Patent Grant
10801747
The present disclosure relates to the field of heating ventilation and air conditioning (HVAC) systems; particularly, a next generation integrated, adaptive, and modular HVAC system for improved energy efficiency, performance, comfort and air quality, and sustainability incorporating feedback control automation and mobile connectivity.
An HVAC system is the primary platform for providing steady-state thermal comfort and acceptable indoor air quality (IAQ) in residential homes and commercial structures. HVAC systems are well known in the prior art, and function to selectively circulate conditioned air throughout a home or structure according to feedback from a thermostat. When engaged in a cooling mode, a conventional HVAC unit passes air typically over a single cooling evaporator coil and discharges conditioned air throughout the structure via ductwork until a desired temperature is reached. Flowing air over the cooling coil also functions to dehumidify the passing air. The dehumidification effectiveness of an HVAC system is commonly characterized by the sensible heat ratio (SHR), which is the ratio of sensible cooling capacity to the total (sensible plus latent (water vapor)) cooling capacity. Reducing the SHR increases the portion of the total cooling capacity for providing dehumidification. In practice, most residential air conditioners are designed to cycle on and off in response to the cooling required by the occupants. When the temperature of the air in the structure reaches a desired temperature on the thermostat, the unit shuts down until cool air is needed again. However, smart thermostats have been introduced to improve the process with the aim to enhance energy efficiency.
With the rising cost of energy, many homeowners appreciate the benefits of owning an energy efficient home and appliances. An emphasis on energy efficiency can be found in every aspect of the home environment. The addition of energy-efficient windows and insulation to a home have decreased greatly the heating and cooling loads. Retrofit measures and new construction practices are growing to achieve lower infiltration levels under increasingly tighter envelopes. Current best practice strives to make homes as airtight as possible using methods such as controlled ventilation, mechanical systems, and energy recovering ventilation (ERV). Air sealing and air-tight construction have been proven to be able to provide substantial energy reductions often at the cost of low airflow and ventilation. A key barrier to implementation of these approaches is the potential impact on IAQ. Residential IAQ can be adversely affected by volatile organic compounds (VOCs) that are emitted by various sources in homes. Mechanical ventilation can provide acceptable IAQ but at an energy cost. Pollutant source control, active ventilation via sensor diagnostics (e.g., monitoring CO2 levels), and ERVs are methods implemented to reduce the associated ventilation energy and cost penalty for a home. However, the potential benefits of air sealing and the costs of ventilation vary widely: across individual homes; sub-populations by climate; baseline air-tightness and structural characteristics; the performance characteristics of existing or replacement HVAC equipment; and the occupant-influenced appliance operational schedules and settings.
In hot and humid climates, the use of air conditioning systems account for a significant amount (approximately 10%) of the total energy consumed in the residential sector. Numerous attempts have been made in the prior art to improve the energy efficiency of HVAC systems. Over the years, HVAC units have become more efficient to meet the requirements of an efficiency standards agreement signed by leading manufacturers and advocacy organizations (e.g., AHRI, ACEEE, Alliance, NRDC, NEEP, ASAP, CEC) to established new federal standards. Under the agreement, the U.S. is divided into three regions defined by population-weighted heating degree days (HDD) equal or greater than 5000. The agreement allows the US Department of Energy (DOE) to use more than one efficient metric for a product. Common air conditioning performance metrics include the energy efficiency ratio (EER), sensible heat ratio-factor (SHR), and the Seasonal Energy Efficient Ratio (SEER). The EER is a simple metric that represents the ratio between BTU per output in cooling and the input power that can be used to compare approximate energy usage between systems. EER has two main inputs: output cooling energy (in Btu/hr.) and; the input electrical energy (in Watts), as measured at 95° F. outdoor (and 80° F. dry-bulb, 67° F. wet-bulb indoor temperatures). The SEER is a seasonal adjustment applied to EER agreed by manufacturers of residential split units and the higher the number the more efficient the unit rating or ranking. System efficiency (SEER) has two important inputs: steady state efficiency (EERB), as measured at the DOE “B” conditions (82° F. outdoor) and; the cyclic degradation factor (Cd) as calculated from the DOE “C and D” tests. SEER is calculated using the following formula: SEER=EERB*(1−Cd/2).
The energy federal standards have set the minimum residential air conditioner (AC) unit requirements to at least SEER 13. However, the new agreement has raised the bar, for example, with central air conditioners in the South regions required to have a SEER of 14. System redesigns are underway to address these efficiency standards. These include the incorporation of advanced variable-speed (VS) (i.e., inverter) compressor technology within condensing units in air conditioners and heat pumps. Inverter allows for varying the compressor rotation frequency to change flow rate at constant compression ratio and, therefore, at constant volumetric and isentropic efficiencies. However, inverters still contribute to energy loss due to the required voltage-current conversions for operation. The availability of VS systems has also lead to discrepancies with the system ranking between constant speed and variable speed systems when using cyclic testing to determine accurately the EER and SEER metrics for sensible capacity. It has been determined that the cyclic performances of the different systems at wet and dry single coil conditions are not equivalent. The EER ratio at dry coil conditions are higher than at wet coil conditions for both systems. Subsequently, the SEER based on the wet coil cyclic test is lower than the SEER based on the dry coil cyclic test, effecting the relative ranking among the two systems (Henderson, H. I., “An Experimental Investigation of the Effects of Wet and Dry Coil Conditions on Cyclic Performance in the SEER Procedure” (1990). International Refrigeration and Air Conditioning Conference. Paper 83.). This is a conundrum facing the industry under the constraint of using a single set of cooling coil with a single source of constant airflow.
The evaporator coil plays an important role in the reliability and performance of a conventional split system residential AC system. The performance is highly dependent on the optimal air flow rate across the evaporator coil, affecting both the sensible and latent cooling capacities, to achieve a balance between sensible heat transfer and moisture removal, ultimately impacting the overall system efficiency. Excessive coil air flow requires or draws more fan power from the blower and can compromise air moisture removal or dehumidification. As such, the amount of airflow moving across the indoor coil is critical for dehumidification. However, if flow is too low, cooling is reduced resulting in a degradation of cooling system EER. Very low air flow may lead to evaporator coil icing, “freeze up,” refrigerant flood back, compressor failure, structure interior mold issues, and ultimately IAQ. Air flow bypasses, dampers, air filters, and air purifiers have been implemented in various configurations to address some of these issues.
HVAC consumers desire both low energy costs and improved moisture removal in the conditioned space that meet the regional efficiency standards. As homes become more energy efficient, the latent load (water vapor) can be a large fraction of the total cooling load, especially with the introduction of high ventilation rates to address IAQ. The challenge for meeting the needs of energy efficient homes is to address both sensible and latent loads efficiently and effectively by controlling and optimizing the total airflow within a residential home or commercial structure under the constraints of variable physical characteristics (e.g., size, number of ducts, etc.), HVAC equipment sizes, disparate HVAC system components, component matching requirements, disparate operating fans, dampers, inverters, ventilators, and ERVs.
The overall performance of an AC system depends strongly on the entire system as well as the performance of its individual and currently disparate components (e.g., evaporator coil, compressor, fans, etc.). The proper matching of the outdoor condensing unit to the indoor components is necessary to ensure that the complete system delivers on performances and value. Conventional AC systems are sized to meet peak cooling events and therefore are substantially oversized for most time of the year. Oversizing AC equipment increases the amount of time spend at part load and results in high space humidity levels. The customer requirements can be addressed by sizing the proper equipment to produce suitably long duty cycle run-times for effective moisture removal, choice of equipment with low SHR and proper evaporator air flow to produce the rated efficiency. Continuous fan operation is also becoming prevalent for residential applications for a variety of reasons including air filtration and new recommendations for whole-building ventilation. Proper duct design to reduce system static pressure can reduce fan speed energy and improve overall system EER. In a typical residence, fixed capacity AC system, avoiding oversizing, can generally provide good relative humidity (RH) control. However, in low-load homes, these systems may be less effective in achieving a desired RH. In addition, very low loads can lead to inadequate airflow affecting IAQ and potentially the health of occupants.
Therefore, the need exists for a next generation integrated and modular HVAC system, having the flexibility from interchangeable and modular components (e.g., coil, damper, etc.), that enables the modulation of the total capacity (sensible plus latent) to meet variable loads and to adjust SHR to meet a variable latent ratio of a conditioned space. The system should be able to modulate airflow in response to a RH-set point, adjusting airflow to achieve low SHR values, and ideally have a low impact on IAQ.
Through applied effort, ingenuity, and innovation, Applicant has identified deficiencies and problems with existing HVAC systems that are constrained by complexity, factors, and limitations such as size, fixed capacity, single coil, fixed airflow, power source and requirements, voltage-current conversion for inverters and fans, and the need to mix and match disparate components, leading to energy inefficiency. Applicant has developed a solution that is embodied by the present invention, which is described in detail below.
The following presents a simplified summary of some embodiments of the invention to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising one or more air inlet, inlet damper, air filtration module, air purification module, air freshener module, dehumidifying coil, dehumidifying coil damper, cooling coil, coil damper, bypass air damper, blower module, air outlet, and a control cabinet. In various embodiments, the dehumidifying coil, dehumidifying coil damper, cooling coil, coil damper, and bypass air damper operate independently. In various embodiments, the said dehumidifying coil and dehumidifying coil damper are contained and operate together within an insertable-removable module (“dehumidifying”), the said cooling coil and coil damper are contained and operate together within an insertable-removable module (“cooling”), and the bypass air damper is contained and operate within an insertable-removable module (“bypass air damper”). The individual modules are insertable-removable into and out of one or more designated slot, rack, space, location, or the like within the modular HVAC unit. The individual modules can be serially connected to one another or may be arranged to function in parallel to facilitate airflow, into, through, within, or out of their inlet or outlet port, structure, or the like, dependent on their individual function. The components are configured to operate as an inter-connected modular system enabling the modulation of the total cooling capacity (sensible plus latent) to meet variable loads and to adjust SHR to meet a variable latent ratio of a conditioned space. In a preferred embodiment, the system modulates the total airflow in response to a relative humidity (RH)-set point of said conditioned space. In another preferred embodiment, the system enables the adjustment of airflow to achieve low sensible heat ratio (SHR) values of said condition space. In various embodiments, the said modules are exchangeable to meet a desired airflow capacity requirement or enable performance matching with one or more internal or external compressor, inverter, condenser, valve, thermostatic valve, electronic expansion valve, fan, pump, or the like components of an AC thermodynamic circuit. In various embodiments, the said modules contain sensors and actuators to enable feedback control by one or more system logic controller. In various embodiments, the modular HVAC unit operates under a programmable master controller allowing a user to determine a chosen RH set-point, airflow, temperature, or the like, of a conditioned space.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising an outside air inlet having an air inlet damper operating in conjunction with one or more adaptive or interchangeable components to maintain an appropriate calculated airflow through a conditioned space while controlling the airflow over one or more coil within said dehumidification module or said cooling module, or combination thereof, to achieve an optimal sensible BTU rate for energy efficiency. The adaptive or interchangeable components include, but not limited to one or more said, air filtration module, air purification module, air freshener module, dehumidifying module, cooling module, bypass air damper module, blower module, air outlet. In various embodiments, the air inlet damper comprises sensors and actuators to enable feedback control by a system logic controller.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising a return air inlet operating in conjunction with one or more adaptive or interchangeable components to maintain an appropriate calculated airflow through the conditioned space while controlling the airflow over one or more cooling coil within said dehumidification module and said cooling module, to achieve an optimal sensible BTU rate for energy efficiency. The adaptive or interchangeable components include, but not limited to one or more said, air filtration module, air purification module, air freshener dispensing module, dehumidifying module, cooling module, bypass air damper module, blower module, air outlet.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising an air filtration unit operating in conjunction with one or more adaptive or interchangeable components. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air purification module, air freshener module, dehumidifying module, cooling module, bypass air damper module, blower module. In various embodiments, the air filtration module comprises a passive filter unit, mechanical filter, polymeric filter, an active filter unit, an active filter unit having sensor and actuators to enable feedback control by a system controller, the like, or combinations thereof. In various embodiments, the filtration module filters the air flowing into, within, through, or air exiting the HVAC system of infiltrates, VOCs, noxious gas, radon, carbon monoxide, carbon dioxide, particles, pathogens, bacteria, mold, fungi, virus, or the like.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising an air purification module operating in conjunction with one or more adaptive or interchangeable components. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air filtration module, air freshener module, dehumidifying module, cooling module, bypass air damper module, blower module, air outlet. In various embodiments, the air purification module comprises a passive purification unit, an active purification unit, an active purification unit having sensors and actuators to enable feedback control by a system controller, or combinations thereof. In various embodiment, the active purification unit contains emitters capable of emitting non-ionizing or ionizing radiation, electromagnetic radiation, ultrasound, chemical, sono-chemical, gas, mists, photo-ionizing radiation, the like, or combinations thereof, to disinfect the air flowing into, within, through, or air exiting the HVAC unit. In various embodiments, the emitters contain sensors and actuators to enable feedback control by a system controller. In various embodiments, the purification unit neutralizes or cleans the said air of infiltrates, VOCs, noxious gas, radon, carbon monoxide, carbon dioxide, pathogens, bacteria, mold, fungi, virus, or the like.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising an air freshener module operating in conjunction with one or more adaptive or interchangeable components. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air filtration module, air purification module, dehumidifying module, cooling module, bypass air damper module, blower module, air outlet. In various embodiments, the air freshener module comprises a passive scent unit, a replaceable scent cartridge, an active scent dispensing unit, an active scent dispensing unit having sensors and actuators (e.g., gas cylinder, propellant) to enable feedback control by a system controller, or combinations thereof. In various embodiment, the active air freshener unit dispenses one or more scents, from one or more, scent source, replaceable scent cartridge, into the air flowing into, within, through, or air exiting the HVAC unit. In various embodiments, the scent source and propelling unit contain sensors and actuators to enable feedback control by a system controller. In various embodiments, the air freshening unit affects the said air, air odor, or the like, to improve IAQ.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising a dehumidification module operating in conjunction with one or more adaptive or interchangeable components to change or maintain humidity (RH) in the conditioned space at a desired level. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air filtration module, air freshener module, cooling module, bypass air damper module, blower module, air outlet. In various embodiments, the dehumidification module contains sensors (e.g., temperature, pressure, humidity, position, etc.) and actuators (e.g., motors) to enable feedback control by a local logic controller, a programmable master system controller, or the like. In various embodiments, the said modules are exchangeable to meet a desired airflow capacity requirement or enable performance matching with one or more internal or external compressor, inverter, condenser, valve, thermostatic valve, electronic expansion valve, fan, pump, heat pump, or the like components of an AC thermodynamic circuit. In various embodiment, the dehumidifying coil and damper operate together under feedback control enabling variable damper position, angle, rotation, to control volumetric airflow over the dehumidification coil.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising a cooling module, functioning to modulate the temperature of the airflow, operating in conjunction with one or more adaptive or interchangeable components to establish a specified total cooling capacity (sensible plus latent) to meet variable loads, or to adjust SHR to meet a variable latent ratio, or change or maintain humidity (RH) of a conditioned space. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air filtration module, air freshener module, dehumidification module, bypass air damper module, blower module, air outlet. In various embodiments, the cooling module contains sensors (e.g., temperature, pressure, humidity, position, etc.) and actuators (e.g., motors) to enable feedback control by a local logic controller, a programmable master system controller, or the like. In various embodiments, the said modules are exchangeable to meet a desired airflow capacity requirement or enable performance matching with one or more internal or external compressor, inverter, condenser, valve, thermostatic valve, electronic expansion valve, fan, pump, or the like components of an AC thermodynamic circuit. In various embodiment, the cooling coil and damper operate together under feedback control enabling variable damper position, angle, rotation, to control volumetric airflow over the cooling coil.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising a bypass air damper module, functioning to modulate the temperature of the airflow, operating in conjunction with one or more adaptive or interchangeable components to establish a specified total cooling capacity (sensible plus latent) to meet variable loads, or to adjust SHR to meet a variable latent ratio, or change or maintain humidity (RH) of a conditioned space. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air filtration module, air freshener module, dehumidification module, cooling module, blower module, air outlet. In various embodiments, the said modules are exchangeable to meet a desired airflow capacity requirement or enable performance matching with one or more internal or external compressor, inverter, condenser, valve, thermostatic valve, electronic expansion valve, fan, pump, or the like components of an AC thermodynamic circuit. In various embodiments, the cooling module contains sensors (e.g., temperature, pressure, humidity, position, etc.) and actuators (e.g., motors) to enable feedback control by a local logic controller, a programmable master system controller, or the like. In various embodiment, the cooling coil and damper operate together under feedback control enabling variable damper position, angle, rotation, to control volumetric airflow within the HVAC unit.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising air blower module operating in conjunction with one or more adaptive or interchangeable components of said modular HVAC system. The adaptive or interchangeable components include, but not limited to one or more said, outside air inlet, outside air inlet damper, return air inlet, air filtration module, air freshener module, dehumidification module, cooling module, air outlet. In various embodiments, the blower module contains sensors (e.g., temperature, pressure, humidity, position, etc.) and actuators (e.g., motors) to enable feedback control by a local logic controller, a programmable master system controller, or the like. In various embodiments, the said module is exchangeable to meet a desired airflow capacity requirement or enable performance matching with one or more internal or external compressor, inverter, condenser, valve, thermostatic valve, electronic expansion valve, fan, pump, or the like components of an AC thermodynamic circuit. In various embodiment, the blower module and one or more said adaptive or interchangeable components operate together under feedback control enabling variable operation, to control volumetric airflow from within the modular HVAC unit through the air outlet of the unit into the conditioned space.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising an access panel, located at a defined interior portion of a wall of the unit, containing one or more I/O interfaces (e.g., male/female plugs, other plugs, etc.), including but not limited to, a water inlet, water discharge, refrigerant inlet/out lines, and power input. The I/O interface panel is accessible from the exterior of the unit through a hinged articulating hatch door. The I/O interface enables the required connections to complete a HVAC circuit for water and refrigerant and power for operating one or more said adaptive or interchangeable components, modules, or sub-unit, sensor, actuator, damper, blower, or the like.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system comprising electronic hardware to enable the system, said adaptive or interchangeable components, modules, or sub-unit, sensor, actuator (e.g., motor), damper, blower, or the like, to operate under variable speed drive (VSD), whereby the speed of one or more actuator or motor is regulated to match its speed with a related or total conditioned space load requirement via a VSD system. In various embodiments, the said VSD system comprises one or more said motor operating under direct current (DC) from power supply sources including but not limited to HVDC, photo-voltaic, solar panels, batteries, or the like. In various embodiments, the said HVAC system incorporates analog or digital circuits to enable variable speed, linear or rotation, operation of actuators, motors, or inverters with the goal to enhance energy efficiency.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system having a control cabinet comprising an electronic control system. The electronic control system comprises hardware and software components configured to enable feedback control, as a master programmable controller, one or more motorized damper, coil, module, air filtration module, a purification module, dehumidification module, cooling module, bypass air damper module, and blower, external or internal compressor, inverter, valve, thermostatic valve, electronic expansion valve, or the like, using one or more sensor and actuator. In various embodiments, the electronic control system controls the operation of external components (e.g., inverter, compressor, valve, etc.) in conjunction with the components the modular HVAC system. In various embodiments, the feedback control logic or methods employed include, but not limited to, classic, modern, and intelligent methods. In various embodiments, the classic methods include on-off, proportional-integral (PI), proportional-integral-derivative (PDI), or the like. In various embodiments, the classic methods include adaptive and optimal, or the like. In various embodiments, the intelligent methods include fuzzy logic and neural network, or the like. In various embodiments, the method is a stochastic optimal control method or the like. In various embodiments, the method is a nonlinear and adaptive control method or the like. In various embodiments, the method is a modern MIMO (multiple input-multiple output) control method. In a preferred embodiment, the electronic control system enables the modulation of the total cooling capacity (sensible plus latent) to meet variable loads and to adjust SHR to meet a variable latent ratio of a conditioned space. In another preferred embodiment, the electronic system modulates the total airflow in response to a relative humidity (RH)-set point of said conditioned space. In yet another preferred embodiment, the system enables the adjustment of airflow to achieve low sensible heat ratio (SHR) values of said condition space.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system having a control cabinet comprising an electronic control system. The electronic control system comprises hardware and software components configured to enable diagnostic feedback from one or more motorized damper, coil, module, air filtration module, air purification module, air freshener module, dehumidification module, cooling module, bypass air damper module, and blower module, external or internal compressor, inverter, valve, thermostatic valve, electronic expansion valve, or the like, using one or more diagnostic sensor. In various embodiments, the electronic control system enables the monitoring of one or more said device to determine operating parameters, set operating parameter, configure functions, for trouble-shooting, setting alerts, determine operating efficiency, tuning, or the like.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system having a control cabinet comprising an electronic control system comprising an electronic data communication module. The communication module contains one or more electronic components, including a wireless transceiver, to enable the transmission or reception of data from an internal or external/remote controller; sensor, actuator, compressor, pump, valve, thermostatic valve, electronic expansion valve, inverter, fan, blower, a remote thermostat, computer, laptop, computing mobile device, mobile phone, cloud server, or the like.
An object of the present disclosure is a self-contained, integrated, and modular HVAC system with a control system that accepts on or more input relating to the environment settings of a condition space from an external, remote, or wireless controller. The said controller may include but not limited to a, thermostat, smart thermostat, a smart environment controller, hand-held controller, computing device, computer, laptop, computing mobile device, mobile phone, smart mobile phone, cloud server, or the like. In various embodiments, the controller provide computing memory storable options for configuring the conditioned space with the non-limiting following parameters: temperature, humidity (RH), airflow, operation schedule (e.g., time of the day, duration of operation), efficiency setting, scent-type, scent cartridge, filtration unit operation schedule, purification unit operation schedule, system diagnostic parameters, component information (e.g., brand, manufacturer, operational parameters, etc.), or the like. In various embodiments, the inputs for the environment settings may be sent to the HVAC control system using a computing application software. In various embodiment, the application software may execute its instructions on a computing system, a computing device, computer, laptop, computing mobile device, mobile phone, smart mobile phone, mobile app, cloud server, or the like. In various embodiments, the said control system may communicate and function with external environment management control system.
Specific embodiments of the present disclosure provide for an adaptive modular HVAC system comprising a housing having a first compartment, a second compartment, and an interface extending between the first compartment and the second compartment, the first compartment defining a return air plenum and the second compartment defining a supply air plenum; a cooling module removably coupled to a first portion of the interface, the cooling module defining a first airflow path, the cooling module having a first cooling coil and a first motorized damper; a dehumidification module removably coupled to a second portion of the interface, the dehumidification module defining a second airflow path, the dehumidification module having a second cooling coil and a second motorized damper; an airflow bypass module removably coupled to a third portion of the interface, the airflow bypass module defining a third airflow path, the airflow bypass module having a third motorized damper; and, a blower coupled to an upper portion of the second compartment of the housing.
Further specific embodiments of the present disclosure provide for an adaptive modular HVAC system comprising a housing having a first compartment, a second compartment, and an interface extending between the first compartment and the second compartment, the first compartment defining a return air plenum and the second compartment defining a supply air plenum; a cooling module removably coupled to a first portion of the interface, the cooling module defining a first airflow path, the cooling module having a first cooling coil and a first motorized damper; a dehumidification module removably coupled to a second portion of the interface, the dehumidification module defining a second airflow path, the dehumidification module having a second cooling coil and a second motorized damper; an airflow bypass module removably coupled to a third portion of the interface, the airflow bypass module defining a third airflow path, the airflow bypass module having a third motorized damper; and, a blower coupled to an upper portion of the second compartment of the housing, the blower comprising a variable speed drive, the variable speed drive comprising an electric motor, a power inverter, and a controller, the controller being configured to dynamically regulate an electrical current to the electric motor.
Still further specific embodiments of the present disclosure provide for an adaptive modular HVAC system comprising a housing having a first compartment, a second compartment, and an interface extending between the first compartment and the second compartment, the first compartment defining a return air plenum and the second compartment defining a supply air plenum; a cooling module removably coupled to a first portion of the interface, the cooling module defining a first airflow path, the cooling module having a first cooling coil and a first motorized damper; a dehumidification module removably coupled to a second portion of the interface, the dehumidification module defining a second airflow path, the dehumidification module having a second cooling coil and a second motorized damper; an airflow bypass module removably coupled to a third portion of the interface, the airflow bypass module defining a third airflow path, the airflow bypass module having a third motorized damper; a blower coupled to an upper portion of the second compartment of the housing, the blower comprising a first variable speed drive, the first variable speed drive being configured to dynamically regulate an electrical current to the electric motor; a compressor unit operably engaged with the first cooling coil and the second cooling coil, the compressor unit comprising a compressor, a condenser, a second variable speed drive, and a thermal expansion valve, the second variable speed drive being configured to dynamically regulate an electrical current to the compressor; a plurality of sensors comprising at least one temperature sensor and at least one humidity sensor; and, a controller, the controller being operably engaged with the first motorized damper, the second motorized damper, the third motorized damper, and the blower, and being configured to receive a data input from the plurality of sensors, the controller being comprised of one or more processors, and a non-transitory computer readable medium having stored thereon a set of instructions being programmable by a user and executable by the at least one of the one or more processors, to cause the at least one of the one or more processors to perform one or more operations, the set of instructions comprising instructions for modulating the position of the first motorized damper in response to a data input from the temperature sensor; instructions for modulating the position of the second motorized damper in response to a data input from the humidity sensor; instructions for modulating the position of the third motorized damper in response to a data input from the temperature sensor and humidity sensor; and, instructions for dynamically regulating the first variable speed drive and the second variable speed drive.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention so that the detailed description of the invention that follows may be better understood and so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific methods and structures may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should be realized by those skilled in the art that such equivalent structures do not depart from the spirit and scope of the invention as set forth in the appended claims.
The above and other objects, features, and advantages of the present disclosure will be more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
Exemplary embodiments are described herein to provide a detailed description of the present disclosure. Variations of these embodiments will be apparent to those of skill in the art. Moreover, certain terminology is used in the following description for convenience only and is not limiting. For example, the words “right,” “left,” “top,” “bottom,” “upper,” “lower,” “inner” and “outer” designate directions in the drawings to which reference is made. The word “a” is defined to mean “at least one.” The terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import.
Embodiments of the present disclosure provide for a next generation, integrated, and modular HVAC system. Embodiments of the present disclosure solve problems associated with prior art HVAC systems that enable the modulation of the total capacity (sensible plus latent) to meet variable loads and to adjust SHR to meet a variable latent ratio of a conditioned space, including: complexity, factors, and limitations such as size, fixed volume capacity, single coil, fixed airflow, power source and requirements, voltage-current conversion for inverters and fans, and the need to mix and match disparate components from various manufacturers, leading to energy inefficiency. In addition, in low-load conditioned spaces, the prior art systems may be less effective in achieving a desired RH. These very low load settings can lead to inadequate airflow with a conditioned space affecting IAQ and potentially the health of occupants.
According to various embodiments of the present disclosure, the complexity, factors and limitations of prior art HVAC systems are solved with a self-contained, integrated, and modular HVAC system comprising one or more air inlet, inlet damper, air filtration module, air purification module, air freshener module, dehumidifying coil, dehumidifying coil damper, cooling coil, coil damper, bypass air damper, blower module, air outlet, and a control cabinet. In an embodiment, the dehumidifying coil, dehumidifying coil damper, cooling coil, coil damper, and bypass air damper operate independently. In an embodiment, the said dehumidifying coil and dehumidifying coil damper are contained and operate together within an insertable-removable module (“dehumidifying”), the said cooling coil and coil damper are contained and operate together within an insertable-removable module (“cooling”), and the bypass air damper is contained and operate within an insertable-removable module (“bypass air damper”). The individual modules are insertable-removable (e.g., swappable, plug-and-play, etc.) into and out of one or more designated slot, rack, chassis, space, location, or the like within the modular HVAC unit. The individual modules can be serially connected to one another or may be arranged to function in parallel to facilitate airflow, into, through, within, or out of their inlet or outlet port, structure, or the like, dependent on their individual function. The components are configured to operate as an inter-connected modular system enabling the modulation of the total cooling capacity (sensible plus latent) to meet variable loads and to adjust SHR to meet a variable latent ratio of a conditioned space. In a preferred embodiment, the system modulates the total airflow in response to a relative humidity (RH)-set point of said conditioned space. In another preferred embodiment, the system enables the adjustment of airflow to achieve low sensible heat ratio (SHR) values of said condition space. In an embodiment, the said modules are exchangeable to meet a desired airflow capacity requirement or enable performance matching with one or more internal or external compressor, inverter, condenser, valve, thermostatic valve, electronic expansion valve, fan, pump, heat pump, or the like components of an AC thermodynamic circuit. In various embodiments, the said modules contain sensors and actuators to enable feedback control by one or more system logic controller. In another embodiment, the modular HVAC unit operates under a programmable master controller allowing a user to determine a chosen RH set-point, airflow, temperature, or the like, of a condition space.
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In various embodiments, the output of HVAC unit 102 may operate in conjunction on or more external compressor unit or conventional water heater. Referring now to
In various embodiments, the coils of said dehumidifying and cooling modules comprises non-limiting characteristics, designs, and dimensions. These non-limiting characteristics, designs, and dimensions include: Face Area (Ft2/Ton), Fin Density (Fin/Inch), number of tube rows, inner tube surface, and Fin Type. In various embodiments, the Face Area can be in the range of 0.75 to 1.0, 1.3 to 1.8, or 1.4 to 1.9, or 1.4 to 3.0. In various embodiments, the Fin Density can be in the range of 10-12, 14-16, or 12-17. In various embodiments, the number of tube rows can be 2, 3, or 2 and 3. In various embodiments, the inner tube surface can be smooth or grooved. In various embodiments, the fin type can be corrugated, flat, or lanced. In various embodiments, the coil operates in conjunction with one or more expansion devices, including but not limited to, capillary tube, piston, or thermal expansion valves (TXV), or the like. In a preferred embodiment, TXV provides variable refrigerant metering, enhances system cyclic performance, improves refrigerant control, limits off-cycle refrigerant migration to the compressor, consistent flow of superheated refrigerant back to the external compressor throughout various operating conditions.
An object of the present disclosure is a self-contained, integrated, and modular HVAC unit 102 comprising electronic hardware to enable the system, said adaptive or interchangeable components, modules, or sub-unit, sensor, actuator (e.g., motor), damper, blower, or the like, to operate under variable speed drive (VSD), whereby the speed of one or more actuator or motor is regulated to match its speed with a related or total conditioned space load requirement. In conventional AC systems, most motors operate only at full speed 100% for short periods of time. This frequently results in many AC systems operating inefficiently during long periods of time. Therefore, there are significant energy losses during the operation time. According to affinity laws, for pumps, fans, and compressors, the relationship between speed and power is such that a 10% reduction in speed generally results in 30% reduction in power. In a preferred embodiment, HVAC unit 102 comprises one or more VSDs to improve productivity and increase energy efficiency. Referring to
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In various embodiments, the control logic may be configured using hardware electronic components. In one embodiment, the control logic may be configured as a set of instructions executable by the at least one of the one or more processors and stored using a non-transitory computer readable medium. The feedback control logic or methods employed by controller 702 include, but not limited to, classic, modern, and intelligent methods. In various embodiments, the classic methods include on-off, proportional-integral (PI), proportional-integral-derivative (PDI), or the like. In various embodiments, the classic methods include adaptive and optimal, or the like. In various embodiments, the intelligent methods include fuzzy logic and neural network, or the like. In various embodiments, the method is a stochastic optimal control method or the like. In various embodiments, the method is a nonlinear and adaptive control method or the like. In various embodiments, the method is a modern MIMO (multiple input-multiple output) control method or the like. In a preferred embodiment, the electronic controller 702 enables the modulation of the total cooling capacity (sensible plus latent) to meet variable loads and to adjust SHR to meet a variable latent ratio of a conditioned space. In another preferred embodiment, the electronic controller 702 enables HVAC unit 120 to modulates the total airflow in response to a relative humidity (RH)-set point of said conditioned space. In yet another preferred embodiment, the control system enables the adjustment of airflow to achieve low sensible heat ratio (SHR) values of said condition space.
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In various embodiments, the master controller 702 comprises hardware and software components configured to enable diagnostic feedback from motorized damper 704, air filtration module 708, air purification module 710, air freshener module 712, dehumidification module 714, cooling module 716, bypass air damper module 718, and blower module 720, internal or external compressor 728, electronic expansion valve 730, or the like, using one or more diagnostic sensor. In various embodiments, the electronic controller 602 enables the monitoring of one or more said device to determine operating parameters, set operating parameter, configure functions, for trouble-shooting, setting alerts, determine operating efficiency, tuning, or the like.
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The present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its exemplary forms with a certain degree of particularity, it is understood that the present disclosure of has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be employed without departing from the spirit and scope of the invention. The terms and expressions which have been employed in the foregoing description are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions to exclude equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
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| Number | Date | Country | |
|---|---|---|---|
| 20200056804 A1 | Feb 2020 | US |
