Integrated Ultrasonic Flow Controller for Compact HVAC Valve Assembly
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Solution Overview
Problem
Existing flow control valves in HVAC systems are complex to assemble, prone to errors due to separate wiring of measuring and control devices, and have imprecise mechanical flow measuring devices with limited ranges, which complicates continuous flow control.
Innovation Solution
An electronic flow controller with a one-piece valve body divided into a valve section and a flow measurement section, where the valve spindle and ultrasound access points are integrated, allowing for hardwired control loops and non-contact temperature measurement, reducing complexity and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate measuring device and control device are used with external wiring, then functional flexibility is improved, but device complexity and assembly error rate increase
Solution Approach 1:
The patent combines the measuring device, control device, and valve into a single integrated unit with a common housing. The measuring device and control device share the same housing space and are mechanically coupled to the valve, eliminating the need for separate external wiring and mounting structures. This integration directly reduces assembly complexity while maintaining all required functions.
2Device complexity
If mechanical flow measuring device is used, then device simplicity is improved, but measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces the traditional mechanical flow measuring device (such as impeller-based meters) with an ultrasonic measuring device. The ultrasonic device uses acoustic waves to measure flow velocity non-contactly, eliminating mechanical moving parts that are prone to wear and failure. This substitution significantly improves measurement precision and reliability while maintaining relatively simple device structure.
3Ease of manufacture
If integrated one-piece valve body is used, then assembly simplicity is improved, but manufacturing precision requirements increase
Solution Approach 1:
While the valve body is manufactured as a single integrated piece, the patent segments the internal functional zones into distinct sections: the valve control section, the ultrasonic measuring section, and the housing section. Each section has optimized internal geometry for its specific function, allowing precise control over fluid flow paths and ultrasonic wave propagation while maintaining the benefits of a one-piece construction that eliminates assembly errors.
4Volume of moving object
If ultrasonic measuring section is placed close to shut-off valve, then device compactness is improved, but measurement accuracy deteriorates due to turbulence
Solution Approach 1:
The patent positions the ultrasonic measuring section in a dedicated zone within the housing that is spatially separated from the valve's shut-off mechanism. The ultrasonic transducers are arranged to measure flow in a region where the flow path is stabilized and turbulence from the valve is minimized. This spatial arrangement in three-dimensional space allows compact overall device size while maintaining accurate flow measurements by avoiding turbulent zones.
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 provides a robust, accurate, and compact flow control system that simplifies assembly, enhances measurement precision, and reduces errors, enabling continuous and precise flow regulation without the need for external cabling.
Implementation Method 1
a measuring path for determining the flow rate by means of ultrasound is formed in the flow measuring section
Implementation Method 2
The second means can include an infrared sensor which is housed in the control unit, the part in thermal contact with the medium flowing through the control valve being the valve spindle of the valve protruding into the control unit
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electronic flow controller (30) for applications in the HVAC field, said electronic flow controller comprising a one-piece valve body (31) which is penetrated by a flowing medium. The valve body is divided into a valve portion (31a) and a flow measurement portion (31b) along the flow direction, wherein a valve element (32) is arranged in the valve section (31a) for the control of flow, wherein said valve element can be controlled from the outside via a valve spindle (33), and wherein a measurement path (36) is formed in the flow measurement portion (31b) for determining the flow rate by means of ultrasound. In order to achieve a compact arrangement and a greatly simplified assembly, accesses (34a, b) for coupling and/or outcoupling ultrasound into or from the measuring path (36) are formed on the valve body (31) in the region of the flow measurement portion (31b). A control unit (62) is placed on the valve body (31), which comprises first means (27, 28) for actuating the valve element (32), said first means being in engagement with the valve spindle (33), and second means (29a, b) for emitting and/or receiving ultrasound signals which are acoustically coupled to the accesses (34a, b) for coupling and/or outcoupling ultrasound.