SYSTEM FOR CURB CAP SIZE SELECTION IN AN EXHAUST FAN

A system for manufacturing a fan. The system includes a data collection device, a user input device, a data storage device, and an assembly subsystem. The data collection device has a display configured to present a first curb cap size and a second curb cap size. The user input device is in communication with the data collection device. The user input device is operable by a user to select either the first curb cap size or the second curb cap size. The data storage device is configured to store a selected curb cap size. The assembly subsystem is configured to receive the selected curb cap size from the data storage device and to manufacture an exhaust fan with a curb cap having the selected curb cap size.

FIELD OF THE DISCLOSURE

The present disclosure relates to a system for manufacturing an exhaust fan, and more particularly to system for manufacturing a fan with either a first curb cap size or a second curb cap size.

BACKGROUND OF THE INVENTION

Fans such as roof mounted exhaust fans remove air from internal spaces within buildings. Depending on the function of the space, time of day, occupancy, building codes, intake, and other factors, such spaces may require more or less air turnover. Roof mounted exhaust fans must be controlled and operated to meet these requirements. Conventional roof mounted exhaust fans are manufactured with curb caps having a limited number of predetermined and preselected sizes based on the size of a motor and/or an impeller of the exhaust fan.

SUMMARY OF THE INVENTION

The present disclosure provides, a system for manufacturing a fan. The system includes a data collection device, a user input device, a data storage device, and an assembly subsystem. The data collection device has a display configured to present a first curb cap size and a second curb cap size. The user input device is in communication with the data collection device. The user input device is operable by a user to select either the first curb cap size or the second curb cap size. The data storage device is configured to store a selected curb cap size. The assembly subsystem is configured to receive the selected curb cap size from the data storage device and to manufacture an exhaust fan with a curb cap having the selected curb cap size.

The present disclosure provides, a computer system configured to facilitate curb cap size selection for manufacturing a fan. The system is configured to present a user a first curb cap size and a second curb cap size via a display of the data collection device. The system is further configured to receive user input from a user input device coupled to the data collection device. The user input indicating one of the first curb cap size and the second curb cap size as a selected curb cap size. The system is further configured to store the user input in a data storage device to be referenced by an assembly subsystem in association with manufacturing of the fan.

The present disclosure provides, a fan assembly comprising a motor and an impeller rotatably coupled to the motor. The motor is configured to be coupled to any one curb cap selected from a group of three or more curb caps. Each of the curb caps of the three or more curb caps have a curb cap size equally spaced in an increment from the other curb caps.

Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.

DETAILED DESCRIPTION

FIGS.1and4illustrate a fan10configured to exhaust air from a room or space within a building. The illustrated fan10is an exhaust fan10which, when mounted to a roof R of the building, is generally directed with a longitudinal axis LA extending away from the roof R or normal thereto. In the illustrated embodiment, for example, the longitudinal axis LA extends perpendicularly away from the roof R. As will be described herein, the fan10is an exemplary exhaust fan10including features which may be present in other types of fans10.

The illustrated exhaust fan10includes a curb cap14configured for engagement with or affixing to a roof curb C on the roof R and to connect the exhaust fan10to ductwork D servicing the building. The ductwork D is in fluid communication with a room and is configured to pass fluid (e.g., air) from the room to the exhaust fan10. A windband18is coupled to the curb cab14and positioned within is a hoodband22. The hoodband22has a first axial end22aand an opposite second axial end22b.The first axial end22ais positioned closer to the curb cap14than the second axial end22b.A hood26is removably coupled to the second axial end22bto provide access to the interior of the hoodband22.

The curb cap14has a planar surface14a,a plurality of sidewalls14b,a plurality of fastener interfaces14cprovided on the plurality of sidewalls14b,an airflow opening14dprovided in the planar surface14a(FIG.4), and a Venturi portion14eadjacent the airflow opening14d.As best illustrated inFIG.4, the fastener interfaces14care configured to receive fasteners (not shown) to secure the exhaust fan10to the curb C.

The Venturi portion14eis a portion of the curb cap14which extends in a direction away from the planar surface14aoppositely from the sidewalls14b.The Venturi portion14evaries in cross-sectional size (e.g., diameter) in a direction generally parallel to the longitudinal axis LA. More specifically, the cross-sectional size (e.g., diameter) of the Venturi portion14eis largest adjacent the planar surface14aand the airflow opening14dand is smallest at a distal end thereof spaced from the planar surface14a.Fluid passing through the exhaust opening14dis passed through the Venturi portion14ewith the Venturi portion14ebeing configured to guide the exhaust airflow and to speed up the exhaust airflow as the exhaust airflow passes through the airflow opening14dand subsequently the Venturi portion14e.The downstream end (e.g., top end as viewed inFIG.4) of the Venturi portion14eis open to the interior of the windband18.

As illustrated inFIGS.3and4, the curb cap14may be sized (e.g., dimensioned) to interface any curb C. Dimension D1represents a first size of the curb cap14and is measured between opposing sidewalls14bthereof. The illustrated curb cap14is shaped as a square, with dimension D1therefore representing a side length thereof. Dimension D2represents a second size of the curb cap14, which is larger than the dimension D1. During manufacturing of the exhaust fan10, the curb cap14may be formed with dimension D1or dimension D2depending on the size and dimensions of the corresponding curb C. Any number and sizes of dimensions D1, D2(e.g., further dimensions D3, D4, D5[not illustrated], etc.) are possible.

In the illustrated embodiment, a cross-sectional shape of the curb cap14in a direction perpendicular to the longitudinal axis LA, as represented by the sidewalls14b,is square. The dimensions D1, D2(D3, D4. . .) represent differing lengths of each side of the curb cap (e.g., sidewalls14b) in separate embodiments of the curb cap14, and more particularly differing lengths of the same corresponding side of those separate curb cap embodiments. In other embodiments, however, the curb cap14may have a different (e.g., circular, rectangular, elliptical, etc.) cross-sectional shape. The dimensions D1, D2may then correlate to different dimensions of the corresponding cross-sectional shape (e.g., a diameter of the circle, a diagonal or length of the rectangle, etc.) such that D1, D2are more generally representative of a primary geometric parameter of that cross-sectional shape, and can so be defined. As will be described in detail below with regard toFIGS.6-9, the dimensions D1, D2of the curb cap14are selectable by a user (e.g., end user, customer, person ordering the exhaust fan10) during a curb cap size selection process216-224(FIG.9) prior to manufacturing of the exhaust fan10to correspond with the corresponding curb C.

The windband18has a reduced size (e.g., diameter) portion18acoupled to the curb cap14and an enlarged size (e.g., diameter) portion18bextending from the reduced size portion18a.The enlarged size portion18bincludes a vent hole18c,and the hoodband22includes a vent hole22c.A breather tube28provides fluid communication from the interior of the hoodband22to the exterior of the windband18. The breather tube28is located between the vent hole18cof the windband18and the vent hole22cof the hoodband22.

Referring toFIG.2, the exhaust fan10further includes a motor30and an impeller34rotatably coupled to the motor30and operably configured to generate exhaust fluid flow. In the illustrated embodiment, the impeller34is positioned to rotate about the longitudinal axis LA. The impeller34may be a squirrel cage type impeller with a plurality of blades34aeach having a chord extending in a direction away from the longitudinal axis LA. The blades34aof the illustrated impeller34are extruded along a height extending parallel to the longitudinal axis LA. In yet other embodiments, the impeller34may be of a different type or the impeller34may be differently oriented and rotate about a differing rotational axis (not shown) not necessarily concurrent or even parallel with the longitudinal axis LA of the exhaust fan10. In yet other embodiments, the blades34amay be otherwise oriented relative to the longitudinal axis LA. The illustrated motor30has a shaft30arotatably oriented coincident with the longitudinal axis LA. In other embodiments, the motor30may be differently oriented with respect to the longitudinal axis LA. In the illustrated embodiment, the shaft30ais coupled to the impeller34such that operation of the motor30and subsequent rotation of the shaft30acauses rotation of the impeller34. In other embodiments, the motor30may be otherwise coupled to the impeller34. For example, any type of drive system (e.g., transmission, gearbox, belt drive, etc.) may be coupled with and/or replace the shaft30afor transmitting force (e.g., torque) from the motor30to the impeller34. Various orientations, configurations, gear ratios, etc. of such a drive system are possible. As shown inFIGS.2-4, the hoodband22circumscribes the motor30and the impeller34. The windband18circumscribes the hoodband22and is radially spaced therefrom.

As illustrated inFIGS.3-5, the curb cap14further includes a first conduit opening14fand a second conduit opening14g(FIG.4) similar to the first conduit opening14f.The conduit openings14f,14gare formed as holes in the planar surface14aof the curb cap14. The first conduit opening14fand the second conduit opening14g(FIG.4) are distinct from one another and are also each distinct from the airflow opening14d.The exhaust fan10further includes a first conduit38and a second conduit42. The first conduit opening14fgenerally corresponds with the first conduit38, and the second conduit opening14ggenerally corresponds with the second conduit42. The conduit38,42in an exemplary embodiment is made of an electrically insulative material. In some embodiments, for example, the conduit38,42may be an electrically insulative plastic. Other types of conduit38,42are possible, however, to include metallic conduits or other materials, which still serve an insulating or isolative function. In other embodiments, one or more layers of the conduit38,42are electrically insulative. The conduit38,42may be fire rated (e.g., flame retardant) to inhibit fire generation.

The exhaust fan10further includes a support pan44, which supports the motor30thereon. The support pan44of the illustrated embodiment is generally oriented perpendicularly from the longitudinal axis LA. The support pan44is positioned within the hoodband22and is shaped as an annular disk. The support pan44is further coupled to the hoodband22and the windband18. More specifically, the first axial end22aof the hoodband22is removably coupled to and supported by the support pan44. In the illustrated embodiment, the support pan44is supported by the enlarged size (e.g., diameter) portion18bof the windband18. The support pan44includes a first pan conduit opening44aand a second pan conduit opening44b.In the illustrated embodiment (FIG.3), each of the pan conduit openings44a,44bare positioned at a periphery of the support pan44, and each of the pan conduit openings44a,44bare shaped as semi-circular cutouts of the support pan44. The support pan44further includes a plurality of airflow holes44c.The conduits38,42each extend at least between the pan conduit openings44a,44bof the support pan44and the conduit openings14f,14gof the curb cap14. The pan conduit openings44a,44bare each aligned with the conduit38,42. In the illustrated embodiment (FIG.4), the conduit38includes a first axial end38aadjacent the curb cap14. The conduit38further includes an opposite second axial end38blocated on an opposite side of the support pan44as the first axial end38a.In other words, the conduits38,42each pass entirely through the support pan44via the pan conduit openings44a,44b.

The conduits38,42are in fluid communication with both the ductwork D and an interior volume V1of the hoodband22. As shown inFIG.4, the volume V1of the hoodband22extends axially along the longitudinal axis LA between the hood26and the support pan44. The volume V1extends radially between the longitudinal axis LA to the inner surfaces (e.g., sidewall) of the hoodband22and the hood26. The first end38aof the conduit38is in fluid communication with (e.g., open to) the ductwork D via the curb cap14. The first axial end38aof the conduit38is positioned within the windband18radially between the windband18and the longitudinal axis LA. The second axial end38bof the conduit38is in fluid communication with the interior volume V1of the hoodband22. The second axial end38bof the conduit38is positioned within the hoodband22radially between the hoodband22and the longitudinal axis LA. In the illustrated embodiment, the second axial end38bof the conduit38is above the support pan44and within the interior volume V1of the hoodband22in an axial direction along the longitudinal axis LA (FIGS.3,4). The conduit38traverses the support pan44to be exposed to the interior of the hoodband22. In the illustrated embodiment ofFIG.4, the conduit38passes axially through the support pan44. In other embodiments, the conduit38may traverse any combination of the windband18(e.g., the enlarged size portion18b,the reduced size portion18a,or a transition region between the enlarged size portion18band the reduced size portion18a), the support pan44, and the hoodband22(e.g., a sidewall thereof). For example, in some embodiments (not shown), the conduit38may extend in an axial direction from the curb cap14to a height corresponding with the motor30(e.g., at the enlarged size portion18bof the windband18), and the conduit38may be connected to a connector or otherwise angled (e.g., by a right angle connector) to communicate with the interior volume V1of the hoodband22(e.g., via a sidewall of the hoodband22), with the conduit38or the connector extending in a radially inward direction toward the longitudinal axis LA.

The windband18defines a volume V2axially below (e.g., facing the curb cap14) a distal end of the enlarged size portion18band above the curb cap14. At an axial position corresponding with the position of the hoodband22, the volume V2is further defined in a radial direction between the outer surface of the hoodband22and the inner surface of the windband18. Axially below the hoodband22, the volume V2is defined in a radial direction between the inner surface of the windband18and the longitudinal axis LA. The conduits38,42are in communication with the ductwork D and the volume V1, and the conduits38,42generally pass through the volume V2.

FIG.3illustrates a top view of the exhaust fan10with the hood26removed to show the interior of the exhaust fan10. The conduit38extends along a conduit axis CA1, and the conduit42extends along a conduit axis CA2. The conduit38,42, is rigid and is shaped as a hollow linear extrusion (e.g., a hollow cylinder, an annular cylinder) in the illustrated embodiment. The conduit axes CA1, CA2in the illustrated embodiment are parallel with the longitudinal axis. In some embodiments, the conduit axes CA1, CA2, may extend in non-parallel directions relative to the longitudinal axis LA, for example, angled with respect to the longitudinal axis LA (e.g., by between 0 and 90 degrees, more specifically, between 1 and 10 degrees) and in any direction, i.e., clockwise, relative thereto. For example, the conduit axes CA1, CA2, or segmented conduit axes CA1, CA2themselves defined by segmented portions of the conduits38,42, (e.g., segmented linear portions of conduits38,42) may intersect, but be angled (e.g., any amount between 0 and 90 degrees, such as 30 degrees, 45 degrees, 60 degrees, etc.) towards or away from the longitudinal axis LA. In other embodiments still, the conduit axes CA1, CA2, or segmented conduit axes CA1, CA2themselves defined by segmented portions of differing conduits38,42(e.g., segmented linear portions of conduits38,42) may be angled in a tangential manner, a partially tangential manner, a helical or helical-type manner, or the like, with the conduits38,42extending generally circumferentially around the longitudinal axis LA as the conduits38,42pass between the curb cap14and into the hoodband22. As illustrated inFIG.4, the conduit38is slightly (e.g., approximately 2 degrees) angled relative to the longitudinal axis LA, and each of conduit38and conduit42may be differently directed or angled to the axis LA and to the other of conduit38,42. In other embodiments, the conduit38,42may be flexible, non-linearly shaped, or cylindrically shaped with one or more differing cross-sectional shapes other than annuluses.

The conduits38,42are in fluid communication with both the ductwork D and an interior volume V1of the hoodband22. As shown inFIG.4, the volume V1of the hoodband22extends axially along the longitudinal axis LA between the hood26and the support pan44. The volume V1extends radially between the longitudinal axis LA to the inner surfaces (e.g., sidewall) of the hoodband22and the hood26. The first end38aof the conduit38is in fluid communication with (e.g., open to) the ductwork D via the curb cap14. The first axial end38aof the conduit38is positioned within the windband18radially between the windband18and the longitudinal axis LA. The second axial end38bof the conduit38is in fluid communication with the interior volume V1of the hoodband22. The second axial end38bof the conduit38is positioned within the hoodband22radially between the hoodband22and the longitudinal axis LA. In the illustrated embodiment, the second axial end38bof the conduit38is above the support pan44and within the interior volume V1of the hoodband22in an axial direction along the longitudinal axis LA (FIGS.3,4). The conduit38traverses the support pan44to be exposed to the interior of the hoodband22. In the illustrated embodiment ofFIG.4, the conduit38passes axially through the support pan44. In other embodiments, the conduit38may traverse any combination of the windband18(e.g., the enlarged size portion18b,the reduced size portion18a,or a transition region between the enlarged size portion18band the reduced size portion18a), the support pan44, and the hoodband22(e.g., a sidewall thereof). For example, in some embodiments (not shown), the conduit38may extend in an axial direction from the curb cap14to a height corresponding with the motor30(e.g., at the enlarged size portion18bof the windband18), and the conduit38may be connected to a connector or otherwise angled (e.g., by a right angle connector) to communicate with the interior volume V1of the hoodband22(e.g., via a sidewall of the hoodband22), with the conduit38or the connector extending in a radially inward direction toward the longitudinal axis LA.

The windband18defines a volume V2axially below (e.g., facing the curb cap14) a distal end of the enlarged size portion18band above the curb cap14. At an axial position corresponding with the position of the hoodband22, the volume V2is further defined in a radial direction between the outer surface of the hoodband22and the inner surface of the windband18. Axially below the hoodband22, the volume V2is defined in a radial direction between the inner surface of the windband18and the longitudinal axis LA. The conduits38,42are in communication with the ductwork D and the volume V1, and the conduits38,42generally pass through the volume V2.

As shown inFIGS.4and5, the exhaust fan10includes a connector46positioned adjacent the first axial end38abetween the curb cap14and the conduit38. The connector46couples the conduit38to the curb cap14. The connector46includes a lip50which is larger in size than the first conduit opening14f.The lip50projects outwardly from the remainder of the connector46. The connector46is press-fit into the first conduit opening14f,and the conduit38is press-fit onto the connector46. The lip50has a curb cap facing-side50a(i.e., a first side) which presses against the planar surface14aof the curb cap14once the connector46is secured to the curb cap14. The lip50further includes a conduit facing-side50b,which the first axial end38aof the conduit38presses against once the conduit38is secured to the connector46. As would be appreciated by one of ordinary skill in the art, inner and outer diameters of the first conduit opening14f,connector46, lip50, and conduit38are selected to permit press-fit coupling between the curb cap14, the connector46, and the conduit38. Another similar connector46may secure the conduit42to the second conduit opening14g.With reference toFIGS.3and4, the second axial end38bof the conduit38is passed through the first pan conduit opening44a.The first pan conduit opening44aand the conduit38are dimensioned such that the support pan44inhibits deflection of the conduit38in directions non-parallel with the longitudinal axis LA. As the illustrated connectors46are configured to interface with both the conduit openings14f,14gand the conduits38,42in press-fit relationships, any sequence of connection between the connectors46, the conduits38,42, and the curb cap14is possible.

Wires W1, W2, which provide power current and/or control signals to the motor30are passed through the conduits38,42from the curb cap14to the interior of the hoodband22for connection with the motor30. The first wire W1passes through the first conduit opening14f,the first conduit38, and the first pan conduit opening44a.The second wire W2passes through the second conduit opening14g,the second conduit42, and the second pan conduit opening44b.

In operation, exhaust generated by the impeller34passes from the room or space within the building, through the ductwork D and the impeller34, and to the surroundings of the exhaust fan10external to the roof R. The exhaust airflow generated by the impeller34passes along a first flow path FP1and a second flow path FP2(FIG.4). The first flow path FP1passes exhaust airflow through, in sequence, the airflow opening14d,the impeller34, and a space (e.g., the volume V1) between the windband18and the hoodband22. The second flow path FP2passes exhaust airflow through, in sequence, the airflow opening14d(and optionally the conduit38,42), the airflow holes44cof the support pan44, the interior of the hoodband22, and the breather tube28before being exhausted to the surroundings of the exhaust fan10. The second flow path FP2may provide cooling airflow for the motor30. When coupled to the hoodband22, the hood26redirects the second flow path FP2towards the breather tube28.

FIGS.6-8illustrate a system100for conducting the curb cap size selection process216-224and facilitating the subsequent manufacturing of the above-described exhaust fan10. The system100provides means for a user to select the above-described dimension D1(e.g., one of D1-D4) of the curb cap14to fit differently sized curbs C. As illustrated inFIG.6, the system100includes a data collection device104having a display108, a user input device124, a data storage device128, and an assembly subsystem132. The components of the system100are in communication (e.g., mechanical, electrical communication) with one another in order to function as described herein. In some embodiments, the data collection device104may be operated by an end user of the exhaust fan10(e.g., a customer, end user, such as a facilities manager of a building) or a designer or other construction personnel, contractor, etc., in the curb cap size selection process216-224before the assembly subsystem132manufactures the exhaust fan10the curb cap14having the desired dimension D1(e.g., one of D1-D4).

The data collection device104, display108, user-input device124, and storage device128may be any type of device or any type of interconnected devices (e.g., a computer, mouse, cell-phone, etc.). In some embodiments, the data collection device104may be a computer connected to a monitor which functions as the display108and a mouse which functions as the user input device124. In other embodiments, the data collection device104may be a tablet or cellular telephone device with an integrated touch screen which functions as the display108and the user input device124. The data storage device128may be either integrated with the data collection device104(e.g., on-board computer or cell-phone storage) or an off-board (e.g., remote) storage device (e.g., a remote database, a remote server). The data storage device128is configured to store data in relation with the selected curb cap size (corresponding with any one of dimensions D1-D4) for future reference. The data storage device128is also configured to store data in relation to other features of the exhaust fan10. For example, the data storage device128may store data relating to specifications (e.g., size, shape, capacity, orientation within the exhaust fan10, etc.) of the motor30or impeller34. Other arrangements or types of devices are possible.

At least one of the data collection device104, user-input device124, storage device128, or the assembly subsystem132includes a processor P. The processor P is configured to facilitate intercommunication of the components of the system100for operation of the curb cap selection process216-224. In the illustrated embodiment ofFIG.6, the processor P is an integrated component of the data collection device104. However, the processor P may be a remote device, or be present on or within either or both of the storage device128and the assembly subsystem132.

The display108of the data collection device104is configured to present a user with a first curb cap size option (corresponding with dimension D1) and a second curb cap size option (corresponding with dimension D2). As shown inFIGS.6-8, the display108can provide visual display of a window116to a user. The window116includes a curb size dropdown menu120. Optionally, the window116or another window116may present other options relating to the construction of the exhaust fan10to the user. For example, the window116may present options relating to size, performance, operating speed, volumetric flow rates, etc., in relation with the motor30and/or the impeller34.

FIG.7illustrates an exemplary view of the display108. The display108shows a graphical user interface including the window116to the user. The window116includes a top ribbon134configured to indicate to the user which order (e.g., order number) the window116currently relates to. The window116further includes a model field135configured to indicate to the user a model number of the exhaust fan10. The first toolbar136includes a plurality of tabs. Each of the tabs of the first toolbar136may relate to different user input data for manufacturing the exhaust fan10. Similarly, the illustrated window116includes a second toolbar140including a second plurality of tabs. In the illustrated embodiment, a “configuration” tab of the first toolbar136is selected, and a “construction” tab of the second toolbar140is selected. When the “configuration” and “construction” tabs are selected, the window116presents at least a fan construction module144. In other embodiments, any combination of tabs, and optionally no tabs, may be selected to present the fan construction module144and the curb cap size dropdown menu120.

The fan construction module144includes at least one fan construction option148and a fan construction indicator152. The fan construction indicator152indicates to the user a corresponding element of the exhaust fan10to be adjusted by adjusting the fan construction option148. In the illustrated embodiment, the fan construction indicator152states “Curb Cap Size (in.)” to indicate to the user that the fan construction option148relates to selecting the desired dimension D1or dimension D2of the curb cap14, as well as the corresponding units (inches). The curb size dropdown menu120is positioned adjacent to the fan construction indicator152. In the illustrated embodiment, the curb size dropdown menu120is automatically populated with a size (e.g., the dimension D1). This automatically populated dimension (e.g., D1) may correlate with a specified size of the curb cap in correspondence with the selected motor30(e.g., any characteristic such as RPM, power, etc. of the motor30) and impeller34(e.g., any characteristic such as blade shape, number of blades, etc. of the impeller34) (e.g., the model number in the model field135). In the illustrated example, the data relating to the motor30and impeller34(e.g., a fan subassembly) has been previously input into the data collection device104, and the data collection device104(e.g., a controller thereof) has determined that a suggested curb cap size (e.g., dimension D1) for the motor30and impeller34is 30 inches, and the suggested curb cap size (e.g., “30” [inches]) is displayed in the curb size dropdown menu120.

The curb size dropdown menu120is further illustrated in an engaged (e.g., “selected”) status inFIG.8. In the engaged status, the display108presents a curb size dropdown field156. The curb size dropdown field156displays a plurality of curb cap size options160A-160C. In the illustrated embodiment, the curb cap size option160A represents the suggested curb cap size (e.g., dimension D1) of 30 inches. The curb cap size options160B-160C represent oversized curb cap sizes (e.g., generally corresponding with dimension D2) of 31 inches, and 32 inches (e.g., dimension D3), respectively. The curb size dropdown field156may display any number of curb cap size options160A-160C. For example, the curb size dropdown field156may display more than four curb cap size options160A-160C.

While the curb cap size options160A-160C present curb cap sizes between 30 and 32 inches, curb cap size options160A-160C may be presented in variously spaced increments. The exemplary cap size options160A-160C are provided in equally spaced one-inch increments from one another. In other examples, the exemplary cap size options160A-160C may be provided in any equally spaced increment (e.g., quarter-inch, half-inch, three-quarter inch, two-inch, greater than two-inch etc. increment) from one another (e.g., 30, 30.5, 31, 31.5 inches) (e.g., 30, 30.25, 30.5, 30.75 inches). In other examples, different and/or unequal spacing between curb cap size options160A-160C is possible (e.g., 30, 30.5, 32, 35inches). In some embodiments, curb cap size options160A-160C may be provided as whole number integers between 10 inches and 100 inches. In other embodiments, curb cap size options160A-160C may be provided between 30 inches and 64 inches. In still other embodiments, a smallest curb cap size option160A of a group of four or more curb cap options (e.g., 30, 31, 32, 34 inches, each being whole number integers) has a curb cap size equivalent to a suggested curb cap size (e.g., dimension D1) for the motor30and the impeller34, and the remaining of the four or more curb caps14have oversized curb cap sizes (e.g., dimensions D2) greater than the suggested curb cap size (e.g., dimension D1). In other instances, more or less than four curb cap sizes (e.g., two curb cap sizes, three curb cap sizes, four curb cap sizes, more than four curb cap sizes dimensions D1) may be capable of being presented and selected. In some alternative embodiments, other curb cap size options (not shown) having undersized cap sizes (e.g., dimensions D5[not shown], 29 inches) lesser than the suggested curb cap size (e.g., dimension D1) may be presented and capable of being selected.

The assembly subsystem132is configured to receive data from the data storage device128indicative of the selected curb cap size (e.g., corresponding with any one of the dimensions D1-D4), and the assembly subsystem132is further configured to manufacture the exhaust fan10with the selected curb cap size (e.g., with dimension D1). In some embodiments, the assembly subsystem132may be operated by human assemblers. In some embodiments, the assembly subsystem132may be operated at least in part by automated (e.g., robotic) assembling machines (not shown).

FIG.9illustrates a method200including the curb cap size selection process216-224as well as manufacturing and installation of the exhaust fan10. The method200is a computer-implemented method conducted at least in part by the aforementioned processor P.

At step204, user input data regarding airflow requirements of the exhaust fan10is gathered. At step208, a motor30and impeller34are selected to meet the airflow requirements of the exhaust fan10. At step212, data indicative of the selected motor30(e.g., a motor characteristic, RPM, power, etc.) and impeller34(e.g., an impeller characteristic, blade shape, number of blades, etc.) is stored in the data storage device128. The dashed lines for steps204,208,212represent optional steps not required for the curb size selection portion of the method200.

Steps216-224generally represent the curb size selection process216-224of the method200. At step216, (in the illustrated embodiment, upon interaction with the dropdown menu120) a first curb cap size option160A and a second curb cap size option160B are presented to the user via the display108. The first curb cap size option160A and second curb cap size option160B are displayed upon selection (e.g., engagement) of the display dropdown menu120by the user. If desired to modify the dimension D1(e.g., any one of D1-D4) of the curb cap14from suggested curb cap size (e.g., based on the motor30and impeller34, dimension D1, 30 inches inFIG.7) to a different curb cap size (e.g., to dimension D2,31inches), the user input device124is operated to select the display dropdown menu120. Upon selection of the display dropdown menu120, the display108expands the curb cap size dropdown menu120to show the curb size dropdown field156and any number of curb cap size options160A-160C.

At step220, the data collection device104gathers further user input data from the user via the user input device124, the data being indicative of a selected curb cap size (e.g., dimension D2, 31 inches). For example, the user may select (e.g., by clicking or tapping on, interacting with) a desired curb cap size (e.g., dimension D2, 31 inches) for the exhaust fan10different than the suggested curb cap size (e.g., dimension D1, 30 inches). During step220, the user input device124is monitored by the processor P to determine which of curb cap size options160A-160C is selected by the user via the user input device124(e.g., upon action of the user to select the first curb cap size or the second curb cap size).

At step224, the selected curb cap size is communicated from the user input device104to the data storage device128(e.g., via the processor P) for storage in the data storage device128. The curb size selection process216-224is complete upon storing the data relating to the selected curb cap size in the data storage device128.

Steps228-232relate to subsequent manufacturing and installation of the exhaust fan10after the curb size selection process216-224. At step228, the assembly subsystem132references the data storage device128and the selected curb cap size (e.g., dimension D2). At step232, the assembly subsystem132manufactures the exhaust fan10with the selected curb cap size (e.g., dimension D2). At step236, the exhaust fan10is installed on the roof curb C.

The curb cap size selection process216-224described above and illustrated in the figures relate to an exhaust fan10which may be referred to as a roof-mounted upblast exhaust fan10mounted to the curb C of the roof R. The above-described features of the exhaust fan10and the curb cap size selection process216-224may be applied equally to other types of fans10other than roof-mounted upblast exhaust fans10. For example, the aforementioned fan10may be in the form of a sidewall fan mounted on a sidewall or a downblast fan. Either type of fan10(e.g., roof-mounted, sidewall-mounted, underhang or downwardly mounted) may be configured as either an exhaust fan (which exhausts air from the ducts D to the surroundings of the fan10) or a supply fan (which supplies outside air into the associated ducts D). In any case, the features described above with regard to the conduit38,42and curb cap size selection process216,224, of the aforementioned exhaust fan10may be present in various forms with any type or combination of supply, exhaust, roof-mounted, sidewall-mounted, downward-mounted or downblast, or other such fan.

The embodiment(s) described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present disclosure. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of one or more independent aspects as described.