Motorized Add-On Controller for Existing Manual Airflow Registers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing HVAC zoning systems face challenges in converting manually-adjustable diffusers to motorized dampers due to high costs and complexity, making them impractical for residential and light commercial applications, which limits energy efficiency and comfort.
Innovation Solution
A motorized add-on controller device that can be installed on existing ceiling/wall registers, allowing for motorized control of diffuser blades via a centralized controller, either digital or analog, with wired or wireless communication, enabling conversion of manually-adjustable diffusers to motorized dampers without requiring new infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional motorized dampers (inline, slot-in, or on-diffuser) are installed, then motorized control of air flow is achieved, but the cost and system complexity increase significantly
Solution Approach 1:
The patent merges the motorized control functionality with the existing manual diffuser by attaching a motor assembly to the diffuser body. This integration allows the existing diffuser structure to serve dual purposes: maintaining its original air distribution function while gaining motorized control capability through the attached motor and linkage mechanism.
Solution Approach 2:
The motorized diffuser assembly becomes a multi-functional device that combines the air distribution function of the original diffuser with the automated control function of the motor assembly. This universal design allows a single component to perform multiple functions, eliminating the need for separate motorized damper installations.
2Extent of automation
If traditional motorized dampers are installed, then motorized control of air flow is achieved, but the installation cost increases
Solution Approach 1:
The system utilizes the existing manual control linkage and blade mechanism of the original diffuser, requiring no replacement of these components. The motor assembly simply attaches to the existing structure and interfaces with the existing blade, allowing the original diffuser to 'serve itself' while gaining motorized capability.
Solution Approach 2:
Instead of discarding the existing manual diffuser, the patent recovers and retains its useful structure (body, blades, linkage) while adding only the necessary motorized components. This approach recovers the value of the existing installation and avoids the cost of replacing entire diffuser assemblies.
3Ease of manufacture
If manually-adjustable diffusers are used, then existing infrastructure is maintained, but automated control and energy efficiency are limited
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated motorized system. The motor assembly converts electrical control signals into mechanical motion that operates the existing diffuser blades, substituting manual mechanical control with automated electromechanical control while retaining the original mechanical blade structure.
Data Source
AI summary
Devices for retrofitting existing, manual airflow registers are described that convert a manual register with blades into a motorized damper. The devices include a support structure attached to the register and having a motor that moves a linking apparatus. The linking apparatus is coupled with a lever of the register that itself is coupled with the blades such that movement of the lever rotates the blades and therefore control the amount of airflow through the register. By moving the linking apparatus via a motor, the lever can also be moved allowing the manual airflow register to be automatically controlled with the need to replace the existing register.