Patent Application
20220074618
This disclosure relates generally to control systems, and, more particularly, to an HVAC control circuit having a connector that allows a separate module, such as a communication module, to be communicatively coupled to the HVAC control circuit.
HVAC systems typically include a system controller that controls operation of components of the system. At least some such controllers include a communication interface to allow the controller to be connected to a remote device, such as a smart phone, a tablet computer, a laptop computer, a desktop computer, or the like. These communication interfaces may include phone setups, universal serial bus (USB), near field communication (NFC), Bluetooth low energy (BLE), or other communication interfaces. These communication interfaces include circuitry that may occupy a significant amount of space on the system controller's circuit board. Furthermore, the system controllers typically include only one of these interfaces, and inclusion of more than one such communication interface occupies additional space of the system controller's circuit board. Because different equipment manufacturers and system installers may have different preferences for the type of communication interface (if any) desired, HVAC system controllers may need to produce several variations of the same system controller, each with a different type of communication interface (or no interface at all). Furthermore, the communication interface may be used in a limited number of circumstances, such as for initial configuration of the HVAC system, and may not be needed afterwards. Thus, the communication interfaces may occupy space on the circuit board and increase the cost of the system controller, while only being needed for a limited period of time.
This background section is intended to introduce the reader to various aspects of art that may be related to the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
In one aspect, an HVAC system includes at least one HVAC component, an HVAC controller, and a communication module. The HVAC controller is configured to control the at least one HVAC component according to the HVAC configuration parameters. The HVAC controller includes a first substrate, a processor mounted on the first substrate, a memory mounted on the first substrate and in communication with the processor, a control interface mounted on the first substrate and communicatively coupled to the processor and the at least one HVAC component, and a first communication interface mounted on the first substrate and communicatively coupled to the processor. The communication module connects the HVAC controller to a remote device controls the HVAC component. The communication module includes a second substrate, a communication circuit mounted on the second substrate, and a second communication interface mounted on the second substrate and communicatively coupled to the communication circuit. The second communication interface is removably connected to the HVAC controller's first communication interface to communicatively connect the communication module to the HVAC controller's processor to allow the processor to communicate with the remote device through the communication module.
In another aspect, an HVAC controller includes, a substrate, a processor mounted on the substrate, a memory mounted on the substrate and in communication with the processor, a control interface mounted on the substrate and communicatively coupled to the processor and the at least one HVAC component, and a communication interface mounted on the substrate and communicatively coupled to the processor. The communication interface is configured for connecting to a mating connector of a communication module in order to communicate with a remote device.
In yet another aspect, a method of configuring an HVAC controller includes, removably connecting a communication module to the HVAC controller by connecting a mating connector of the communication module to the HVAC controller's communication interface, communicatively connecting a remote device to the HVAC controller through the communication module, and storing one or more configuration parameters for the HVAC system from the remote device to the HVAC controller's memory through the communication module.
Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.
Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
Embodiments of this disclosure will be described with reference to an example heat exchange system for convenience and without limitation to the specific system. The controllers, methods, and systems may be used in any suitable HVAC system.
Referring to
Refrigerant is circulated through the system 100 by the compressor 108. An internal blower 112 forces air from the temperature controlled environment into contact with the internal heat exchanger 102 to exchange heat between the refrigerant and the temperature controlled environment. The internal blower 112 subsequently forces the air back into the temperature controlled environment. Similarly, an external blower 114 forces air from an ambient environment into contact with the external heat exchanger 104, and subsequently back into the ambient environment. The direction of refrigerant flow is controlled by a reversing valve 116 fluidly connected between the compressor 108 and each heat exchanger 102, 104.
The operation of the system 100 is generally controlled by a controller 200 and a thermostat 118 coupled to the controller 200. The thermostat 118 is coupled to one or more temperature sensors (not shown) for measuring the temperature of the temperature controlled environment. The controller 200 is coupled to the reversing valve 116, the compressor 108, and the blowers 112, 114 for controlling operation of the components in response to control signals received from the thermostat 118 and for controlling operation of the components during defrost cycles.
The system 100 also includes an auxiliary heater 120 coupled to the controller 200 and the thermostat 118. The auxiliary heater 120 is configured to supply additional heat to the system 100 when the system is in a heating mode and/or to supply heat to the temperature controlled environment when the system 100 is in a defrost mode. In alternative embodiments, the auxiliary heater 120 is omitted from the system 100.
The system 100 also includes sensors 122, 124 for monitoring environmental conditions of the system 100. Sensors 122, 124 are coupled to the controller 200 for relaying information about the system 100 to the controller 200 in the form of electrical signals. In the illustrated embodiment, sensors 122, 124 are temperature sensors. The system 100 may include additional or alternative sensors, such as photo-optical sensors, pressure sensors, tactile sensors, and refrigerant pressure sensors.
In operation, the compressor 108 receives gaseous refrigerant that has absorbed heat from the environment of one of the two heat exchangers 102, 104. The gaseous refrigerant is compressed by the compressor 108 and discharged at high pressure and relatively high temperature to the other heat exchanger. Heat is transferred from the high pressure refrigerant to the environment of the other heat exchanger and the refrigerant condenses in the heat exchanger. The condensed refrigerant passes through the expansion device 106, and into the first heat exchanger where the refrigerant gains heat, is evaporated and returns to the compressor intake.
The controller 200 is connectable with a mobile device 300, such as a smart phone, tablet, laptop, etc., (hereinafter referred to as “mobile device”) via a communication interface (not shown in
The processor 202 is configured for executing instructions. In some embodiments, executable instructions are stored in the memory 204. The processor 202 may include one or more processing units (e.g., in a multi-core configuration). The term processor, as used herein, refers to central processing units, microprocessors, microcontrollers, reduced instruction set circuits (RISC), application specific integrated circuits (ASIC), logic circuits, and any other circuit or processor capable of executing the functions described herein. The above are examples only, and are thus not intended to limit in any way the definition and/or meaning of the term “processor.”
The media output component 206 is configured for presenting information to a user 208. The media output component 206 is any component capable of conveying information to the user 208. In some embodiments, the media output component 206 includes an output adapter such as a video adapter and/or an audio adapter. The output adapter is operatively connected to the processor 202 and operatively connectable to an output device such as a display device (e.g., a liquid crystal display (LCD), organic light emitting diode (OLED) display, cathode ray tube (CRT), “electronic ink” display, one or more light emitting diodes (LEDs)) or an audio output device (e.g., a speaker or headphones). Some embodiments do not include the media output component 206, and all output to the user is made via remote device 300.
The controller 200 includes, or is connected to, the input device 210 for receiving input from the user 208. The input device is any device that permits the controller 200 to receive analog and/or digital commands, instructions, or other inputs from the user 208, including visual, audio, touch, button presses, stylus taps, etc. The input device 210 may include, for example, a variable resistor, an input dial, a keyboard/keypad, momentary push button/buttons, a pointing device, a mouse, a stylus, a touch sensitive panel (e.g., a touch pad or a touch screen), a gyroscope, an accelerometer, a position detector, or an audio input device. A single component such as a touch screen may function as both an output device of the media output component 206 and the input device 210. Some embodiments do not include input device 210, and all input to the controller 200 is made via remote device 300.
The memory 204 stores computer-readable instructions for control of the system 100 as described herein. In some embodiments, the memory area stores computer-readable instructions for providing a user interface to the user 208 via media output component 206 and, receiving and processing input from input device 210. The memory 204 is any device allowing information such as executable instructions and/or other data to be stored and retrieved. The memory 204 may include one or more computer-readable media. The memory 204 includes, but is not limited to, random access memory (RAM) such as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and non-volatile RAM (NVRAM). Although illustrated as separate from the processor 202, in some embodiments the memory 204 is combined with the processor 202, such as in a microcontroller or microprocessor, but may still be referred to separately. The above memory types are example only, and are thus not limiting as to the types of memory usable for storage of a computer program.
The control interfaces 212 enable the controller 200 to communicate with and control components of the system. These remote devices include sensors, valve control systems, safety systems, compressors, blowers, and the like. The control interfaces 212 are wired control interfaces in the example embodiment. Wired control interfaces 212 may use any suitable wired communication protocol for direct communication including, without limitation, USB, RS232, I2C, SPI, analog, and proprietary I/O protocols. In other embodiments, the control interfaces 212 may include wireless control interfaces for communicating with and controlling components of the system.
The communication interface 214 allows additional functionality to be added to the controller 200. In the example embodiments, additional communication functionality is added to the controller 200 by attaching a communication module 400 to the controller 200 through the communication interface 214 and a mating interface on the communication module (not shown in
The communication module 400 may be a wired or a wireless communication module 400. Wired communications modules 400 may include a universal serial bus (USB) circuit, a transistor-transistor logic (TTL) circuit, an RS-485 circuit, and/or a wired network adapter allowing the computing device to be coupled to a network, such as the Internet, a local area network (LAN), a wide area network (WAN), a mesh network, and/or any other network to communicate with remote devices and systems via the network. Wireless communications modules 400 may include a near field communication (NFC) transceiver, a radio frequency (RF) transceiver, a Bluetooth® adapter, a Wi-Fi transceiver, a ZigBee® transceiver, an infrared (IR) transceiver, a Sub-GHz circuit, a long range (LoRa) circuit, and/or any other device and communication protocol for wireless communication. (Bluetooth is a registered trademark of Bluetooth Special Interest Group of Kirkland, Wash.; ZigBee is a registered trademark of the ZigBee Alliance of San Ramon, Calif.) Moreover, some embodiments include combinations of more than one communication circuit or protocol (whether wired or wireless) on the communication module 400.
In the example embodiment, the communication module 400 is an NFC transceiver operable for wireless communication with a nearby NFC communication enabled remote device, such as mobile device 300. Information may be retrieved from controller 200 or transmitted to controller 200 using the wireless communication interface 214 when the controller 200 is powered on and/or when it is powered off. Because NFC communication requires that the communicating transceivers be in close proximity (e.g., about one inch apart or closer), the mobile device 300 and the controller 200 may only communicate via NFC when the mobile device 300 is in close proximity to the controller 200. Thus, the user/installer may input into the mobile device 300 or the mobile device may select settings or other data to be provided to the controller 200 (e.g., the user may configure the system 100) when the mobile device 300 is not in close proximity to the controller 200 (and thus not communicating with the controller 200), and then place the mobile device 300 in close proximity to the controller 200 to establish communication and transmit the information from the mobile device 300 to the controller 200. References to communicating via NFC or being in communication with a device via NFC herein refer to being in communication when in close proximity to each other.
The processor 302 is configured for executing instructions. In some embodiments, executable instructions are stored in the memory 304. The processor 302 may include one or more processing units (e.g., in a multi-core configuration). The term processor, as used herein, refers to central processing units, microprocessors, microcontrollers, reduced instruction set circuits (RISC), application specific integrated circuits (ASIC), logic circuits, and any other circuit or processor capable of executing the functions described herein. The above are examples only, and are thus not intended to limit in any way the definition and/or meaning of the term “processor.”
The media output component 306 is configured for presenting information to a user 308. The media output component 306 is any component capable of conveying information to the user 308. In some embodiments, the media output component 306 includes an output adapter such as a video adapter and/or an audio adapter. The output adapter is operatively connected to the processor 302 and operatively connectable to an output device such as a display device (e.g., a liquid crystal display (LCD), organic light emitting diode (OLED) display, cathode ray tube (CRT), “electronic ink” display, one or more light emitting diodes (LEDs)), and/or an audio output device (e.g., a speaker or headphones).
The mobile device 300 includes the input device 310 for receiving input from the user 308. The input device is any device that permits the mobile device 300 to receive analog and/or digital commands, instructions, or other inputs from the user 308, including visual, audio, touch, button presses, stylus taps, etc. The input device 310 may include, for example, keyboard/keypad, a pointing device, a mouse, a stylus, a touch sensitive panel (e.g., a touch pad or a touch screen), a gyroscope, an accelerometer, a position detector, or an audio input device. A single component such as a touch screen may function as both an output device of the media output component 306 and the input device 310.
The memory 304 stores computer-readable instructions for operation of the mobile device 300. The memory 304 also stores computer-readable instructions for configuring and communicating with system 100, and specifically for configuring and communicating with the controller 200. In some embodiments, the memory 304 stores computer-readable instructions for providing a user interface to the user 308 via media output component 306 and, receiving and processing input from input device 310. The memory 304 is any device allowing information such as executable instructions and/or other data to be stored and retrieved. The memory 304 may include one or more computer-readable media. The memory 304 includes, but is not limited to, random access memory (RAM) such as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), and non-volatile RAM (NVRAM). Although illustrated as separate from the processor 202, in some embodiments the memory 204 is combined with the processor 202, such as in a microcontroller or microprocessor, but may still be referred to separately. The above memory types are example only, and are thus not limiting as to the types of memory.
The first communication interface 214 and second communication interface 404 are mating connectors configured for connection with each other. Furthermore, the first communication interface 214 physically supports the communication module 400 via its mating connection to the second communication interface 404. In the example embodiment, the first communication interface 214 and second communication interface 404 are 4 pin connectors. In other embodiments, the first communication interface 214 and second communication interface 404 are 6 pin connectors. In some embodiments, the first communication interface 214 is configured to physically support the communication module 400, by including one or more support pins (not shown) for strengthening the connection of the first communication interface 214 to the substrate 218, by use of thicker or reinforced material in the connector, by including a latch for retaining the second communication interface, and the like.
Using the communication interface 214 to connect an external module (e.g., communication module 400) to the controller 200 allows additional functionality to be added to the controller 200 without taking up additional space on the substrate 218. Moreover, it allows different communications or other functionality to be added to the same controller 200, reducing the need for different versions of the same controller to provide different types of communication. Further, different communication modules may be plugged into the same controller at different time, allowing the same controller to be accessed using different communications methods. For example, a system manufacturer may use one type of communication module to communicate with the controller during manufacturing, and an installer may use a different type of communication module to communicate with the controller during installation of the system. The module plugged into to the communication interface 214 may be removed, if desired, after it has been used, thus allowing the same module to be used with multiple systems.
The user has the ability to physically install the controller 200 in the HVAC system 100 as well as to communicatively connect the controller 200 to at least one HVAC component to be controlled by the controller 200. The HVAC controller 200 may be installed in the HVAC system 100 before or after the communication module 400 is connected to the controller 200 to allow more flexibility of use.
The logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other embodiments are within the scope of the following claims.
It will be appreciated that the above embodiments that have been described in particular detail are merely example or possible embodiments, and that there are many other combinations, additions, or alternatives that may be included.
Also, the particular naming of the components, capitalization of terms, the attributes, data structures, or any other programming or structural aspect is not mandatory or significant, and the mechanisms that implement the disclosure or its features may have different names, formats, or protocols. Further, the system may be implemented via a combination of hardware and software, as described, or entirely in hardware elements. Also, the particular division of functionality between the various system components described herein is merely one example, and not mandatory; functions performed by a single system component may instead be performed by multiple components, and functions performed by multiple components may instead performed by a single component.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
This disclosure has been described in terms of example embodiments of a novel controls system in HVAC system. Various changes, modifications, and alterations in the teachings of the present disclosure may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present disclosure encompass such changes and modifications.
This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure 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.
