Actuator-Control Unit Coupling for Tool-Free HVAC Valve Assembly
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Solution Overview
Problem
Existing motor-driven control devices for HVAC applications require significant space, precise alignment, special tools, and various fixing materials for assembly, making them cumbersome and difficult to use in limited spaces.
Innovation Solution
A control device with a self-centering, backlash-free interface using spur gearing (Hirth serration) between the control unit and actuator unit, where the actuator unit is mechanically coupled via a spring or lateral latching guides, allowing for easy assembly without tools or materials, and featuring a space-saving design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a square drive shaft with form-locking features is used to connect the actuator unit to the control unit, then the mechanical coupling is secure, but the assembly requires significant space, precise alignment, special tools, and various fixing materials
Solution Approach 1:
The patent replaces the traditional mechanical form-locking connection (square drive shaft with keyway) with a magnetic field-based coupling system. The actuator unit contains a permanent magnet that magnetically couples with a ferromagnetic material in the control unit, eliminating the need for complex mechanical alignment and fixing materials while maintaining secure mechanical coupling.
Solution Approach 2:
The patent changes the coupling mechanism from mechanical interlocking to magnetic attraction by introducing a permanent magnet with specific magnetic field strength. This parameter change allows the actuator to be securely coupled to the control unit through magnetic force alone, without requiring precise mechanical alignment or additional fixing materials.
2Stability of the object's composition
If a traditional actuator interface with alignment features is used, then the mechanical connection is stable, but the assembly requires precise alignment and special tools
Solution Approach 1:
The patent substitutes the mechanical alignment system (with alignment features and keyways) with a magnetic guidance system. The permanent magnet in the actuator unit automatically guides the actuator into correct alignment with the control unit through magnetic attraction, eliminating the need for precise manual alignment or special alignment tools while maintaining connection stability.
3Reliability
If multiple fixing materials and tools are used for assembly, then the connection is secure, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent replaces the multi-step mechanical assembly process (requiring screws, clips, or other fixing materials) with a single-step magnetic coupling process. The actuator unit is simply brought near the control unit, and the permanent magnet automatically secures the connection through magnetic attraction, dramatically reducing assembly time and eliminating the need for multiple fixing materials.
4Adaptability or versatility
If a hollow shaft actuator design is used, then the actuator can be mounted over a square spindle, but the space requirements increase and alignment becomes more difficult
Solution Approach 1:
The patent replaces the hollow shaft mounting design with a compact magnetic coupling system. The permanent magnet is integrated into the actuator's housing, allowing the actuator to be securely mounted to the control unit through magnetic attraction without requiring a hollow shaft structure. This reduces the overall space requirement while maintaining mounting flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easy, tool-free assembly in confined spaces, reducing installation complexity and space requirements, while maintaining operational stability and efficiency.
Implementation Method 1
The actuator unit (24) comprises a permanent magnet for magnetically coupling with a ferromagnetic material in the control unit (10)
Data Source
AI summary
A control device (10′) comprises a control unit (10′) with a control element for controlling a fluid flow and being rotatable about a first axis (13) between an open position and a closed position, and a separate motor-driven actuator unit (24), which is mechanically coupled to said control unit (10′) to rotate said control element about said first axis (13) in a controllable fashion, whereby said actuator unit (24) comprises a driving part (25) with a driving element (31) being rotatable about a second axis (26), to be mechanically coupled to said control element in a coupling position to rotate said control element about said first axis (13), and a control part (28) for driving said driving element (31) in a controllable fashion. Said driving element (31) is removably coupled to said control unit (10′) by means of a spur gearing (Hirth serration) (22, 29).