The disclosure relates to a method for estimating the external static pressure in an air duct of an air conditioning system and a method for controlling the air conditioning system.
In residential or commercial heating, ventilation, and air conditioning (also known as HVAC) systems, a system controller acquires data regarding external static pressure (ESP) from different locations in air ducts. The external static pressure (ESP) serves as a vital parameter for the system controller and provides valuable information about the operational performance of the HVAC systems, for example, for the identification of any faulty components and pinpointing a specific area in the air ducts that requires adjustment in airflow. The information is crucial for optimizing the performance of the HVAC systems.
Currently, each air duct is equipped with a filter that is renewed every three months. However, many of these filters are far from being fully clogged within this time frame. By monitoring the changes in static pressure in the air ducts, the level of filter clogging can be determined. The method helps to prevent the replacement of the filters that are not yet clogged, thereby reducing unnecessary expenses.
Static pressure measurement devices are commonly used for measuring the static pressure in the air ducts of HVAC systems. However, the static pressure measurement devices on the market are often bulky and costly. The installation of such a device in each air duct is impractical due to the high expenses, complex wiring, and inconvenient installation involved.
To solve the aforesaid problems, the first objective of the disclosure is to provide a first method for estimating the external static pressure in an air duct. The method comprises:
In a class of this embodiment, the external static pressure (ESP) on the air duct is calculated using a function of a first-order binary equation: ESP=F(CFM, POWER).
In a class of this embodiment, the first-order binary equation is simplified as follows: F(X, Y, K)=K0+K1·X+K2·Y+K3·X·Y, where a variable X is the constant volumetric airflow rate (CFM); a variable Y is the input power (POWER); K0, K1, K2, and K3 are coefficients; and F(X, Y, K) is the external static pressure (ESP).
In a class of this embodiment, the constant volumetric airflow rate (CFM) is determined by a function CFM=F(POWER, V), where POWER is the input power and V is a rotational speed of the PM motor.
The second objective of the disclosure is to provide a second method for controlling a constant volumetric airflow rate of an air conditioning system, the air conditioning system comprising a system controller and a plurality of air ducts disposed at different locations; the method comprising: disposing a permanent magnetic (PM) motor and a fan in each air duct, and the fan being powered by the PM motor; applying a constant current to the PM motor so that the air duct outputs a constant volumetric airflow rate in a unit of cubic feet per minute (CFM); calculating an external static pressure (ESP) on the air duct using two variables: the constant volumetric airflow rate (CFM) of the air duct and an input power (POWER) of the PM motor; transmitting data of the external static pressure (ESP) to the system controller; and analyzing the data to maintain a constant volumetric airflow rate within the air conditioning system.
In a class of this embodiment, the system controller is configured to receive the date of the external static pressure (ESP) measured by PM motors at different locations and provides appropriate instructions to the PM motors to maintain a constant volumetric airflow rate (CFM) within the plurality of air ducts.
The third objective of the disclosure is to provide a third method for determining whether a filter of a conditioning system is clogged and requires replacement, the air conditioning system comprising a system controller and a plurality of air ducts disposed at different locations, and each air duct comprising a filter; the method comprising: disposing a permanent magnetic (PM) motor and a fan in each air duct, and the fan being powered by the PM motor; applying a constant current to the PM motor so that the air duct outputs a constant volumetric airflow rate in a unit of cubic feet per minute (CFM); calculating an external static pressure (ESP) on the air duct using two variables: the constant volumetric airflow rate (CFM) of the air duct and an input power (POWER) of the PM motor; transmitting data of the external static pressure (ESP) to the system controller; and determining whether the filter of the conditioning system is clogged and requires replacement according to the data of the external static pressure (ESP)
In a class of this embodiment, when the data of the external static pressure (ESP) measured by one of the plurality of PM motors under a certain constant volumetric airflow rate (CFM) and a specific input power (POWER) exceeds a preset static pressure threshold (ESPmax), the system controller issues an alarm signal to indicate that the filter at a certain location is clogged and requires replacement.
In a class of this embodiment, during the replacement of a new filter, the system controller records the data of the external static pressure (ESP) measured by one of the plurality of PM motors under a certain constant volumetric airflow rate (CFM) and a specific input power (POWER) as an initial external static pressure, for future big data analysis to identify a potential fault location within the air conditioning system using the recorded data.
The fourth objective of the disclosure is to provide a method for determining whether a fault exists within an air conditioning system, the air conditioning system comprising a system controller and a plurality of air ducts disposed at different locations, and each air duct comprising a filter; the method comprising: disposing a permanent magnetic (PM) motor and a fan in each air duct, and the fan being powered by the PM motor; applying a constant current to the PM motor so that the air duct outputs a constant volumetric airflow rate in a unit of cubic feet per minute (CFM); calculating an external static pressure (ESP) on the air duct using two variables: the constant volumetric airflow rate (CFM) of the air duct and an input power (POWER) of the PM motor; transmitting data of the external static pressure (ESP) to the system controller; and determining whether a fault exists within the air conditioning system according to the data of the external static pressure (ESP).
In a class of this embodiment, the system controller is configured to receive real-time date of the external static pressure (ESP) measured by the plurality of PM motors; and the data is analyzed using big data techniques to identify any fault within the air conditioning system.
The following advantages are associated with the method for estimating an external static pressure (ESP) in an air duct of the disclosure:
To further illustrate the disclosure, embodiments detailing a method for estimating the external static pressure in an air duct of an air conditioning system and a method for controlling the air conditioning system are described below. It should be noted that the following embodiments are intended to describe and not to limit the disclosure.
Referring to
Referring to
Referring to
The sensorless brushless DC motor operates using vector control, specifically Field-Oriented Control (FOC). The real-time input power and rotational speed of the motor can be calculated using a method as described in the following patents: U.S. Pat. No. 9,752,976 and CN201410042547.8. The two patents disclose the method for achieving constant airflow control of a PM motor through direct power control. The constant airflow control can also be implemented in a sensorless brushless DC motor that comprises Hall sensors for detecting the rotor position, and more detailed information about the method can be found in the two patents: U.S. Pat. No. 9,752,976 and CN201410042547.8.
The disclosure provides a first method for estimating the external static pressure by a PM motor using constant current control. For more detailed information on the constant airflow control technique, refer to the following two patents: U.S. Pat. No. 9,752,976 and CN201410042547.8.
The first method develops a mathematical model for estimating external static pressure using constant current control by a motor. The mathematical model comprises three system variables: the external static pressure (ESP), the input power (POWER), and the constant volumetric airflow rate (measured in units of Cubic Feet per Minute, CFM). Generally, a motor is used to drive the fan, generating a stable airflow by pushing the air into the air ducts. The process results in a constant volumetric airflow rate in the air ducts. By regulating the input power and the rotational speed, constant airflow control is achieved under specific external static pressure conditions.
Building upon the constant airflow control method disclosed in the two patents, U.S. Pat. No. 9,752,976 and CN201410042547.8, the external static pressure (ESP) can be mathematically expressed as a function of the constant volumetric airflow rate (CFM) and the input power (POWER). The function is expressed as follows:
ESP=F(CFM,POWER) Function 1
In the process of mathematical modeling, the data collected during the development of the method disclosed in the two patents, U.S. Pat. No. 9,752,976 and CN201410042547.8, is used to minimize the burden of data collection.
All the variables and the characteristic curves in
F(X,Y,K)=K0+K1·X+K2·Y+K3·X·Y Function 2
The constant airflow control is achieved through direct power control (as described in the two patents U.S. Pat. No. 9,752,976 and CN201410042547.8). Four experimental data points (ESP1, POWER1, CFM1), (ESP2, POWER2, CFM2), (ESP3, POWER3, CFM3), and (ESP4, POWER4, CFM4) are substituted into the Function 2 to form a system of equations. By solving the system of equations, the coefficients K0, K1, K2, and K3 are determined. This forms the mathematical model for estimating the external static pressure using constant current control by a PM motor. Under constant airflow control, the external static pressure (ESP) is dependent on the input power (POWER) and the constant volumetric airflow rate (CFM) for any given value.
The first method comprises calculating the external static pressure (ESP) on the air duct using two variables: the constant volumetric airflow rate (CFM) and the input power (POWER). Specifically, a PM motor and a fan are disposed in the air duct; the PM motor comprises a stator assembly, a permanent-magnet rotor assembly, and a motor controller; the motor controller comprises a MCU; the fan is powered by the PM motor; and the PM motor operates using constant current control to ensure a constant volumetric airflow rate (CFM) within the air duct.
A function for estimating the external static pressure (ESP), expressed as ESP=F(CFM, POWER), is a first-order binary equation.
Four experimental data points (ESP1, POWER1, CFM1), (ESP2, POWER2, CFM2), (ESP3, POWER3, CFM3), and so on are substituted into the function ESP=F(POWER, CFM) to form a system of equations. By solving the system of equations, the coefficients K0, K1, K2, and K3 are determined.
The first-order binary equation is simplified as follows:
F(X,Y,K)=K0+K1·X+K2·Y+K3·X·Y
The constant airflow control is achieved through direct power control to ensure a constant volumetric airflow rate within the air conditioning system. In other words, the constant volumetric airflow rate (CFM) is determined by the function F(POWER, V), where POWER is the input power and V is the rotational speed of the PM motor.
The effectiveness of the first method is verified through experimental data, as shown in Table 1.
The results of Table 1 indicate that the error between the measured ESP and the estimated ESP calculated using Equation 2 is within 0.06. Most of the errors fall below 0.04, which is considered acceptable since precise detection of external static pressure (ESP) is not explicitly required by the customers. The results also demonstrate the effectiveness of the first method. Moreover, the mathematical model minimizes the computational burden on the MCU, significantly reducing the processing demands. The external static pressure (ESP) is determined by two variables: the constant volumetric airflow rate (CFM) and the input power (POWER). The first method eliminates the requirement for extra static pressure measurement devices, and allows real-time estimation of the external static pressure (ESP). The estimated data enables a comprehensive understanding of the operational performance of the HVAC system and facilitates the implementation of appropriate control measures, all achieved without any additional costs or modifications to the product structure.
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The system controller is configured to receive the date of the external static pressure (ESP) measured by the plurality of PM motors and provides appropriate instructions to maintain a constant volumetric airflow rate (CFM) within the plurality of air ducts.
As shown in
When the data of the external static pressure ESP measured by one of the plurality of PM motors, under a constant volumetric airflow rate (CFM) and a specific input power (POWER), exceeds a preset static pressure threshold (ESPmax), the system controller issues an alarm signal to indicate that a filter at a certain location is clogged and requires replacement.
The system controller records an initial external static pressure during the replacement of a new filter, enabling future big data analysis using the recorded data to identify a potential fault location.
By monitoring and measuring the changes in external static pressure (ESP) in the air ducts, the level of filter clogging can be determined. The method helps to prevent the replacement of the filters that are not yet clogged, thereby reducing unnecessary expenses.
The disclosure further provides a method for controlling an air conditioning system, specifically a method for determining if any faults exist within the air conditioning system. The air conditioning system comprises the system controller and the plurality of air ducts disposed at different locations; the plurality of PM motors is respectively disposed in the plurality of air ducts to power the corresponding fan; the plurality of PM motors operate using constant current control to ensure a constant volumetric airflow rate (CFM) within the plurality of air ducts. The method comprises: measuring the external static pressure (ESP) on each air duct by the PM motor using the method as described in Example 1; transmitting the data of the external static pressure (ESP) to the system controller; and analyzing the data to determine if any faults exist within the air conditioning system.
The system controller is configured to receive the real-time date of the external static pressure (ESP) measured by the plurality of PM motors; and the data is analyzed using big data techniques to identify any faults within the air conditioning system.
Specifically, the PM motor supplies the data of the external static pressure (ESP) on the plurality of air ducts to the system controller. The data is transmitted remotely through the Internet of Things (IoT) to a centralized computer center for analysis. The process facilitates remote monitoring and enhances the significance of ESP feedback, particularly in commercial environments.
It will be obvious to those skilled in the art that changes and modifications may be made, and therefore, the aim in the appended claims is to cover all such changes and modifications.
Number | Date | Country | Kind |
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202210595496.6 | May 2022 | CN | national |
This application is a continuation-in-part of International Patent Application No. PCT/CN2022/119516 with an international filing date of Sep. 19, 2022, designating the United States, now pending, and further claims foreign priority benefits to Chinese Patent Application No. 202210595496.6 filed May 30, 2022. The contents of all the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, MA 02142.
Number | Date | Country | |
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Parent | PCT/CN2022/119516 | Sep 2022 | US |
Child | 18518403 | US |