Patent Description:
<CIT> discloses an energy recovery system having the features of the preamble of independent claim <NUM>.

In accordance with the present invention, an energy recovery system for an air handling unit includes an energy recovery wheel configured to rotate about a first axis, a motor, and a drive wheel coupled to the motor for rotation about a second axis that is offset from the first axis and the energy recovery wheel and having an outer surface engaged directly with an outer surface of the energy recovery wheel. The energy recovery system further includes an actuator mount configured to support the motor relative to the energy recovery wheel, the actuator mount including a motor mount coupled to the motor and a stationary mount coupled to the air handling unit in a fixed position and configured to support the motor mount for pivotable movement about an actuator pivot axis so that the drive wheel is pivotable into contact with the outer surface of the energy recovery wheel.

In some embodiments, the energy recovery system further includes a tensioning system configured to bias the motor to pivot about the actuator pivot axis to urge the drive wheel into contact with the outer surface of the energy recovery wheel. In some embodiments, the tensioning system includes an adjustable spring mount coupled to the motor and a biasing spring coupled to the adjustable spring mount. In some embodiments, the biasing spring is coupled to a first end of the motor mount to bias an opposite, second end of the motor mount toward the energy recovery wheel, the drive wheel being coupled to the motor at the second end of the motor mount. In some embodiments, the biasing spring is coupled to an end of the spring mount spaced apart from the motor mount at the first end to bias the second end of the motor mount toward the energy recovery wheel. In some embodiments, the adjustable spring mount is adjustable, in particular rotatable relative to the motor to increase or decrease a spring force provided by the biasing spring on the adjustable spring mount.

In some embodiments, the motor mount includes a mount plate supporting the motor, a pair of mount flanges coupled to the mount plate, and a mount rod coupled to the mount flanges and providing the actuator pivot axis.

In some embodiments, the energy recovery system further includes a vibration dampening bushing coupled to the mount rod and arranged to lie between the mount rod and at least one of the stationary mount and the mount plate to dampen vibrations therebetween.

In some embodiments, motor mount comprises a pair of flanges including a first mount flange formed to include a first flange aperture, a second mount flange spaced apart from the first mount flange along the actuator pivot axis and formed to include a second flange aperture, and a mount rod received within the first mount flange and the second mount flange, and at least one stationary-mount aperture formed in the stationary mount to couple the motor mount and the wheel actuator to the stationary mount. In some embodiments, the energy recovery system further includes a first vibration dampening bushing arranged to lie between the mount rod and the first mount flange and a second vibration dampening bushing arranged to lie between the mount rod and the second mount flange.

Additional features of the present invention will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the invention as presently perceived.

An energy recovery system <NUM> in accordance with the present invention, includes a support frame <NUM>, an energy recovery wheel <NUM>, and a wheel actuator <NUM> as shown in <FIG>. The support frame <NUM> is configured to support the wheel actuator <NUM> within an air handling unit (not shown). The support frame <NUM> may form a part of the air-handling unit or may be separate from the air-handling unit and coupled to the energy recovery wheel <NUM> such that the support frame <NUM>, energy recovery wheel <NUM>, and wheel actuator <NUM> form a removable subassembly within the air-handling unit. The air handling unit includes or defines an air-supply section <NUM> that supplies outdoor air into a building and an air-exhaust section <NUM> that removes indoor air from the building at the same time to ventilate the building with fresh, outdoor air. The indoor air and the outdoor air both pass through the energy recovery wheel <NUM> to exchange heat and/or moisture between the indoor air and the outdoor air. The energy recovery wheel <NUM> is driven in rotation by the wheel actuator <NUM> relative to the air handling unit and is arranged to lie in both the air-supply section and the air-return section to exchange heat and/or moisture between the indoor air and the outdoor air in order to reduce energy losses.

The energy recovery wheel <NUM> rotates about a central rotational axis <NUM> relative to the support frame <NUM> so that portions of the energy recovery wheel <NUM> are continuously moved into and out of the air-supply section <NUM> and the air-return section <NUM> as the indoor and outdoor air flows therethrough. The energy recovery wheel <NUM> includes an outer shell <NUM> and an energy absorption media <NUM> arranged to lie within a perimeter of the outer shell <NUM>. The outer shell <NUM> engages the wheel actuator <NUM> and is driven by the wheel actuator <NUM> to rotate the energy recovery wheel <NUM> about the central rotational axis <NUM> during operation of the energy recovery system <NUM>. The expression "energy recovery wheel" should be interpreted to include, without limitation thereto, a rotary wheel, a thermal wheel, a sensible wheel, a heat wheel, a desiccant wheel, a dehumidification wheel, a heat and/or moisture recovery wheel, a total energy recovery wheel, a enthalpy wheel, a regeneratable rotary dehumidification wheel, a rotary enthalpy wheel, a rotating wheel exchanger and the like. The energy absorption media <NUM> may be corrugated or fluted sheets of material that absorbs heat and/or moisture from one of the indoor air and the outdoor air and releases the heat and/or moisture into the other of the indoor air and the outdoor air.

The wheel actuator <NUM> is mounted to the support frame <NUM>, or another portion of the air-handling unit, as shown in <FIG> and <FIG>. In the illustrative embodiment, the wheel actuator <NUM> is located at a lower corner of the support frame <NUM> relative to the energy recovery wheel <NUM>, however, in other embodiments the wheel actuator <NUM> may be located in another location relative to the energy recovery wheel <NUM>. The wheel actuator <NUM> includes a motor <NUM> and a drive wheel <NUM> coupled to the motor <NUM>. The motor <NUM> is configured to drive rotation of the drive wheel <NUM> about a wheel rotation axis <NUM>. The drive wheel <NUM> directly engages the outer shell <NUM> of the energy recovery wheel <NUM> and drives the energy recovery wheel <NUM> to rotate about the central rotational axis <NUM> during operation.

Some prior wheel actuators include a belt that wraps around the outer shell of the energy recovery wheel and that is driven by a drive wheel. However, in this instance the drive wheel is spaced apart from the outer shell and slots are formed in various seal members <NUM> separating the air-supply section <NUM> and the air-exhaust section <NUM> to provide clearance for the belt. Unlike systems using those prior wheel actuators, the drive wheel <NUM> in the illustrated embodiment is placed in direct contact with the outer shell <NUM> so that the belt and the corresponding slots in the seal members <NUM> can be omitted thereby improving efficiency of the system <NUM> as shown in <FIG>. The seal member <NUM> interfaces with a radially-outer surface <NUM> of the outer shell <NUM> and extends generally parallel with the rotation axis <NUM> from a forward end of the outer shell <NUM> to a rear end of the outer shell <NUM>. Each seal member <NUM> is formed without any slots opening toward the outer shell <NUM> between the forward end and the rear end.

The motor <NUM> may include an induction motor, a permanent magnet synchronous motor (PMSM), a direct PMSM motor, a direct induction motor, or any other suitable type of motor. The motor <NUM> may be brushed or brushless. The motor <NUM> may be powered via direct current (DC) or alternating current (AC), or may be an electrically communicated (EC) motor, in some embodiments.

The drive wheel <NUM> includes a wheel hub <NUM> and a peripheral skin <NUM> that circumscribes an outer surface of the wheel hub <NUM> as shown in <FIG>. The wheel hub <NUM> may be made from aluminum or any other suitable material and is solid to reduce inertia and energy consumption. The peripheral skin <NUM> may include polyurethane or another suitable material to increase friction between the drive wheel <NUM> and the outer shell <NUM>. The peripheral skin <NUM> may have a flat outer surface or may be formed to include thread <NUM> to increase grip on the outer shell <NUM>. The thread <NUM> is defined by a plurality of channels <NUM> formed into the peripheral skin <NUM>. The plurality of channels <NUM> illustratively form a plurality of diamond-shaped pads <NUM>, however, in other embodiments the plurality of channels <NUM> may define pads or structures having a different shape. The diamond-shaped pads <NUM> may reduce noise and heat and may increase durability of the peripheral skin compared to threads having pads with different shapes or no shape.

The energy recovery system <NUM> further includes an actuator mount <NUM> configured to position and retain the wheel actuator <NUM> relative to the energy recovery wheel <NUM> as shown in <FIG>. The actuator mount <NUM> includes a stationary mount <NUM> and a motor mount <NUM> coupled to the wheel actuator <NUM>. The stationary mount <NUM> is configured to couple to the support frame <NUM> in a fixed position relative to the energy recovery wheel <NUM>. The motor mount <NUM> is coupled to the stationary mount <NUM> and is configured to pivot about an actuator pivot axis <NUM> to allow movement of the wheel actuator <NUM> relative to stationary mount <NUM>. Pivoting of the motor mount <NUM> allows the wheel actuator <NUM> to move relative to the energy recovery wheel <NUM> or remain in contact with the energy recovery wheel <NUM>. In some embodiments, the stationary mount <NUM> is a part of the support frame <NUM> or a part of the air-handling unit.

The actuator mount <NUM> further includes a tensioning system <NUM> configured to bias the motor mount <NUM> to pivot about the actuator pivot axis <NUM> in direction <NUM> so that the drive wheel <NUM> is biased into contact with the outer shell <NUM> of the energy recovery wheel <NUM> and applies a load <NUM> on the outer shell <NUM>. The tensioning system <NUM> includes a pair of adjustable spring mounts <NUM> coupled to the motor mount <NUM> and a corresponding pair of biasing springs <NUM>. Each of the biasing springs <NUM> extends between the motor mount <NUM> and a portion of the stationary mount <NUM>, although in other embodiments, the biasing springs <NUM> may be coupled to a portion of the support frame <NUM> or another part of the air-handling unit. Illustratively, the biasing springs <NUM> are tension springs and are coupled to a first end <NUM> of the motor mount <NUM> to bias an opposite, second end <NUM> of the motor mount <NUM> toward the energy recovery wheel <NUM>. The actuator pivot axis <NUM> is located between the first end <NUM> and the second end <NUM> to provide this motion.

Although the illustrative embodiment includes two tension springs <NUM>, it should be noted that any number of springs may be used to bias the second end <NUM> of the motor mount <NUM> and the drive wheel <NUM> toward the energy recovery wheel <NUM>. In other embodiments, a different type of biasing element may be used in place of the tension springs <NUM> such as compression springs, torsion springs, leaf springs, hydraulics, elastic members, etc..

Each biasing spring <NUM> is coupled to a corresponding adjustable spring mount <NUM> as shown in <FIG> and <FIG>. Each adjustable spring mount <NUM> is rotatable relative to the motor mount <NUM> to increase or decrease a spring force provided by the biasing springs <NUM> on the adjustable spring mount <NUM> and the first end <NUM> of the motor mount <NUM>. Each adjustable spring mount <NUM> includes an eyelet <NUM> to which a respective biasing spring <NUM> is coupled and a threaded shaft <NUM> coupled to the first end <NUM> of the motor mount <NUM>. A nut <NUM> threadingly engages with a respective threaded shaft <NUM> to retain each adjustable spring mount <NUM> to the motor mount <NUM>. The threaded shaft <NUM> may threadingly engage with the motor mount <NUM> such that the retainer nut <NUM> can be omitted. Rotation of the nut <NUM> and/or the threaded shaft <NUM> of each adjustable spring mount increases or decreases a distance between the eyelet <NUM> and the motor mount <NUM> to increase or decrease the force provided by each spring <NUM> on each respective adjustable spring mount <NUM>.

The motor mount <NUM> includes a mount plate <NUM> supporting the wheel actuator <NUM>, a mount bracket <NUM> coupled to the mount plate <NUM>, and a pair of mount rods <NUM>, <NUM> coupled to the mount bracket <NUM> and extending outwardly from the mount plate <NUM>. The mount rods <NUM>, <NUM> are arranged along the actuator pivot axis <NUM> and set within u-shaped channels <NUM>, <NUM> formed in the stationary mount <NUM> to support the motor mount <NUM> on the stationary mount <NUM>.

The motor mount <NUM> may further include a vibration-dampening bushing <NUM>, <NUM> coupled to each mount rod <NUM>, <NUM>. Each vibration-dampening bushing <NUM>, <NUM> is at least partially received within a corresponding channel <NUM>, <NUM> to lie between a corresponding mount rod <NUM>, <NUM> and the stationary mount <NUM> to dampen vibrations produced by the wheel actuator <NUM> during operation.

The stationary mount <NUM> includes a pair of side brackets <NUM>, <NUM>, a base crossbeam <NUM>, and a motor-mount support <NUM> as shown in <FIG>. The pair of side brackets <NUM>, <NUM> are spaced apart from one another by a distance that corresponds with a width of the support frame <NUM> so that each side bracket <NUM>, <NUM> can be attached to corresponding frame members <NUM>, <NUM> of the support frame <NUM> as shown in <FIG>. The base crossbeam <NUM> extends between the side brackets <NUM>, <NUM> and is formed to include apertures <NUM> that can be used to attach an end of each biasing spring <NUM>. The motor-mount support <NUM> also extends between the side brackets <NUM>, <NUM> and is configured to position the motor mount <NUM> and the wheel actuator <NUM> adjacent to the energy recovery wheel <NUM>.

The u-shaped channels <NUM>, <NUM> are formed in the motor-mount support <NUM> and open upwardly so that the mount rods <NUM>, <NUM> can be lowered into each corresponding channel <NUM>, <NUM> during installation as suggested in <FIG>. Once the mount rods <NUM>, <NUM> are set within the u-shaped channels <NUM>, <NUM>, the biasing springs <NUM> can be attached to each adjustable spring mount <NUM> and the base crossbeam <NUM> via apertures <NUM>. The motor mount support includes an upper crossbeam <NUM> located above the motor mount <NUM> to block over-rotation of the motor mount <NUM> during installation. The mount rods <NUM>, <NUM> are held by gravity in each u-shaped channel <NUM>, <NUM>, but tension provided by the biasing springs <NUM> also helps retain the mount rods <NUM>, <NUM> in the u-shaped channels <NUM>, <NUM>.

Another embodiment of an energy recovery system <NUM> is shown in <FIG>. The energy recovery system <NUM> is substantially similar to energy recovery system <NUM> and includes a support frame <NUM>, an energy recovery wheel <NUM>, and a wheel actuator <NUM>. Similar reference numbers in the <NUM> series are used to describe similar features between energy recovery system <NUM> and energy recovery system <NUM>. Accordingly, the disclosure of energy recovery system <NUM> is incorporated by reference for energy recovery system <NUM>.

The wheel actuator <NUM> includes a motor <NUM> and a drive wheel <NUM> coupled to the motor <NUM>. The motor <NUM> is configured to drive rotation of the drive wheel <NUM> about a wheel rotation axis <NUM>. The drive wheel <NUM> directly engages the outer shell <NUM> of the energy recovery wheel <NUM> and drives the energy recovery wheel <NUM> to rotate about a central rotational axis during operation.

The energy recovery system <NUM> further includes an actuator mount <NUM> configured to position and retain the wheel actuator <NUM> relative to the energy recovery wheel <NUM> as shown in <FIG>. The actuator mount <NUM> includes a stationary mount <NUM>, a motor mount <NUM> coupled to the wheel actuator <NUM>, and a tensioning system <NUM>. The stationary mount <NUM> is coupled to the support frame <NUM> in a fixed position relative to the energy recovery wheel <NUM>. The stationary mount <NUM> is located in an upper half of the support frame <NUM> to use gravity to at least partially bias the wheel actuator <NUM> into contact with the energy recovery wheel <NUM>. The motor mount <NUM> is coupled to the stationary mount <NUM> and is configured to pivot about an actuator pivot axis <NUM> to allow movement of the wheel actuator <NUM> relative to the energy recovery wheel <NUM> while supporting the wheel actuator <NUM> relative to the energy recovery wheel <NUM>. In some embodiments, the stationary mount <NUM> is a part of the support frame <NUM> or a part of the air-handling unit. The tensioning system <NUM> is optional but, if included, is configured to bias the motor mount <NUM> to pivot about the actuator pivot axis <NUM> so that the drive wheel <NUM> is biased into contact with the outer shell <NUM> of the energy recovery wheel <NUM>.

Another embodiment of a wheel actuator <NUM> and an actuator mount <NUM> that can be used with energy recovery system <NUM>, <NUM> is shown in <FIG> and <FIG>. The wheel actuator <NUM> and the actuator mount <NUM> are substantially similar to wheel actuator <NUM> and actuator mount <NUM>, respectively. Similar reference numbers in the <NUM> series are used to describe similar features between wheel actuator <NUM> and actuator mount <NUM> and wheel actuator <NUM> and actuator mount <NUM>, respectively. Accordingly, the disclosure of wheel actuator <NUM> and actuator mount <NUM> is incorporated by reference for wheel actuator <NUM> and actuator mount <NUM>.

The wheel actuator <NUM> includes a motor <NUM> and a drive wheel <NUM> coupled to the motor <NUM>. The motor <NUM> is configured to drive rotation of the drive wheel <NUM> about a wheel rotation axis <NUM>. The drive wheel <NUM> directly engages the outer shell <NUM> of the energy recovery wheel <NUM> and drives the energy recovery wheel <NUM> to rotate about the central rotational axis <NUM> during operation.

The actuator mount <NUM> is configured to position and retain the wheel actuator <NUM> relative to the energy recovery wheel <NUM>. The actuator mount <NUM> includes a stationary mount <NUM>, a motor mount <NUM> coupled to the wheel actuator <NUM>, and a tensioning system <NUM>. The stationary mount <NUM> is coupled to the support frame <NUM> in a fixed position relative to the energy recovery wheel <NUM>.

The tensioning system <NUM> includes a pair of adjustable spring mounts <NUM> coupled to the motor mount <NUM> and a corresponding pair of biasing springs <NUM>. Each of the biasing springs <NUM> extends between the motor mount <NUM> and a portion of the stationary mount <NUM>, although in other embodiments, the biasing springs <NUM> may be coupled to a portion of the support frame <NUM> or another part of the air-handling unit. Each biasing spring <NUM> is coupled to a corresponding adjustable spring mount <NUM>. Each adjustable spring mount <NUM> is rotatable relative to the motor mount <NUM> to increase or decrease a spring force provided by the biasing springs <NUM> on the adjustable spring mount <NUM> and the motor mount <NUM>.

The motor mount <NUM> includes a mount plate <NUM> supporting the wheel actuator <NUM>, a pair of mount flanges <NUM>, <NUM> coupled to the mount plate <NUM>, and a mount rod <NUM>. The pair of mount flanges <NUM>, <NUM> are coupled to opposite lateral sides of the mount plate <NUM> and extend upwardly away from the mount plate <NUM>. Each mount flange <NUM>, <NUM> is formed to include a mount aperture <NUM>, <NUM>. The mount rod <NUM> is arranged along the actuator pivot axis <NUM> and received within apertures <NUM>, <NUM> formed in the stationary mount <NUM> and apertures <NUM>, <NUM> formed in mount flanges <NUM>, <NUM> to support the motor mount <NUM> on the stationary mount <NUM>.

Claim 1:
An energy recovery system (<NUM>, <NUM>) for an air handling unit comprising:
an energy recovery wheel (<NUM>, <NUM>) configured to rotate about a first axis (<NUM>),
a motor (<NUM>, <NUM>, <NUM>), and
a drive wheel (<NUM>, <NUM>, <NUM>) coupled to the motor (<NUM>, <NUM>, <NUM>) for rotation about a second axis (<NUM>, <NUM>, <NUM>) that is offset from the first axis (<NUM>) and the energy recovery wheel (<NUM>, <NUM>) and having an outer surface engaged directly with an outer surface (<NUM>) of the energy recovery wheel (<NUM>, <NUM>),
characterized by
an actuator mount (<NUM>, <NUM>, <NUM>) configured to support the motor (<NUM>, <NUM>, <NUM>) relative to the energy recovery wheel (<NUM>, <NUM>), the actuator mount (<NUM>, <NUM>, <NUM>) including a motor mount (<NUM>, <NUM>, <NUM>) coupled to the motor (<NUM>, <NUM>, <NUM>) and a stationary mount (<NUM>, <NUM>, <NUM>) coupled to the air handling unit in a fixed position and configured to support the motor mount (<NUM>, <NUM>, <NUM>) for pivotable movement about an actuator pivot axis (<NUM>, <NUM>, <NUM>) so that the drive wheel (<NUM>, <NUM>, <NUM>) is pivotable into contact with the outer surface (<NUM>) of the energy recovery wheel (<NUM>, <NUM>).