GB2538019A

GB2538019A - HVAC actuator with integrated motor

Info

Publication number: GB2538019A
Application number: GB1614124.4A
Authority: GB
Inventors: Bourqui Yvan
Original assignee: Johnson Electric SA
Current assignee: Johnson Electric SA
Priority date: 2016-08-18
Filing date: 2016-08-18
Publication date: 2016-11-02
Also published as: GB201614124D0

Abstract

A heating ventilation and air conditioning actuator device 12 comprises an actuator housing 18 and a motor housing 20 integrally formed as one-piece with an actuator wall 24 of the actuator housing. The motor may include a stator 32 abutable with the actuator wall, and a rotor 34 receivable therein, a drive shaft 26 being rotatable by the rotor and extending through the actuator wall into an interior of the actuator housing. The actuator housing may include a bearing 36 provided on a further actuator wall 38 opposing the first actuator wall. The bearing supports the drive shaft to prevent or limit deformation of the drive shaft. A HVAC unit comprises at least one said HVAC actuator device, at least one lever mechanism drivable by the HVAC actuator device, and one or more flaps pivotable by the lever mechanism when actuated by the HVAC actuator device. The HVAC unit may be included in a vehicle.

Description

HVAC Actuator With Integrated Motor The present invention relates to a Heating, Ventilation and Air Conditioning, hereinafter HVAC, actuator with integrated motor, to a HVAC unit having such an actuator, and to a vehicle having the said HVAC unit.

A HVAC actuator unit is known which utilises a separate motor housing that abuts a HVAC actuator housing. However, this can lead to the motor housing moving relative to the actuator housing, and also therefore a drive shaft of the motor which projects into the actuator housing moving lateral causing disengagement from a gear train mechanism within the actuator housing.

The present invention seeks to provide a solution to these problems.

According to a first aspect of the invention, there is provided a HVAC actuator device comprising an actuator housing and a motor housing integrally formed as one-piece with an actuator wail of the actuator housing.

Preferably, the motor housing includes a stator abutable with the actuator wall, and a 15 rotor receivable therein, a drive shaft being rotatable by the rotor and which extends through the actuator wall into an interior of the actuator housing Furthermore, the actuator housing may include a bearing formed on a further actuator wall opposing the first said actuator wall, the bearing preventing or limiting deformation of the in use drive shaft when journaled therewith.

According to a second aspect of the invention, there is provided a HVAC unit comprising at least one HVAC actuator device in accordance with the first aspect of the invention, at least one lever mechanism drivable by the HVAC actuator device, and one or more flaps pivotable by the lever mechanism when actuated by the HVAC actuator device Preferably, the HVAC unit further comprises a further said HVAC actuator device, a further said lever mechanism drivable by the said further HVAC actuator device, and one or more further flaps pivotable by the further lever mechanism when actuated by the further HVAC actuator device According to a third aspect of the invention, there is provided a vehicle including a HVAC unit in accordance with the second aspect of the invention The invention win now be more particularly described, with reference to the accompanying drawings, in which.

Figure 1 shows one example of an engine of a vehicle having an embodiment of a HVAC unit in accordance with the second aspect of the invention; and Figure 2 shows an exploded view of an embodiment of a HVAC actuator device, 10 forming part of the HVAC unit shown in Figure 1 and in accordance with the first aspect of the invention.

Referring to the drawings, there is shown part of a HVAC unit 10, typically incorporated in or adjacent to an engine bay of a vehicle and driven, for example, by a compressor, which is not shown, on or adjacent to the engine. The HVAC unit 10 includes a plurality of HVAC actuator devices 12, although only one may be provided, which drive one or more associated lever mechanisms 14 which in turn operate, in this case, one or more relevant flaps 16 to direct air flow into and/or from an occupant cabin of the vehicle.

The flaps 16 are typically rotatably mounted at or adjacent to one or more air flow 20 conduits, preferably being tubes, allowing flow therealong to be regulated and controlled.

The lever mechanisms 14 may comprise one or more rigid and elongate levers which, in the case of a plurality of levers, may form a linkage between an output of the FIVAC actuator device 12 and the associated flaps 16, thereby enabling controlled pivoting of 25 the flaps 16.

Each HVAC actuator device 12, as best shown in Figure 2, preferably includes an actuator housing 18 and a motor housing 20 for an integrated, preferably DC, electric motor 22 provided thereon. The attachment of the motor housing 20 is by way of integral forming, such as through plastics moulding or casting, as one-piece with an actuator wall 24, in this case being a side wall, of the actuator housing 18. The motor housing 20 is preferably cylindrical either entirely or along at least a majority of its longitudinal extent. However, other cross-sectional shapes may be envisaged, such as oval or with opposing flats.

A proximal end of the motor housing 20 relative to the actuator housing 18 is at least in part open to provide an aperture for receiving a drive shaft 26 therethrough. A distal end opposite the proximal end closes the motor housing 20, for example, by way of an end cap 28 which may conveniently include an electrical connector to provide electrical power to the rotor, for example, through a commutator 30 or via a brushless arrangement.

A, typically magnetic, stator 32 is receivable, typically as a sliding push or press fit, within the motor housing 20 abutable with the actuator wall 24, and a rotor 34 is rotatably receivable therein. The stator 32 is preferably cylindrical, but may be other shapes to accommodate the shape of the motor housing. The drive shaft 26 is rotatable by the rotor 34 and extends through the actuator wall 24 into an interior of the actuator housing 18.

The drive shaft 26 may be supported at the actuator wall 24 by a bearing, which is not shown. Additionally or alternatively, a further bearing 36 may be provided, either by way of integral forming or by being separately attached, on a further actuator wall 38 opposing the first above-mentioned actuator wall 24. A projecting distal end 40 of the drive shaft 26 is journaled with the further bearing 36 This is particularly beneficial due to the further bearing 36 preventing or limiting deformation of the in use drive shaft 26 when supported thereby.

A gear 42 is preferably provided on the drive shaft 26, and a gear train or gear mechanism, which is not shown, is preferably provided in the actuator housing 18, being drivable by the drive-shaft gear. The actuator housing 18 is then closed by a cover plate 44, and the closure may be permanent, for example, by welding or bonding, or releasable, for example, by screw-threaded fasteners and/or clips. An output aperture 46 is typically provided, for example, in the cover plate 44, to allow an output shaft of the gear train to exit for coupling to one or more levers of the associated lever mechanism 14.

It is thus possible to provide a HVAC actuator device which requires a reduced amount of material and is more robust due to the integrally formed motor housing, whilst still 5 remaining relatively lightweight. This also therefore improves longevity and slightly decreases vibrational noise during operation. It is also advantageous to include the internal drive-shaft support bearing which is spaced from the motor housing to support the distal end of the drive shaft. This prevents or limits bending torque stress associated with the operation of the DC motor being transmitted to the drive shaft, and thus 10 potentially undesirable drive shaft deformation causing disengagement of the drive gear from the rest of the gear train within the actuator housing.

The words 'comprises/comprising' and the words 'having/including' when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, but do not preclude the presence or addition of 15 one or more other features, integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.