HVAC self-balancing components and controls
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Solution Overview
Problem
Current fluid flow measurement devices are expensive and have limited turndown ratios, making them ineffective for accurately measuring low fluid flows, leading to inefficient HVAC systems that consume excess energy and fail to provide comfort in buildings.
Innovation Solution
A multi-stage damper system with a variable orifice plate and actuator assembly that uses new correlations and equations to measure and control fluid flow, providing a high turndown ratio and accurate measurement of low fluid flows, and is integrated with a controller to regulate the flow based on pressure differentials and flow coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional flow measurement devices are used, then measurement capability is provided, but cost is high and turndown ratio is limited
Solution Approach 1:
The patent replaces conventional mechanical flow measurement devices with a differential pressure-based measurement system using a simple orifice plate and pressure sensors. This substitution eliminates complex mechanical moving parts while achieving accurate flow measurement through pressure differential detection, thereby reducing device cost and complexity while maintaining measurement precision.
Solution Approach 2:
The patent changes the measurement parameter from direct flow measurement to pressure differential measurement. By measuring the pressure drop across an orifice plate and using the differential pressure to calculate flow rate, the system achieves high turndown ratio and accurate low flow measurement without requiring complex mechanical devices, thus reducing cost while improving measurement capability.
2Measurement precision
If conventional flow measurement devices are used, then measurement capability is provided, but turndown ratio is limited
Solution Approach 1:
The patent measures pressure differential rather than flow directly, and uses the relationship between pressure drop and flow rate to calculate flow. This parameter change enables accurate measurement across a wide turndown ratio including very low flows, because differential pressure measurement is sensitive to small flow changes while maintaining accuracy at higher flows as well.
Solution Approach 2:
By replacing mechanical flow measurement mechanisms with differential pressure sensing, the system achieves a turndown ratio exceeding 100:1, allowing accurate measurement from very low to high flow rates with a single device configuration, thereby dramatically improving adaptability.
3Measurement precision
If HVAC systems operate at minimum measurable flow, then measurement accuracy is maintained, but energy consumption increases
Solution Approach 1:
The patent enables accurate measurement of very low flows by measuring differential pressure across an orifice plate. This allows HVAC systems to operate at lower flow rates while maintaining measurement accuracy, thereby reducing energy consumption without sacrificing the ability to measure and control flow precisely.
Solution Approach 2:
The differential pressure measurement system automatically provides accurate flow measurement across the entire operating range including low flows, enabling the HVAC system to self-regulate at optimal lower flow rates without requiring manual intervention or complex control mechanisms, thus reducing energy consumption while maintaining measurement precision.
4Measurement precision
If multiple device sizes are used to cover different flow ranges, then measurement accuracy is maintained, but product portfolio complexity increases
Solution Approach 1:
The patent creates a universal flow measurement device that can accurately measure flows across a wide range from very low to high rates using a single orifice plate size and differential pressure sensors. This multi-functional capability eliminates the need for multiple specialized device sizes, reducing product portfolio complexity while maintaining measurement accuracy across all flow ranges.
Solution Approach 2:
By measuring differential pressure rather than flow directly, the system achieves accurate measurement across all flow ranges with a single device configuration. This parameter change allows one device size to replace multiple device sizes, thereby reducing the number of device variants needed in the product portfolio while maintaining measurement precision.
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 precise measurement and control of fluid flows, reducing energy consumption and improving HVAC system efficiency by allowing for accurate regulation of fluid flow, even at low velocities, and streamlining product portfolios by reducing the number of device sizes needed.
Implementation Method 1
determine a pressure differential based on a first pressure obtained between the first and second sensors
Implementation Method 2
resolve contradictions observed between theory and practice dating back to the 1600's. Specifically, the correlations and related techniques disclosed herein, including the Flow and Discharge Coefficient Equations, can be used to address contradictions, inconsistencies, and/or limitations with respect to the vena contracta and other flow phenomena
Data Source
AI summary
An intelligent self-balancing downstream device that can obtain accurate flow measurements (e.g., flow of a liquid or gas through a tube) that can perform the self-balancing in situ and during operation to satisfy a set point and without k factors or the use of TAB balancers. The downstream device may be controllable by a single software system or network. The downstream device can operate in a single zone or be coupled with multiple like apparatuses. It has a high turndown ratio and self-balances, which can allow for continuous commissioning with built-in fault diagnostic systems. A fluid metering device can include control systems that operate progressively based on unique actuation mechanisms and/or algorithms that allow for precise flow control and feedback to self-balance and commission the system.