Control box for heating or cooling installations
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Solution Overview
Problem
Existing controller boxes for heating or cooling systems face challenges with incorrect installation depth and tilting, leading to improper alignment and functionality, particularly when installed at angles, due to complex compensation mechanisms and additional components required for depth and plane parallelism adjustments.
Innovation Solution
A controller box design featuring a transition piece with angled inner and outer grooves allows for adjustable alignment of the thermostat cover relative to the wall installation box, enabling compensation for incorrect installation positions without additional adjustment means, ensuring the cover is flush and the thermostat axis is perpendicular to the wall, using a cross-plate clutch mechanism for radial and axial displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If extension elements are fitted between the valve and the thermostat for depth compensation, then the installation depth can be adjusted, but the installation becomes more complex and additional connecting elements are required
Solution Approach 1:
The transition piece is integrated directly into the thermostat housing, with the control panel nested within the transition piece structure. This eliminates the need for separate extension elements while providing depth adjustment capability through the movable control panel assembly.
Solution Approach 2:
The transition piece serves multiple functions: it provides depth compensation, allows angular adjustment for tilted installations, and houses the control panel mechanism. This multi-functionality replaces what would otherwise require multiple separate components.
2Manufacturing precision
If additional adjustment means are used to compensate for twisted or tilted wall installation box, then alignment can be restored, but the device complexity and number of components increases
Solution Approach 1:
The control panel is designed to be rotatable and laterally movable relative to the thermostat housing, allowing dynamic adjustment to compensate for twisted or tilted installations. This mobility eliminates the need for rigid adjustment mechanisms.
Solution Approach 2:
The transition piece features asymmetric groove patterns that enable selective adjustment in specific directions. The grooves are positioned to allow rotation and lateral movement that compensates for installation errors while maintaining proper alignment.
3Manufacturing precision
If the control panel position is changed axially or radially to compensate for installation errors, then alignment can be restored, but the setting range correspondence with setpoint marking is lost
Solution Approach 1:
The transition piece acts as an intermediary between the thermostat housing and the control panel. It provides reference grooves that maintain the correct angular relationship between the setpoint scale and the cover markings, even when the control panel is rotated or moved laterally to compensate for installation errors.
Solution Approach 2:
The asymmetric groove configuration in the transition piece ensures that the control panel can only be positioned in specific orientations that maintain proper alignment between the setpoint scale and cover markings, preventing loss of measurement precision during adjustment.
4Stability of the object's composition
If firmly mounted connecting elements are used between thermostat and valve, then structural stability is improved, but maintenance and disassembly become more difficult
Solution Approach 1:
The thermostat assembly is segmented into distinct components: the thermostat housing with valve connection, the transition piece, and the control panel. This segmentation allows the control panel to be easily removed for maintenance while keeping the firmly connected thermostat housing intact.
Data Source
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AI summary
The invention relates to a control box (1) with a wall-mounted box (2) open on one side and a valve (4) for heating or cooling systems installed therein, a thermostat (5) mounted on the valve (4), the thermostat comprising a superstructure (5a) consisting of a cover (3) and an operating element (55a), and a substructure (5b) consisting of a position sensor (13) with adjustment (14) and fastening means (16), wherein a cover (3) with operating element (55a) that can be attached to the wall-mounted box (2) forms the superstructure (5a) of the thermostat (5) and the position sensor (13) with adjustment (14) and fastening means (16) forms the substructure (5b), wherein both assemblies are displaceable relative to each other with respect to the three spatial axes (6) x, y and z of the wall-mounted box (2) and by joining the superstructure (5a) to the substructure (5b) both a a functioning thermostat (5) is formed,as well as the distance between the cover (3) and the wall mounting box (2) is adjustable to compensate for the installation depth.