Motorized gear and coupling system

Abstract

A system for controlling airflow in a plenum, that comprises a worm gear and planetary gear that are removably coupled to a worm shaft and planetary shaft, respectively. The planetary shaft controls the movement of a damper between an open position permitting maximum airflow through the plenum, and a closed position restricting airflow through the plenum. A motor or gear-motor is positioned at the plenum for driving the worm shaft. The motor is controlled by a remotely located controller that includes a power supply for operating the motor and that has a display providing a continuous indication of the position of the damper between the open and closed positions. The controller is connected to the motor through a cable with a detachable electrical connection between the cable and the controller. Alternatively, the movement of the damper is controlled by a drive shaft, which connects the motor or gear motor directly to the damper without intervening gearing. The motor is positioned in the airflow of the plenum. The cable may extend through the plenum to a diffuser or other opening in the plenum for connection to the controller, or may exit through a hole formed in the plenum.

1 . A damper system for controlling airflow through a plenum, comprising:
 a damper within the plenum, the damper rotatable between a first position permitting maximum airflow and a second position restricting airflow to a minimum;   a motor for rotating the damper between the first and second positions; and   a controller for operating the motor, the controller having a display for providing an indication of the position of the damper relative to the first and/or second positions.   
     
     
         2 . The damper system of  claim 1 , wherein the controller further comprises a microprocessor for determining the position of the damper and for directing the display to provide an indication of the position of the damper relative to the first and/or second positions. 
     
     
         3 . The damper system of  claim 2 , wherein the motor rotates the damper at a constant speed and the microprocessor determines the position of the damper based on the time of rotation from the first or second position. 
     
     
         4 . The damper system of  claim 3 , wherein the damper is a rotary damper comprising a plurality of blades that rotate relative to each other about a common axis, the rotation of the blades defining a blade rotation plane, and at least one blade having an edge with a flange projecting orthogonal to the blade rotation plane, the flange forming a stop for restricting the overrotation of the blades beyond the first or second positions. 
     
     
         5 . The damper system of  claim 1 , wherein the display comprises a plurality of LEDs for providing a continuous sequence of indicia providing an indication of the position of the damper relative to the first and/or second positions. 
     
     
         6 . The damper system of  claim 5 , wherein the indicia further provide an indication of the direction of rotation of the damper. 
     
     
         7 . A damper system for controlling airflow through a plenum, comprising:
 a damper within the plenum, the damper continuously rotatable between a first position permitting maximum airflow and a second position restricting airflow to a minimum;   a motor for rotating the damper between the first and second positions: and   a controller for operating the motor, the controller having a display providing a continuous indication of the position and direction of rotation of the damper relative to the first and/or second positions.   
     
     
         8 . The damper system of  claim 7 , wherein the display comprises a plurality of LEDs for providing a continuous sequence of indicia, each indicia providing an indication of the position of the damper relative to the first and/or second positions. 
     
     
         9 . The damper system of  claim 8 , wherein the controller further comprises a microprocessor for determining the position of the damper and for directing the display to provide an indication of the position of the damper relative to the first and/or second positions. 
     
     
         10 . The damper system of  claim 9 , wherein the motor rotates the damper at a constant speed and the microprocessor determines the position of the damper based on the time of rotation from the first or second position. 
     
     
         11 . The damper system of  claim 1 , wherein the damper is a rotary damper comprising a plurality of blades that rotate relative to each other about a common axis, the rotation of the blades defining a blade rotation plane, and at least one blade having an edge with a flange projecting orthogonal to the blade rotation plane, the flange forming a stop for restricting the overrotation of the blades beyond the first or second positions. 
     
     
         12 . A damper system for controlling airflow through a plenum, comprising:
 a damper within the plenum, the damper rotatable between a first position permitting maximum airflow and a second position restricting airflow through the plenum; and   a gear system positioned at the plenum, comprising:
 a drive shaft; 
 a worm gear; 
 a first coupling for removable securing the drive shaft to the worm gear, the first coupling integral to the worm gear; 
 a planetary shaft for controlling the rotation of the damper between the first and second positions; 
 a planetary gear in rotational engagement with the worm gear, the planetary shaft removably secured to the planetary gear; 
 a second coupling for removable securing the planetary shaft to the planetary gear; 
   a motor connected with and configured to rotate the drive shaft; and   a controller for operating the motor, the controller having a display for providing a continuous indication of the position of the damper relative to the first and/or second positions.   
     
     
         13 . The damper system of  claim 12 , wherein the controller further comprises a microprocessor for determining the position of the damper and for directing the display to provide an indication of the position of the damper relative to the first and/or second positions. 
     
     
         14 . The damper system of  claim 13 , wherein the motor rotates the drive shaft at a constant speed, the worm gear and planetary gear have a known gear ratio, and the microprocessor determines the position of the damper based on the time of rotation from the first or second position. 
     
     
         15 . The damper system of  claim 12 , wherein the display comprises a plurality of LEDs for providing a continuous sequence of indicia corresponding to the position of the damper relative to the first and/or second positions. 
     
     
         16 . The damper system of  claim 15 , wherein each indicia further provides an indication of the direction of rotation of the damper. 
     
     
         17 . The damper system of  claim 12 , wherein the a first coupling comprises:
 a first set screw;   a first bore for receiving the first set screw; and   an first opening for receiving the drive shaft; and   wherein the drive shaft is removably secured within the first opening by the first set screw.   
     
     
         18 . The system of  claim 17 , wherein the second coupling comprises:
 a second set screw;   a second bore for receiving the second set screw; and   a second opening for receiving the planetary shaft; and   wherein the planetary shaft is removably secured within the second opening by the second set screw.