Modular HVAC Field Device Assembly Using Stackable Functional Blocks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and cost of manufacturing HVAC field devices are increased due to the need for a wide range of variants to cover various mechanical and electrical functions, with existing methods limiting the flexibility and scalability of adding new functions without compromising structural integrity or requiring extensive reconfiguration.
Innovation Solution
A method of manufacturing HVAC field devices by stacking base and add-on blocks with interchangeable connection interfaces of different types, allowing for unlimited combinations of blocks to be connected without physical space constraints, enabling flexible extension of mechanical and electrical functions while maintaining structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple variants of HVAC field devices are manufactured to cover various mechanical and electrical functions, then the adaptability and versatility of the system is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The HVAC field device is divided into a base block and separate add-on blocks, each with specific functions. The base block contains common components (housing, connection interfaces, electronic circuit), while add-on blocks provide specialized functions (sensors, actuators, communication modules). This segmentation allows manufacturing a limited number of base block variants rather than numerous complete device variants, reducing manufacturing complexity while maintaining functional versatility.
Solution Approach 2:
The base block is designed with universal connection interfaces (first-type and second-type mechanical interfaces, electrical interfaces) that can accommodate multiple types of add-on blocks. This universality allows a single base block design to support numerous functional configurations by simply changing the add-on blocks, thereby achieving high adaptability without increasing base block manufacturing complexity.
2Adaptability or versatility
If connection interfaces are added to accommodate more add-on blocks, then the adaptability is improved, but the structural integrity and rigidity deteriorate
Solution Approach 1:
Instead of adding connection interfaces in the planar direction (which would compromise structural integrity), the patent extends the connection capability in the vertical dimension by stacking add-on blocks. The base block has connection interfaces on its top and bottom surfaces, allowing add-on blocks to be connected in a vertical stack. This dimensional change enables multiple connection points without weakening the base block's structural rigidity in the horizontal plane.
3Adaptability or versatility
If the number of connection interfaces is increased, then the versatility is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The connection interfaces are segmented into distinct types (first-type mechanical interface, second-type mechanical interface, electrical interface) located on different surfaces of the base block. Each interface type has standardized dimensions and tolerances defined separately. This segmentation allows each interface to be manufactured and calibrated independently, reducing the overall precision requirements compared to having all interfaces on a single plane where cumulative alignment errors would occur.
4Ease of manufacture
If a modular block structure is implemented, then the ease of manufacture and assembly is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple interface types (mechanical connection interfaces and electrical connection interfaces) into integrated connection assemblies on the base block. The mechanical interfaces (protrusions and recesses) and electrical interfaces (contact points) are combined in such a way that a single add-on block connection simultaneously establishes both mechanical support and electrical connectivity. This merging reduces the number of separate components and assembly steps, thereby improving ease of manufacture and assembly while avoiding excessive system architecture complexity.
Data Source
AI summary
A method of manufacturing an HVAC field device (1) from a plurality of HVAC device blocks (10, 20.1-n), comprising the steps of providing a base HVAC device block (10); providing one or more add-on HVAC device block(s) (20.1-n) and stacking the base HVAC device block (10) and the one or more add-on HVAC device block(s) (10, 20.1-n), thereby mechanically connecting a connection interface (15A, 25A.1-n) of the first type to a connection interface (25B.1-n) of the second type of adjacent HVAC device blocks (10, 20.1-n).