Volume flow regulator
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Solution Overview
Problem
Existing volume flow controllers are complex and costly due to numerous individual components, leading to susceptibility to faults and high manufacturing expenses, especially in metal-based systems, which often result in noisy operation and reduced functionality over time.
Innovation Solution
A simplified volume flow controller design utilizing a metal sheet pipe section, confuser, diffuser, and control flap, with components connected via beads and a friction connection, eliminating the need for complex manufacturing processes and adhesives, ensuring accurate measurement and regulation of air flow without additional noise or disruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes (deep-drawing, forging, welding, sintering) are used for metal volume flow controllers, then manufacturing precision and structural strength are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple manufacturing operations into a single stamping process. The control flap, axis, and connection elements are integrated into one stamped metal component, eliminating the need for separate deep-drawing, forging, and welding operations. This merging of operations reduces manufacturing complexity while maintaining structural precision through the inherent accuracy of stamping processes.
Solution Approach 2:
The stamped metal control flap serves multiple functions simultaneously: it acts as the flow control element, provides the axis rotation mechanism, includes integrated connection features for mounting, and incorporates sealing surfaces. This multi-functionality eliminates the need for separate components that would traditionally require multiple manufacturing processes, thereby reducing overall device complexity.
2Adaptability or versatility
If multiple individual components are used in volume flow controllers, then functional versatility is improved, but reliability deteriorates due to increased susceptibility to faults and malfunctions
Solution Approach 1:
The patent merges multiple functional components into a single stamped metal control flap assembly. The control flap itself, its mounting features, the rotation axis, and connection elements are integrated into one robust component. This reduction in component count directly improves reliability by eliminating potential failure points at joints and interfaces, while the integrated design maintains all necessary functional versatility for flow control applications.
3Measurement precision
If traditional metal volume flow controllers with multiple components are used, then measurement accuracy is maintained, but manufacturing cost increases due to complex production processes
Solution Approach 1:
The patent combines the manufacturing of the control flap, axis, and mounting features into a single stamping operation. This integrated approach maintains the precise geometric relationships necessary for accurate flow measurement while dramatically simplifying the manufacturing process. The stamped component provides consistent dimensional accuracy without requiring multiple sequential manufacturing steps.
Solution Approach 2:
The stamped metal control flap assembly can be produced as a cost-effective, standardized component that replaces expensive custom-fabricated parts. While individual stamped components may have limited service life compared to precision-forged parts, the low manufacturing cost and ease of replacement make this an economically superior solution that maintains measurement accuracy throughout the service life.
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 significantly reduces manufacturing costs and maintains measurement accuracy at low pressures and air speeds, providing a durable, efficient, and cost-effective solution with fewer components, minimizing the risk of malfunctions and noise generation.
Implementation Method 1
The narrowing and subsequent expansion of the cross section of the nozzle takes place via a confuser in the inlet and a diffuser in the outlet in such a way that no boundary layer separation of the air flow occurs, which would falsify the measurements.
Implementation Method 2
Measuring the static pressure in front of the nozzle and in the nozzle neck results in a pressure difference through which the volume flow is calculated (see Bernoulli equation).
Implementation Method 3
components connected via beads and a friction connection
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
Volume flow controller made of metal for measuring and controlling the volume flow in air conditioning and ventilation systems, consisting of a tube section (1) with an air inlet (27) and an air outlet (28), with a confuser (6) and a diffuser (7 ) are arranged, the confusor (6) and the diffuser (7) having a non-positive connection (20) in a common nozzle neck (19), the confusor (6) on the other side of the nozzle neck (19) being attached to a first bead (21) of the tube section (1) has a first positive/non-positive connection (22) and the diffuser (7) has a second positive/non-positive connection (24) on the other side of the nozzle neck (19) on a second bead (23) of the tube section (1).