ASSEMBLY, BLOWER AND ASSOCIATED METHOD

Abstract

According to an embodiment of the invention, an electric machine is provided. The machine includes a support structure, a stator secured to the support structure, and a rotor rotatably secured to the support structure. The machine also includes a circuit board positioned at least partially within the support structure. The circuit board is adapted for controlling an electromagnetic field produced by the stator. The machine also includes a potting material in contact with a first surface of the circuit board and a barrier for at least partially containing the potting material.

Description

BACKGROUND OF THE INVENTION

The embodiments described herein relate generally to fluid moving devices, and more specifically, to a blower for moving air.

Blowers consist of a moving element(s), for example a fan blade(s) that moves within a confined space, for example a furnace or within an air duct. The size, attitude and shape of the blade(s), as well as, the size and shape of the confined space effects the volume of air that a blower provides. The size, attitude and shape of the blade(s), as well as, the size and shape of the confined space also effects the efficiency of the blower.

For a single speed blower motor the efficiency of the blower may be optimized by providing an optimized fixed position of the blades on the fan and an optimized fixed size and shape of the confined space. For multiple speed motors, for example for modern electronically commutated motors (ECM), a single configuration of fan blades or of the confined shape will not be optimum of all of the available speeds and air flows that the blower with the multiple speed motor may provide.

Other fluid moving devices move a liquid, for example water. Such liquid moving devices include pool and spa pumps that include rotating members in the form of impellers that moves within a confined space, for example within the housing of the pump. The size, attitude and shape of the impeller(s), as well as, the size and shape of the confined space of the pump housing effects the volume of water that a pump provides. The size, attitude and shape of the impeller(s), as well as, the size and shape of the confined space also effects the efficiency of the pump.

Fluid moving devices, including for example air moving devices, such as blowers, and liquid moving devices, such as pumps, typically provide fluid flow. Fluid flow is volumetric and includes fluctuations due to density, velocity and pressure.

For a single speed pump motor the efficiency of the pump may be optimized by providing an optimized fixed position of the impellers on the pump and an optimized fixed size and shape of the pump housing. For multiple speed motors, for example for modem electronically commutated motors (ECM), a single configuration of pump impellers or of the pump housing will not be optimum of all of the available speeds and fluid flows that the pump with the multiple speed motor may provide.

The present invention is directed to alleviate at least some of these problems with the prior art.

BRIEF DESCRIPTION OF THE INVENTION

According to an embodiment of the invention, an assembly having a moveable surface adapted to advance the flow of fluid in a fluid flow device is provided. The assembly includes a body and a member moveably secured to the body. The assembly also includes a motion device secured to the body and adapted to move the member relative to the body.

According to an aspect of the invention, the body includes a blower housing and the member includes a wall of the blower housing.

According to another aspect of the invention, the assembly also includes a controller for controlling the motion device.

According to yet another aspect of the invention, the assembly is configured such that the controller is adapted to move the member relative to the body in response to changing operating conditions including at least one of air flow, temperature, pressure and turbulence.

According to another aspect of the invention, the assembly is configured such that the body includes a blower wheel and such that the member includes a blade.

According to another aspect of the invention, the assembly is configured such that the body includes a fan body and such that the member includes a blade.

According to another aspect of the invention, the assembly is configured such that the motion device includes a servo motor.

According to another aspect of the invention, the assembly is configured such that the motion device includes a shape memory alloy wire.

According to another aspect of the invention, the assembly also includes a second member moveably secured to the body and spaced from the first member. The first member and the second member are connected to an intermediate member.

According to another aspect of the invention, the assembly is configured such that the body includes a housing and such that the member includes a dampener vane.

According to another embodiment of the invention, a blower having a moveable member adapted to influence the flow of air through the blower is provided. The blower includes a body and a member moveably secured to the body. The blower also includes a motion device secured to the body and adapted to move the member relative to the body

According to an aspect of the invention, the blower is configured such that the body includes a blower housing and such that the member includes a wall of the blower housing.

According to another aspect of the invention, the blower is configured such that the wall is made of a flexible material.

According to yet another aspect of the invention, the blower is configured such that the body includes a blower wheel and such that the member includes a vane.

According to another aspect of the invention, the blower is configured such that the motion device includes a servo motor.

According to another aspect of the invention, the blower is configured such that the motion device includes a shape memory alloy wire.

According to another aspect of the invention, the blower further includes a controller for controlling the motion device.

According to another aspect of the invention, the blower is configured such that the controller is adapted to move the member relative to the body in response to changing operating conditions including at least one of air flow, temperature, pressure and turbulence.

According to another aspect of the invention, the blower is configured such that the body includes a blower wheel and such that the member includes a blade. The blower further includes a second vane moveably secured to the blower wheel and spaced from the first vane. The first vane and the second vane are connected to an intermediate member. The intermediate member is connected to the motion device.

According to yet another embodiment of the invention, a method for altering the flow of air in a blower is provided. The method includes the steps of providing a body, providing a member, moveably securing the member to the body, providing a motion device and moving the member relative to the body with the motion device.

According to another aspect of the invention, the method further includes the steps of providing a controller for controlling the motion device, measuring at least one of temperature, air flow, turbulence and pressure, and moving the member relative to the body with the motion device in response to changes in at least one of temperature, air flow, turbulence and pressure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view, partially in cross section, of an embodiment of the present invention in the form of a configurable blower having a blower housing with a moveable wall;

FIG. 2 is a perspective view of the blower of FIG. 1;

FIG. 3 is a plan view, partially in cross section, of an embodiment of the present invention in the form of a configurable blower with a servo and associated linkage;

FIG. 4 is a plan view of a servo for use in the blower of FIG. 3;

FIG. 5 is a plan view, partially in cross section, of an embodiment of the present invention in the form of a configurable blower with a generator for generating energy to control the moveable components of the configurable blower;

FIG. 6 is a plan view, partially in cross section, of an embodiment of the present invention in the form of a flow chamber having a moveable wall in a first position, moveable by a shape memory alloy wire;

FIG. 7 is a plan view, partially in cross section, of an embodiment of the present invention in the form of a squirrel cage fan with a moveable blade;

FIG. 8 is a perspective view of an embodiment of the present invention in the form of a squirrel cage fan with a moveable vanes in the outlet duct;

FIG. 8A is an partial enlarged view of the fan of FIG. 8 showing the moveable blade in greater detail;

FIG. 8B is an partial enlarged view of the fan of FIG. 8 showing the first vane being pivoted by an actuator wire;

FIG. 9 is a plan view of an embodiment of the present invention in the form of a fan having a moveable blade;

FIG. 9A is an partial enlarged view of the fan of FIG. 9 showing the moveable blade in greater detail;

FIG. 10 is a perspective view of the fan of FIG. 9;

FIG. 11 is a plan view of a blade of the fan of FIG. 9;

FIG. 12 is another plan view of a blade of the fan of FIG. 9;

FIG. 13 is a graph of attack angle of a blade versus lift;

FIG. 14 is a perspective view of the fan of FIG. 9 mounted in an outdoor HVAC unit;

FIG. 15 is a plan view, partially in cross section, of an embodiment of the present invention in the form of a moveable fan blade and a moveable damper vane positioned in the outdoor HVAC unit of FIG. 14;

FIG. 15A is a partial enlarged view of a fan blade of the outdoor HVAC unit of FIGS. 14-15 utilizing an actuation wire;

FIG. 15B is a partial enlarged view of a moveable damper vane of the outdoor HVAC unit of FIGS. 14-15 utilizing an actuation wire; and

FIG. 16 is a flow chart of another embodiment of the present invention in the form of a method for providing an electric machine.

DETAILED DESCRIPTION OF THE INVENTION

Fluid moving devices typically include moving, typically rotating, members or elements moved by a power source, typically an electric motor. The fluid may be a liquid, for example water, or a gas, for example air.

Liquid moving devices include pool and spa pumps that include rotating elements in the form of impellers that moves within a confined space, for example within the housing of the pump. The size, attitude and shape of the impeller(s), as well as the size and shape of the confined space of the pump housing, effects the volume of water that a pump provides. The size, attitude and shape of the impeller(s), as well as, the size and shape of the confined space also effect the efficiency of the pump.

For a single speed pump motor the efficiency of the pump may be optimized by providing an optimized fixed position of the impellers on the pump and an optimized fixed size and shape of the pump housing. For multiple speed motors, for example for modem electronically commutated motors (ECM), a single configuration of pump impellers or of the pump housing will not be optimum of all of the available speeds and fluid flows that the pump with the multiple speed motor may provide.

Gas moving devices are in many forms and are used to move a variety of gases. One such gas is air and the air is typically moved by elements or members that are located in blowers or fans.

Blowers and fans consist of a moving element(s), for example a blower wheel element(s) or a fan blade(s), respectively, that moves within a confined space, for example a furnace or within an air duct. The size, attitude and shape of the element(s) or blade(s), as well as, the size and shape of the confined space effect the volume of air that a blower provides. The size, attitude and shape of the element(s) or blade(s), as well as, the size and shape of the confined space also effect the efficiency of the blower.

For a single speed blower motor the efficiency of the blower may be optimized by providing an optimized fixed position of the elements or blades on the Wheel or fan and an optimized fixed size and shape of the confined space. For multiple speed motors, for example for modern electronically commutated motors (ECM), a single configuration of elements or blades or of the confined shape will not be optimum of all of the available speeds and air flows that the fan or blower with the multiple speed motor may provide.

According to an embodiment of the present invention and referring to FIGS. 1 and 2, an assembly 10 having a moveable surface 12 adapted to advance the flow of fluid 14 in a fluid flow device 16 is provided. The assembly 10 includes a body 18 and a member 20 moveably secured to the body 18. The assembly 10 also includes a motion device 22 secured to the body 18 and adapted to move the member 20 relative to the body 18.

The fluid flow device 16 may he any device that provides for the flow of a fluid. For example the fluid flow device 16 may be a liquid pump or, as shown in the embodiment of FIGS. 1 and 2, an air flow device. As an air flow device, the device 16 may be in the form of a fan or, as shown, as blower 16. The blower 16 includes the assembly 10.

The body 18 may have any suitable size and shape and may be designed to accommodate the blower 16. For a cylindrical squirrel cage or generally cylindrically shaped blower 16, the body 18 typically is generally cylindrical and defines an inlet 24 positional centrally along rotational axis 26 of the blower 16. The body 18 typically further defines an outlet 28 extending outwardly from periphery 30 of the body, typically in a spirally extending fashion. The blower 16 serves to advance air flow 32 in the direction of arrows 34 from inlet 24 to outlet 28. The body 18 may be made of any suitable materials and may, for example, be made of a polymer, a metal or a composite. The body 18 may be cast, molded fabricated or welded, or a combination thereof.

The member 20 may be any member capable of modifying the air flow 32. The member 20 may have any suitable size and shape. The member 20 may be made of any suitable materials and may, for example, be made of a polymer, a metal or a composite. The member 20 may be cast, molded fabricated or welded, or a combination thereof.

The motion device 22 may be any device capable of moving the member 20. The motion device 20 may have any suitable size and shape. The motion device 20 may be made of any suitable materials and may, for example, be made of a polymer, a metal or a composite. The motion device 20 may be cast, molded fabricated or welded, or a combination thereof.

As shown in the embodiment of FIGS. 1 and 2, the body 18 includes a blower housing 36 and the member 20 includes a wall 38 of the blower housing 24. The wall 38 may be integral with the housing 36 or may be a separate component. The wall 38 may be connected to the housing 36 by, for example, a hinge 40 which may be a living hinge.

Similar to the body 18, the blower housing 36 may be made of any suitable materials and may, for example, be made of a polymer, a metal or a composite. The blower housing 36 may be cast, molded fabricated or welded, or a combination thereof, The blower housing 36 may be secured to assembly 10 at, for example, assembly frame 42.

The blower 16 may include generally cylindrical body or blower frame 44 to which one or more blades or fins 46 are secured, typically equally spaced about periphery 48 of the frame 44.

As shown in FIG. 1, the member 20, that may for example include or be in the form of wall 38 that extends from hinge 40 and may be a separate component or integral with housing 36. The wall 38 may be made from any suitable, durable material, For example the wall 38 may be made from a polymer, a composite or a metal. The wall 38 may have any suitable shape and may as shown be generally rectangular and generally sheet-like and arcuate.

The wall 38, as shown in FIG. 2, may be moveable from a first or open position 50 shown as a phantom line to a second or closed position 52 shown in solid. As shown in FIG. 2, the wall 38, when in closed position 52, is closely conforming to blades 46 of the squirrel cage fan 16. As shown in FIG. 1, the wall 38, when in open position 50, is spaced from blades 46 of the squirrel cage fan 16. Air flow 32 from the fan 16 adjacent the outlet 28 may be varied by moving the wall from the open position 50 to the closed position 52 and back.

While, as shown, a pivoting, hinged arrangement for moveably positioned the wall 38 onto the housing 36 may be used, it should be appreciated that other arrangements may be used to provide a moveable wall. For example, the wall may extend outwardly as a drawer face along drawer guide rails, not shown, or the wall may be flexible and/or expandable and be moved outwardly by, for example, air pressure.

The wall 38 is moved by motion device 22. The motion device may be any device capable of moving the wall. The motion device 22 may manually move the wall or do so under power and/or remotely. It should be appreciated that the motion device may be merely capable of positioning the wall 38 in either the open position 50 or the closed position 52. Such a motion device may be in the form of a solenoid. Preferably the motion device 22 may be used to selectively position the wall 38 in any desired position from the open position 50 to the closed position 52. The motion device may, as shown, be an electric motor or a servo 22 which may be configured to so selectively position the wall 38.

To selectively position the wall and according to another aspect of the invention, the assembly 10 may further include a controller 54 for controlling the motion device 22, The controller may be any device capable of sending signals, either by hard wiring or wirelessly to the motion device 22. The controller 54 may receive signals, either by hard wiring or wirelessly, from a signaling device 56 in the form of, for example, a master controller, a input/output device or a smart device, for example an, I-Phone, an android phone, a laptop or a notebook.

According to yet another aspect of the invention, the assembly 10 may be configured such that the controller 54 is adapted to move the member 20 or wall 38 relative to the body or housing 40 in response to inputs 58 including, for example changing operating conditions 58. Such changing operating conditions may include at least one of air flow, temperature, pressure and turbulence.

As shown in FIG. 1, the squirrel cage fan or blower 16 may be rotated by, for example an electric motor 60. The electric motor 60 may be any motor capable of rotating the blower 16 and may for example be a constant speed motor or a variable speed motor. The motor 60 may, for example, be an induction motor, a permanent magnet motor, a switched reluctance motor or an Electrioncally Commutated motor (ECM).

According to another embodiment of the present invention and referring to FIG. 3 and FIG. 4, assembly 110 is shown. The assembly 110 is similar to assembly 10 of FIG. 1 and FIG. 2 and includes a squirrel cage blower 116 similar to blower 16 of the assembly 10. The blower 116 is driven by motor 160 similar to motor 60 of FIG. 1. The blower 116 includes a moveable wall 138 similar to wall 36 of FIG. 1 and is moved by motion device 122.

The motion device 122 includes a servo motor 123. The servo motor 123 include an arm 125 which is connected to a linkage 127. The linkage 127 is connected to the wall 138 to move the wall 138. As shown the motion device 122 is connected to a battery 129 that serves to power the motion device 122.

Referring now to FIG. 4, the servo motor 223 is shown in greater detail. The servo motor 223 may be a radio controlled hobby type servo motor.

According to another embodiment of the present invention and referring now to FIG. 5, assembly 210 is shown. The assembly 210 is similar to assembly 10 of FIG. 1 and includes a squirrel cage blower 216 similar to blower 16 of the assembly 10. The blower 216 is driven by motor 260 similar to motor 60 of FIG. 1. The blower 216 includes a moveable wall 238 similar to wall 38 of FIG. 1 and is moved by motion device 222.

The motion device 222 includes a servo motor 223. The servo motor 223 includes an arm 225 which is connected to a linkage 227. The linkage 227 is connected to the wall 238 to move the wall 238. As shown the motion device 222 is connected to a battery 229 that serves to power the motion device 222. As shown the blower is connected to a generator 231 that provides electricity to controller 254, similar to controller 54 of FIG. 1. Electricity from the controller 254 is sent to the battery 229 to keep it fully charged.

According to another embodiment of the present invention and referring now to FIG. 6, assembly 310 is shown. The assembly 310 is similar to assembly 10 of FIG. 1 and may include a squirrel cage blower 316 similar to blower 16 of the assembly 10. The blower 316 is driven by motor 360 similar to motor 60 of FIG. 1. The blower 316 includes a moveable wall 338 similar to wall 38 of FIG. 1 and is moved by motion device 322.

The motion device 322 is different than the motion device 122 of assembly 110. The motion device 322 includes a shaped memory alloy actuator wire 313. The wire 313, when exposed to an electrical current, contracts. This contraction is in the order of magnitude of 3 to 4 percent of its length and thus provides for a stroke or movement of the wire of around 3 to 4 percent of the wire's length. The wire thus typically may need a device attached to the wire 313 to multiply the stroke it can provide so that it may effectively move the wall 338 sufficiently. For example and as shown the motion device 322 may further include a multiplier 315.

The multiplier 315 may be any mechanical device capable of multiplying the movement provided by the wire 313. For example the multiplier may be a normal bias spring, a dead weight bias, a leaf spring bias, a right angle pull, a simple lever, an adjusting curvature, and a clam shell. The multiplier 315 may be attached to the wire to increase the motion provided by the wire 313.

The wire 313 may be electrically connected to power source 317 either directly through a switch 319 or, as shown, through controller 354, similar to controller 54 of apparatus 10 as shown in FIG. 1.

The wire 313 is a shaped memory alloy actuator wire. The shaped memory alloy actuator wire may be available as a Flexinol® actuator wire. Such Flexinol® actuator wires are available from Dynalloy, Inc, 1562 Reynolds Avenue, Irvine, Calif. 92614.

The multiplier 315 may be any mechanical device and such devices are described in greater detail in a publication titled “Technical Characteristics of Flexinol® Actuator Wires”, F1140 Rev 1.2, available from Dynalloy, Inc. 1562 Reynolds Avenue, Irvine, Calif. 92614 and available online at http://www.dynalloy.com hereby incorporated in its entirety by reference.

According to another embodiment of the invention and referring now to FIG. 7, assembly 410 is shown. The assembly 410 includes a body 418 in the form of a squirrel cage fan 416. A moveable member 416 in the form of a first fin or blade 446 is moveably positionable on periphery 448 of the body 418.

The fin or blade 446 may be moveable from a first or tangential position 450 (shown as a dashed line) aligned with periphery 448 of the body 418 to a second or radial position 452 (shown as a phantom line) extending radially outward from axis 426 of fan 416. Air flow 432 from the fan 416 may be varied by pivoting the blade 446 from the open position 450 to the closed position 452 and back.

The blade 446 may be pivoted in any suitable manner. For example and as shown in FIG. 7, a pivoting device 422 in the form of a motor or, as shown, a servo is mounted to the periphery 448 of the fan 416. The blade 446 is mounted to the servo 422 which rotates the blade 446. A battery 429 may be used to provide power to the servo 422.

While a single, pivoting blade arrangement for moveably positioning a single blade may be used, it should be appreciated and, as shown, other arrangements including multiple, pivoting, spaced apart, blades may be used. For example, additional pivoting blades 446, (shown as dashed lines) may each be positioned on periphery 448 of the body 418.

The additional pivoting blades 446 may be pivoted in an suitable manner. For example and as shown adjacent blades 446 are connected at their periphery by links 445. When the servo 422 which rotates the blade 446 is energized, the adjacent blades 446 are pivoted by the links connected to the blade rotated by the servo 422.

Alternately, each blade 446 may have its own servo 422 as shown in phantom.

Alternately, the first blade 446 may be pivoted by the use of an actuator wire 413, similar to wire 313 of the assembly 310 of FIG. 6. The stroke of the wire 413 may be multiplied by multiplier 415, similar to multiplier 315 of the assembly 310 of FIG. 6. The additional blades 446 may either be connected by links 445 or each blade may be connected to a wire 413 and a multiplier 415.

To selectively position the blades 446 and according to another aspect of the invention, the assembly 410 may further include a controller 454 for controlling the blades 446. The controller 454 may be any device capable of sending signals, either by hard wiring or wirelessly to the servo 422 or to the wire 413. The controller 454 may receive signals, either by hard wiring or wirelessly, from a signaling device 456 in the form of, for example, a master controller, a input/output device or a smart device, for example an, I-Phone, an android phone, a laptop or a notebook.

According to yet another aspect of the invention, the assembly 410 may be configured such that the controller 454 is adapted to move the blades 446 in response to changing inputs 458, for example to operating conditions. Such changing operating conditions may include at least one of air flow, temperature, pressure and turbulence.

According to another embodiment of the invention and referring now to FIG. 8, assembly 510 is shown. The assembly 510 includes a housing 518. The assembly also includes a squirrel cage fan 516 rotatable positioned in the housing 518. The fan 516 is rotated by motor 560 secured to housing 518. The housing 518 forms an inlet 524 and an outlet 528 such that airflow 532 advances through the assembly 510 in the direction of arrows 534. As shown in FIG. 8, member 520 in the form of a dampener vane is positioned in outlet 526 and is used to vary the airflow 532 through the assembly 510.

The dampener vane 520 may be positioned anywhere and in any orientation within the outlet 528 of the assembly 510. For convenience for example the vanes may be oriented horizontally and/or vertically. As shown in FIG. 8, a first dampener vane 519 is positioned horizontally in the outlet 528,

According to another aspect of the invention, the assembly is configured such that the first dampener vane 519 may he pivoted such that its affect on airflow 532 may be easily adjusted. As shown in FIG. 8, the vane 519 may be moveable from a first open or horizontal position 550 (shown as a solid line) aligned with arrow 534 showing the air flow 532 of the assembly 510 to a second closed or vertical position 452 (shown as a dashed line) extending normal to arrow 534. Back pressure and thus air flow 532 from the fan 516 may be varied by pivoting the vane 519 from the open position 550 to the closed position 552 and back.

The vane 519 may be pivoted in any suitable manner. For example and as shown in FIG. 8A, a pivoting device 522 in the form of a motor or as shown a servo is mounted to the housing 518 of the assembly 510. The vane 519 is mounted to the servo 522 which rotates the vane 519.

While a single, pivoting vane arrangement for moveably positioning a single vane may be used, it should be appreciated and, as shown, other arrangements including multiple, pivoting, spaced apart, vanes may be used. For example, additional pivoting vanes 520, (shown as solid lines) may each be secured to housing 518 of the assembly 510 and may be oriented, for example, horizontally or vertically.

The additional pivoting vanes 520 may be pivoted in any suitable manner. For example and as shown adjacent vanes 520 are connected at their periphery by links 545. When the servo 522 which rotates the first vane 519 is energized, the adjacent vanes 520 are pivoted by the links 545 connected to the vanes 520 rotated by the servo 522.

Alternately, each vane 520 may have its own servo 522 as shown in phantom.

Alternately and as shown in FIG. 8B, the first vane 519 may be pivoted by the use of an actuator wire 513, similar to wire 313 of the assembly 310 of FIG. 6. The stroke of the wire 513 may be multiplied by multiplier 515, similar to multiplier 315 of the assembly 310 of FIG. 6. The additional vanes 520 may either be connected by links 545 or each blade may be connected to a wire 513 and a multiplier 515.

To selectively position the vanes 520 and according to another aspect of the invention, the assembly 510 may further include a controller 554 for controlling the vanes 520. The controller may be any device capable of sending signals, either by hard wiring or wirelessly to the servo 522 or to the wire 513. The controller 554 may receive signals, either by hard wiring or wirelessly, from a signaling device 556 in the form of, for example, a master controller, a input/output device or a smart device, for example an, I-Phone, an android phone, a laptop or a notebook.

According to yet another aspect of the invention, the assembly 510 may be configured such that the controller 554 is adapted to move the vanes 520 in response to inputs 558, for example to changing operating conditions. Such changing operating conditions may include at least one of air flow, temperature, pressure and turbulence.

According to another embodiment of the invention and referring now to FIGS. 9 and 10, assembly 610 is shown. The assembly 610 includes a motor 660 to which a blade 616 is rotatably secured. The blade 616 is rotated by motor 660.

The blade 616 may be positioned anywhere and in any orientation with respect to the motor 660. For example the blade 616 extends radially from the motor 660 and is position at an angle relative to axis of rotation 626 of the motor 660.

According to another aspect of the invention, the assembly is configured such that the blade 616 may be pivoted such that its affect on airflow 632 may be easily adjusted. As shown in FIG. 9, the blade 616 may be moveable from a first position 650 (shown as a solid lines) generally normal to rotational axis 626 of motor 660 to a second position 652 (shown as a phantom lines) extending generally parallel to rotational axis 626 of motor 660. Air flow 632 from blade 616 may be varied by pivoting the blade 616 from the first position 650 to the second position 652 and back.

The blade 616, for example first blade 620, may be pivoted in any suitable manner. For example and as shown in FIG. 9, a pivoting device 622 in the form of a motor or, as shown, a servo is mounted to the motor 660. The blade 616 is mounted to the servo 622 which rotates the first blade 620.

While a single, pivoting blade arrangement for moveably positioning first blade 620 may be used, it should be appreciated and, as shown, other arrangements including multiple, pivoting, spaced apart, blades 616 may be used. For example, additional pivoting blades 616, (shown as solid lines) may each be secured to motor 660 and may be oriented, for example, extending from motor 660.

The additional pivoting blades 616 may be pivoted in any suitable manner. For example and as shown adjacent blades 616 are connected at their periphery by links 645 that may, for example, have a ring shape. When the servo 522, which rotates the first blade 620, is energized, the adjacent blades 616 are pivoted by the links 645 connected to the first blade 620 rotated by the servo 622.

Alternately, each blade 620 may have its own servo 622.

Alternately and as shown in FIG. 9A, the first blade 620 may be pivoted by the use of an actuator wire 613, similar to wire 313 of the assembly 310 of FIG. 6. The stroke of the wire 613 may be multiplied by multiplier 615, similar to multiplier 315 of the assembly 310 of FIG. 6. The additional blades 616 may either be connected by links 645 or each blade may be connected to its own wire 613 and its own multiplier 615.

To selectively position the blades 620 and according to another aspect of the invention, the assembly 610 may further include a controller 654 for controlling the blades 620. The controller may be any device capable of sending signals, either by hard wiring or wirelessly to the servo 622 or to the wire 613. The controller 654 may receive signals, either by hard wiring or wirelessly, from a signaling device 656 in the form of, for example, a master controller, a input/output device or a smart device, for example an, I-Phone, an android phone, a laptop or a notebook.

According to yet another aspect of the invention, the assembly 610 may be configured such that the controller 654 is adapted to move the blades 620 in response to inputs 658, for example to changing operating conditions. Such changing operating conditions may include at least one of air flow, temperature, pressure and turbulence.

It should be appreciated that the motor 660 and the blades 616 may be positioned or mounted to any surface. For example the motor and blades may be mounted to a ceiling to provide air flow below. Alternatively and as shown in FIGS. 9-10 the motor and blades may be mounted in ducting 680 to provide an assembly 610 including an inlet 624 and an outlet 628.

Referring now to FIGS. 11-13, the blades 616 may have any suitable shape and may, as shown be shaped to provide desirable aerodynamic characteristics. For example and as shown in FIG. 11, the blade 616 may have an upper surface 682 spaced a first direction from longitudinal centerline 678 of the blade 616 and a lower surface 684 spaced a second opposed direction from longitudinal centerline 678 of the blade 616. The upper surface 682 may have a convex shape to provide lift to the blade 616. The longitudinal centerline 678 of the blade 616 forms an angle of attack a, when the blade 616 is advanced in the direction of arrow 634. The lift of the blade 616 results in an effective angle of attack α_rel.

Referring now to FIG. 12, the blade is exposed to two external forces when advanced in the direction of arrow 634. The first force is the drag force D in a direction generally opposed to the direction of arrow 634. The second force is the lift force L in a direction generally upward and normal to the direction of arrow 634.

Referring now to FIGS. 10-13 and more particularly to FIG. 13, drag is plotted on the abscissa and lift is plotted on the ordinate as the angle of attack α_rel is increased, The angle α_rel varies with the speed of the motor 660. Two different curves are shown, one for each of two separate motor speeds. It should be appreciated that a certain angle of attack α_rel and at a certain speed, lift is maximized. That angle of attack is the α_optimum, it is at that α_optimum, that the blade 620 should be positioned. Thus, to optimize lift, the angle of attack may be varied as speed is varied by using the servo 622 or wire 613 to position the blade for optimum operation.

According to another embodiment of the invention and referring now to FIGS. 14 and 15, assembly 710 is shown. The assembly 710 includes a motor 760 to which a blade 716 is rotatably secured. The blade 716 is rotated by motor 760.

The blade 716 may be positioned anywhere and in any orientation with respect to the motor 760. For example the blade 716 extends radially from the motor 760 and is position at an angle relative to axis of rotation 726 of the motor 760.

According to another aspect of the invention, the assembly is configured such that a first blade 720 of the blades 716 may be pivoted such that its affect on airflow 732 may be easily adjusted. As shown in FIG. 15, the blade 716 may be moveable from a first position 750 (shown as a solid line) skewed to the rotational axis 726 of motor 760 to a second position 752 (shown as a dashed line) extending normal with rotational axis 726 of motor 760 and generally perpendicular to rotational axis 726. Air flow 732 from blade 716 may be varied by pivoting the blade 716 from the first position 750 to the second position 752 and back.

The blade 716 may be pivoted in any suitable manner. For example and as shown in FIG. 9, a pivoting device 722 in the form of a motor or as shown a servo is mounted to the motor 760. The blade 716 is mounted to the servo 722 which rotates the blade 716.

While a single, pivoting blade arrangement for moveably positioning a single blade may be used, it should be appreciated and, as shown, other arrangements including multiple, pivoting, spaced apart, blades may be used. For example, additional pivoting blades 716, (shown as solid lines) may each be secured to motor 760 and may be oriented, for example, extending from motor 760.

The additional pivoting blades 716 may be pivoted in any suitable manner. For example and as shown adjacent blades 716 are connected at their periphery by links 745 that my, for example, have a ring shape. When the servo 722 which rotates first blade 720 is energized, the adjacent blades 716 are pivoted by the links 745 connected to the blade rotated by the servo 722.

Alternately, each blade 716 may have its own servo 722.

Alternately and referring to FIG. 15A, the first blade 720 may be pivoted by the use of an actuator wire 713, similar to wire 313 of the assembly 310 of FIG. 6. The stroke of the wire 713 may be multiplied by multiplier 715, similar to multiplier 315 of the assembly 310 of FIG. 6. The additional blades 716 may either be connected by links 745 or each blade may be connected to a wire 713 and a multiplier 715.

To further control air flow 732 from the assembly 710 and according to another aspect of the invention and referring again to FIG. 15, a member 773 in the form of a dampener vane is positioned in outlet 728 and is used to vary the airflow 732 through the assembly 710.

The dampener vane 773 may be positioned anywhere and in any orientation within the outlet 728 of the assembly 710. For convenience for example, the vanes may be oriented horizontally and/or vertically. As shown in phantom in FIG. 8, a first dampener vane 719 is positioned horizontally in the outlet 728.

According to another aspect of the invention, the assembly is configured such that the first dampener vane 719 may be pivoted such that its affect on airflow 732 may be easily adjusted. As shown in FIGS. 14-15, the first vane 719 may be moveable from a first open or vertical position 762 (shown as a solid line) aligned with arrow 734 showing the air flow 732 of the assembly 710 to a second closed or horizontal position 764 (shown as phantom lines) extending normal to arrow 734. Back pressure and thus air flow 732 from the fan 716 may be varied by pivoting the first vane 719 from the open position 762 to the closed position 764 and back.

The vane 719 may be pivoted in any suitable manner. For example and as shown in FIG. 15, a pivoting device 766 in the form of a motor or as shown a servo is mounted to the housing 718 of the assembly 710. The first vane 719 is mounted to the servo 766 which rotates the vane 719.

While a single, pivoting vane arrangement for moveably positioning a single vane may be used, it should be appreciated and, as shown, other arrangements including multiple, pivoting, spaced apart, vanes may be used. For example, additional pivoting vanes 773, (shown as solid lines) may each be secured to housing 718 of the assembly 710 and may be oriented, for example, horizontally or vertically.

The additional pivoting vanes 773 may be pivoted in any suitable manner. For example and as shown adjacent vanes 773 are connected at their periphery by links 768. When the servo 766 which rotates the first vane 719 is energized, the adjacent vanes 773 are pivoted by the links 768 connected to the blade rotated by the servo 766. Alternately, each vane 773 may have its own servo 766.

Alternately and referring to FIG. 15B, the first vane 719 may be pivoted by the use of an actuator wire 770, similar to wire 313 of the assembly 310 of FIG. 6. The stroke of the wire 770 may be multiplied by multiplier 772, similar to multiplier 315 of the assembly 310 of FIG. 6. The additional vanes 773 may either be connected by links 745 or each blade may be connected to a wire 770 and a multiplier 772.

Referring again to FIG. 15, to selectively position the blades 716 and to selectively position the vanes 773 and according to another aspect of the invention, the assembly 710 may further include a controller 754 for controlling the blades 716 and the vanes 773. The controller 754 may be any device capable of sending signals, either by hard wiring or wirelessly, to the servo 722 or to the wire 713 to control the blades 716 and of sending signals, either by hard wiring or wirelessly, to the servo 766 or to the wire 770 to control the vanes 773. The controller 754 may receive signals, either by hard wiring or wirelessly, from a signaling device 756 in the form of for example, a master controller, a input/output device or a smart device, for example an, I-Phone, an android phone, a laptop or a notebook.

According to yet another embodiment of the invention and referring to FIG. 16, a method 800 for altering the flow of air in a blower is provided. The method includes the step 812 of providing a body, the step 814 of providing a member, the step 816 of moveably securing the member to the body, the step 818 of providing a motion device and the step 820 of moving the member relative to the body with the motion device is provided.

According to another aspect of the invention, the method further includes the steps of providing a controller for controlling the motion device, measuring at least one of temperature, air flow, turbulence and pressure, and moving the member relative to the body with the motion device in response to changes in at least one of temperature, air flow, turbulence and pressure.

The methods, systems, and apparatus described herein facilitate efficient and economical assembly of an electric machine. Exemplary embodiments of methods, systems, and apparatus are described and/or illustrated herein in detail. The methods, systems, and apparatus are not limited to the specific embodiments described herein, but rather, components of each apparatus and system, as well as steps of each method, may be utilized independently and separately from other components and steps described herein. Each component, and each method step, can also be used in combination with other components and/or method steps.

When introducing elements/components/etc. of the methods and apparatus described and/or illustrated herein, the articles “a”, “an”, “the”, and “the” are intended to mean that there are one or more of the element(s)/component(s)/etc. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional element(s)/component(s)/etc. other than the listed element(s)/component(s)/etc.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Described herein are exemplary methods, systems and apparatus utilizing lower cost materials in a permanent magnet machine that reduces or eliminates the efficiency loss caused by the lower cost material. Furthermore, the exemplary methods system and apparatus achieve increased efficiency while reducing or eliminating an increase of the length of the machine. The methods, system and apparatus described herein may be used in any suitable application. However, they are particularly suited for HVAC and pump applications.

Exemplary embodiments of the fluid flow device and system are described above in detail. The electric machine and its components are not limited to the specific embodiments described herein, but rather, components of the systems may be utilized independently and separately from other components described herein. For example, the components may also be used in combination with other machine systems, methods, and apparatuses, and are not limited to practice with only the systems and apparatus as described herein. Rather, the exemplary embodiments can be implemented and utilized in connection with many other applications.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. An assembly adapted to advance the flow of fluid in a fluid now device, said assembly comprising:

a body;

a member moveably secured to said body; and

a motion device secured to said body and adapted to move said member relative to said body.

2. An assembly in accordance with claim 1:

wherein said body comprises a blower housing; and

wherein said member comprises a wall of said blower housing.

3. An assembly in accordance with claim 1, further comprising a controller for controlling said motion device.

4. An assembly in accordance with claim 4, wherein said controller is adapted to move said member relative to said body in response to changing operating conditions including at least one of air flow, temperature, pressure and turbulence.

5. An assembly in accordance with claim 1:

wherein said body comprises a blower wheel; and

wherein said member comprises a blade.

6. An assembly in accordance with claim 1:

wherein said body comprises a fan body; and

wherein said member comprises a blade.

7. An assembly in accordance with claim 1, wherein said motion device comprises a servo motor.

8. An assembly in accordance with claim 1, wherein said motion device comprises a shape memory alloy wire.

9. An assembly in accordance with claim 1:

further comprising a second member moveably secured to said body and spaced from said first member, said first member and said member vane connected to an intermediate member.

10. An assembly in accordance with claim 1:

wherein said body comprises a housing; and

wherein said member comprises a dampener vane.

11. A blower having a moveable member adapted to influence the flow of air through the blower, said blower comprising:

a body;

a member moveably secured to said body; and

a motion device secured to said body and adapted to move said member relative to said body.

12. A blower in accordance with claim 11:

wherein said body comprises a blower housing; and

wherein said member comprises a wall of said blower housing.

13. A blower in accordance with claim 12, wherein the wall is made of a flexible material.

14. A blower in accordance with claim 11:

wherein said body comprises a blower wheel; and

wherein said member comprises a vane.

15. A blower in accordance with claim 11, wherein said motion device comprises a servo motor.

16. A blower in accordance with claim 11, wherein said motion device comprises a shape memory alloy wire.

17. A blower in accordance with claim 11, further comprising a controller for controlling said motion device.

18. A blower in accordance with claim 17, wherein said controller is adapted to move said member relative to said body in response to changing operating conditions including at least one of air flow, temperature, pressure and turbulence.

19. A blower in accordance with claim 11:

wherein said body comprises a blower wheel; and

wherein said member comprises a blade; and

further comprising a second vane moveably secured to said blower wheel and spaced from said first vane, said first vane and said second vane connected to an intermediate member, said intermediate member connected to said motion device.

20. A method for altering the flow of air in a blower, comprising

providing a body;

providing a member;

moveably securing the member to the body;

providing a motion device; and

moving the member relative to the body with the motion device.

21. The method in accordance with claim 20, further comprising:

providing a controller for controlling the motion device;

measuring at least one of temperature, air flow, turbulence and pressure; and

moving the member relative to the body with the motion device in response to changes in at least one of temperature, air flow, turbulence and pressure.