharged from the downstream axial flow fan unit, although working on the air flow discharged from the axial flow fan unit disposed upstream thereof.
Therefore, the swirling flow in the air flow discharged from the downstream axial flow fan unit cannot be removed although the above-described honeycomb acts to remove the swirling flow from the air flow discharged from the upstream axial flow fan unit. In view of the whole body of the inline axial flow fan, therefore, the U.S. Pat. No. 4,167,861 is not necessarily considered to provide an effective solution to the above-described problem of noise generation.
SUMMARY OF THE INVENTIONIt is an object of the invention to provide an axial flow fan adapted to increase the air volume and to reduce the noise of inline axial flow fan units thereof.
The above object is accomplished in an axial flow fan comprising: a first axial flow fan unit disposed on an upstream side with respect to an air flow; a first honeycomb disposed downstream of the first axial flow fan unit; a second axial flow fan unit disposed downstream of the second honeycomb; and a second honeycomb disposed downstream of the second axial flow fan unit, wherein a stator vane constituting the first honeycomb is configured to be warped against a rotation direction of the first axial flow fan unit while a stator vane constituting the second honeycomb is configured to direct a trailing edge thereof in parallel to a direction of the air flow.
The above object is further accomplished in the axial flow fan wherein the stator vane constituting the first honeycomb is warped in a “U” shape.
The above object is further accomplished in the axial flow fan wherein the stator vane constituting the first honeycomb is divided into two parts.
The above object is further accomplished in an axial flow fan comprising: a first axial flow fan unit disposed on an upstream side with respect to an air flow; a first honeycomb disposed downstream of the first axial flow fan unit; a second axial flow fan unit disposed downstream of the first honeycomb; and a second honeycomb disposed downstream of the second axial flow fan unit, the second axial flow fan unit rotating in a different way from the first axial flow fan unit, wherein a stator vane constituting the first honeycomb is configured to direct a ventral side thereof against a rotation direction of the first axial flow fan unit, while a stator vane constituting the second honeycomb is configured to direct a trailing edge thereof in parallel to a direction of the air flow.
The above object is accomplished in the axial flow fan comprising an inline axial flow fan wherein the first and second axial flow fan units and the first and second honeycombs are used as a device for cooling server apparatuses.
The invention can provide the axial flow fan adapted to increase the air volume and to reduce the noise of the inline axial flow fan units thereof.
A first embodiment of the invention will be described as below with reference to the accompanying drawings. Referring to
Referring to
Referring to
Referring to
According to the above-described patent literature 1, the honeycomb 2 is interposed between the first axial flow fan unit 1 and the second axial flow fan unit 3 but the second honeycomb 4 on the downstream side is not provided. In the structure of the patent literature 1, therefore, a swirling flow can be removed from an air flow discharged from the first axial flow fan unit 1 by the effect of the honeycomb 2 but the swirling flow cannot be removed from the air flow discharged from the second axial flow fan unit 3.
In this connection, the present inventors have achieved the following embodiments by installing the second honeycomb 4 downstream of the second axial flow fan unit 3 and making various studies on the configuration of the stator vanes of the second honeycomb 4.
First EmbodimentNamely,
In
The first rotor blade 102a and the second rotor blade 102b rotate in the same direction and have rotary shafts in aligned relation. The first stator vane 203a is warped in a “U” shape against a rotation direction of the rotor blade 102a and the rotor blade 102b. The second stator vane 203b is configured to direct a trailing edge thereof in parallel to the air flow direction.
These honeycombs 2, 4 allow the air flow to enter the rotor blade 102a at a relative velocity 302a for a rotational field and at an absolute velocity 303a for a static field. In the rotational field commonly represented by the three-dimensional cylindrical coordinate system, the relative velocity is given as a sum of a circumferential velocity and the absolute velocity.
Passing through the rotor blade 102a, the air flow exits at a relative velocity 302b for the rotational field and at an absolute velocity 303b for the static field.
Referring to
Pth=ρu(vθout−vθin)=ρu(wθin−wθout) Equation 1
The equation 1 represents the theoretical total pressure rise of the air flow provided by the effect of the rotor blade. In the equation, “Pth” denotes a theoretical total pressure rise; “ρ” denotes an air density; “u” denotes a circumferential velocity; “wθin” denotes a swirl component of the relative inflow velocity; “wθout” denotes a swirl component of the relative exit velocity; “vθin” denotes a swirl component of the absolute inflow velocity; and “vθout” denotes a swirl component of the absolute exit velocity. The equation 1 means that the theoretical total pressure rise of the air flow is proportional to the velocity variation of the air flow caused by the effect of the rotor blade.
In the above-described first rotor blade 102a, a theoretical total pressure rise corresponding to an inflow velocity and an exit velocity of the air flow through the first rotor blade 102a of
The air flow exiting from the first rotor blade 102a enters the first stator vane 203a at the absolute velocity 303b for the static field and exits from the stator vane at an absolute velocity 303c as decelerated by the effect of the first stator vane 203a. As a consequence of the configuration of the first stator vane 203a warped in the “U” shape against the rotation direction of the second rotor blade 102b, the absolute velocity 303c contains a swirl component, called a negative preswirl, in the opposite direction to the rotation direction of the second rotor blade 102b.
The equation 2 represents the theoretical static pressure rise in the air flow provided by a common effect of the stator vane. In the equation, “ΔPs” denotes a theoretical static pressure rise; “ρ” denotes an air density; “vin” denotes an absolute inflow velocity; and “vout” denotes an absolute exit velocity. The equation 2 indicates that the absolute velocity of the air flow is decreased by the effect of the stator vane whereby the static pressure in the air flow is increased.
In the first stator vane 203a, a theoretical static pressure rise corresponding to an inflow velocity and an exit velocity of the air flow through the first stator vane 203a of
The air flow exiting from the first stator vane 203a enters the second rotor blade 102b at a relative velocity 302c for the rotational field and at the absolute velocity 303c for the static field. The air flow passes through the second rotor blade 102b and exits at a relative velocity 302d for the rotational field and at an absolute velocity 303d for the static field. At this time, the swirl component of the absolute inflow velocity in the equation 1 representing the theoretical total pressure rise of the air flow has the negative sign. Therefore, the theoretical total pressure rise is increased in value as compared with a case where the swirl component of the absolute inflow velocity has the positive sign. This effect permits the reduction of the circumferential velocity when as much theoretical total pressure rise as that of a case where the swirl component of the absolute inflow velocity has the positive sign is imparted to the air flow.
L′A=LA+60 log10(N′/N) Equation 3
The equation 3 represents the variation of noise level associated with the variation of motor revolving speed. In the equation, “N” denotes a pre-variation revolving speed; “N′” denotes a post-variation revolving speed; “LA” denotes a pre-variation noise level; and “L′A” denotes a post-variation noise level.
If the motor revolving speed is reduced by reducing the circumferential velocity of the second rotor blade 102b, the noise level is lowered as indicated by the equation 3.
The air flow exiting from the second rotor blade 102b enters the second stator vane 203b at the absolute velocity 303d for the static field and exits therefrom at an absolute velocity 303e as decelerated by the effect of the second stator vane 203b. At this time, the air flow obtains as much theoretical total pressure rise as determined by the equation 2.
Referring to
In this embodiment, if the first axial fan unit 1 shown in
As shown in
According to this embodiment as described above, the first stator vane 203a and the second stator vane 203b have different configurations so that the axial flow fan can achieve not only the reduced noise level and the increased air volume but also the effect to suppress the failure induced degradation of performance.
Now, description is made on a case where the first axial flow fan unit 1 and the second axial flow fan unit 2, described with reference to
A set of two axial flow fan units arranged in tandem and rotated in the different directions is generally called a duplicate contra-rotating fan. In this duplicate contra-rotating fan, an air flow through an axial flow fan unit on the upstream side in the air flow direction contains a swirling flow, which acts as the negative preswirl to the downstream fan unit. Hence, the pressure rise increased by the negative preswirl, as described in the first embodiment, can always be prospected.
However, if inflow condition for the air into the upstream axial flow fan unit varies due to the change in the operating environment or the like so that the negative preswirl to the downstream axial flow fan unit is increased too much, an air flow along a dorsal side of the blade becomes unable to withstand such a large pressure rise and sustains flow separation. This results in pressure loss.
Second EmbodimentAccording to a second embodiment, therefore, there are provided the first rotary rotor blade 102a and a second rotary rotor blade 102c. In the structure wherein the second rotor blade 102c rotates in the different direction, the first stationary stator vane 203a is configured to direct a dorsal side thereof against the rotation direction of the first rotor blade 102a, while the second stationary stator vane 203b is configured to direct the trailing edge thereof in parallel to the air flow direction.
Referring to
Referring to
As described above, this embodiment affords an effect to suppress the loss encountered by the axial flow fan or more particularly the duplicate contra-rotating fan by virtue of the structure wherein the stator vane 203a of the first honeycomb 2 and the stator vane 203b of the second honeycomb 4 have different configurations from those of the stator vane 203a of the first honeycomb 2 and the stator vane 203b of the second honeycomb 4 shown in
A third embodiment of the invention is described with reference to
Referring to
Referring to
In other words, the first stator vane 203a and the second stator vane 203b are two parts that form the first stator vane 203a described in the first embodiment shown in
Next, the operation of this embodiment is described with reference to
The air flow through the first rotor blade 102a enters the first stator vane 203a at an absolute velocity 301b for the static field. The air flow passing through the first stator vane 203a via the static field enters the second stator vane 203b at the absolute velocity 303c, the swirl component of which is reduced in the static field. The air flow through the second stator vane 203b has the absolute velocity 303d, which contains the negative preswirl against the second rotary rotor blade 102b. When the negative preswirl is applied to the air flow entering the second rotor blade 102b, the swirling flow of the air flow is reduced by the effect of the first stator vane 203a. Thus is obtained an effect to suppress the production of flow separation from the air flow passing through the second stator vane 203b. As a result, the loss caused by the air flow separation can be reduced or preferably eliminated.
As described above, this embodiment has the structure wherein the stator vane 203a of the first honeycomb 2 and the stator vane 203b of the second honeycomb 2a, shown in
Another advantageous effect of this embodiment is that the first stator vane 203a and the second stator vane 203b can be relatively easily formed by molding, as described above.
Fourth EmbodimentA fourth embodiment of the invention is described with reference to
Referring to
As shown in
Next, the operation of this embodiment is described with reference to
The air flow passes through the first stator vane 203a to obtain the absolute velocity 303b for the static field before entering the first rotor blade 102a. Since an operating environment assumed in a design phase differs from an actual operating environment, the loss may be caused by the air flow separation which may occur depending upon the air inflow condition varied due to the change in the operating environment. A function of the first stator vane 203a is to reduce or preferably to eliminate this loss.
As described above, this embodiment has the structure wherein the stator vane 203a of the first honeycomb 2, the stator vane 203b of the second honeycomb 2a and the stator vane 203c of the third honeycomb 5, shown in
A fifth embodiment of the invention is described with reference to
Referring to
According to the invention, the structure of the first embodiment, for example, may be adopted to form the cooling fan module 503 so that a blade server can attain high air volume and low noise by virtue of the effects of the first embodiment. It is also possible to provide the cooling fan module excellent in redundancy in the event of a failure.
The applications of the cooling fan module according to the embodiment include, but are not limited to the blade server, all kinds of server apparatuses such as rack mount servers and PC servers.
According to the invention as described above, a notable noise reduction can be achieved because the effect of the first honeycomb permits the second axial flow fan unit to be reduced in the revolving speed. In addition, the cooling fan module is increased in the air volume because the static pressure is increased due to the effects of the first honeycomb and the second honeycomb.
In addition, if the first axial flow fan unit should fail, the drop of cooling capacity can be reduced because the second honeycomb is provided.
On the other hand, the first honeycomb acts to prevent the air flow separation occurring in the second axial flow fan unit, thereby suppressing the generation of loss. Furthermore, the first honeycomb also acts to reduce the loss resulting from the varied inflow condition of the air into the first axial flow fan unit.
In addition, the provision of the axial flow fan featuring the low noise and high air volume makes it possible to fabricate a cooling fan module for server that is excellent in redundancy in the event of a failure.
Claims
1. An axial flow fan comprising: a first axial flow fan unit disposed on an upstream side with respect to an air flow; a first honeycomb disposed downstream of the first axial flow fan unit; a second axial flow fan unit disposed downstream of the second honeycomb; and a second honeycomb disposed downstream of the second axial flow fan unit,
- wherein a stator vane constituting the first honeycomb is configured to be warped against a rotation direction of the first axial flow fan unit, while a stator vane constituting the second honeycomb is configured to direct a trailing edge thereof in parallel to a direction of the air flow.
2. The axial flow fan according to claim 1, wherein the stator vane constituting the first honeycomb is warped in a “U” shape.
3. The axial flow fan according to claim 1, wherein the stator vane constituting the first honeycomb is divided into two parts.
4. An axial flow fan comprising: a first axial flow fan unit disposed on an upstream side with respect to an air flow; a first honeycomb disposed downstream of the first axial flow fan unit; a second axial flow fan unit disposed downstream of the first honeycomb; and a second honeycomb disposed downstream of the second axial flow fan unit, the second axial flow fan unit rotating in a different way from the first axial flow fan unit,
- wherein a stator vane constituting the first honeycomb is configured to direct a ventral side thereof against a rotation direction of the first axial flow fan unit, while a stator vane constituting the second honeycomb is configured to direct a trailing edge thereof in parallel to a direction of the air flow.
5. The axial flow fan according to claim 1, comprising an inline axial flow fan that uses the first and second axial flow fan units and the first and second honeycombs as a cooling device for server apparatuses.
6. The axial flow fan according to claim 2, comprising an inline axial flow fan that uses the first and second axial flow fan units and the first and second honeycombs as a cooling device for server apparatuses.
7. The axial flow fan according to claim 3, comprising an inline axial flow fan that uses the first and second axial flow fan units and the first and second honeycombs as a cooling device for server apparatuses.
8. The axial flow fan according to claim 4, comprising an inline axial flow fan that uses the first and second axial flow fan units and the first and second honeycombs as a cooling device for server apparatuses.
Type: Application
Filed: Jul 15, 2011
Publication Date: Jan 26, 2012
Inventors: Yusuke UCHIYAMA (Hitachinaka), Taku Iwase (Mito), Shigeyasu Tsubaki (Odawara)
Application Number: 13/183,479
International Classification: F04D 29/54 (20060101);