NOISE ABATEMENT SYSTEMS AND METHODS FOR A FURNACE

BACKGROUND

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described 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.

Heating, ventilation, and/or air conditioning (HVAC) systems are utilized in residential, commercial, and industrial environments to control environmental properties, such as temperature and humidity, for occupants of the respective environments. For example, an HVAC system may include one or more heat exchangers, such as a heat exchanger configured to place an air flow in a heat exchange relationship with a working fluid of a vapor compression circuit, a heat exchanger configured to place the air flow in a heat exchange relationship with combustion products (e.g., a furnace), or both. In some HVAC systems, a furnace may be utilized to heat the air flow supplied to a conditioned space. For example, a furnace may include a burner configured to combust an air and fuel mixture to generate combustion products that are drawn through heat exchanger tubes of the furnace. Unfortunately, during operation of conventional furnaces, undesirable vibrations and/or acoustic noise may be generated. For example, one or more components of the furnace may vibrate and/or generate sound that may be audible by occupants of a space conditioned by the HVAC system. In some instances, the vibrations and/or acoustic waves generated by the furnace may reduce an operational life of the furnace.

SUMMARY

A summary of certain embodiments disclosed herein is set forth below. It should be noted that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.

In an embodiment, a furnace for a heating, ventilation, and air conditioning (HVAC) system, comprises a burner configured to ignite a mixture of air and fuel and a sensor configured to detect a parameter indicative of an intensity of sound generated by the furnace and configured to transmit a signal indicative of a value of the parameter. The furnace further comprises a controller configured to receive the signal indicative of the value of the parameter, compare the value of the parameter to a threshold value, and in response to a determination that the value of the parameter meets or exceeds the threshold value, control operation of the furnace to adjust a flow rate of the air, a flow rate of the fuel, or both.

In another embodiment, a controller for a furnace comprises a non-transitory, computer-readable medium having instructions stored thereon that, when executed by processing circuitry of the controller, are configured to cause the controller to receive a call for heating, and in response to receipt of the call for heating, initiate operation of a burner of the furnace to ignite an air and fuel mixture, operate the furnace to generate the air and fuel mixture at a first air to fuel ratio, receive, via a sensor disposed within the furnace, a signal indicative of a value of a parameter, where the parameter is associated with a level of sound generated by the furnace. Further, in response to a determination that the value of the parameter exceeds a threshold value, the controller is configured to determine an adjustment to operation of the furnace, and adjust operation of the furnace to generate the air and fuel mixture at a second air to fuel ratio different from the first air to fuel ratio.

In a further embodiment, a furnace for a heating, ventilation, and air conditioning (HVAC) system, comprises a housing, a burner disposed within the housing, where the burner is configured to ignite a mixture of air and fuel to produce combustion products. The furnace also includes a draft inducer fan configured to draw the combustion products through a heat exchanger of the furnace, a sensor disposed within the housing, where the sensor is configured to detect a parameter indicative of a level of sound generated by the furnace. The furnace further comprises a controller communicatively coupled to the sensor, where the controller is configured to receive a signal indicative of a value of the parameter from the sensor, compare the value of the parameter to a threshold value, and in response to a determination that the value exceeds the threshold value, adjust operation of the draft inducer fan to adjust an air to fuel ratio of the mixture of air and fuel.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a schematic of an embodiment of a building incorporating a heating, ventilation, and/or air conditioning (HVAC) system in a commercial setting, in accordance with an aspect of the present disclosure;

FIG. 2 is a perspective view of an embodiment of a packaged HVAC unit that may be used in an HVAC system, in accordance with an aspect of the present disclosure;

FIG. 3 is a cutaway perspective view of an embodiment of a split, residential HVAC system, in accordance with an aspect of the present disclosure;

FIG. 4 is a perspective view of an embodiment of a furnace, in accordance with an aspect of the present disclosure;

FIG. 5 is a schematic of an embodiment of a furnace, in accordance with an aspect of the present disclosure;

FIG. 6 is a schematic of an embodiment of a controller of a furnace, in accordance with an aspect of the present disclosure;

FIG. 7 is a flow chart of an embodiment of a method for controlling operation of a furnace, in accordance with an aspect of the present disclosure;

FIG. 8 is a flow chart of an embodiment of a method for controlling operation of a furnace, in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will be described below. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

As used herein, the terms “approximately,” “generally,” and “substantially,” and so forth, are intended to convey that the property value being described may be within a relatively small range of the property value, as those of ordinary skill would understand. For example, when a property value is described as being “approximately” equal to (or, for example, “substantially similar” to) a given value, this is intended to mean that the property value may be within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, of the given value. Similarly, when a given feature is described as being “substantially parallel” to another feature, “generally perpendicular” to another feature, and so forth, this is intended to mean that the given feature is within +/−5%, within +/−4%, within +/−3%, within +/−2%, within +/−1%, or even closer, to having the described nature, such as being parallel to another feature, being perpendicular to another feature, and so forth. Further, it should be understood that mathematical terms, such as “planar,” “slope,” “perpendicular,” “parallel,” and so forth are intended to encompass features of surfaces or elements as understood to one of ordinary skill in the relevant art, and should not be rigidly interpreted as might be understood in the mathematical arts. For example, a “planar” surface is intended to encompass a surface that is machined, molded, or otherwise formed to be substantially flat or smooth (within related tolerances) using techniques and tools available to one of ordinary skill in the art. Similarly, a surface having a “slope” is intended to encompass a surface that is machined, molded, or otherwise formed to be oriented at an angle (e.g., incline) with respect to a point of reference using techniques and tools available to one of ordinary skill in the art.

As briefly discussed above, a heating, ventilation, and/or air conditioning (HVAC) system may be used to thermally regulate a space within a building, home, or other suitable structure. For example, the HVAC system may include a furnace system configured to combust a fuel and air mixture to produce heated combustion products and to transfer heat from the combustion products to an air flow. For instance, the furnace system may include one or more heat exchangers configured to transfer thermal energy from the combustion products to an air flow directed across the heat exchanger by a fan or blower. The air flow may then be directed to a desired heating space, such as an interior of a building. To produce the combustion products, the furnace system may include one or more burners configured to receive a flow of fuel. For example, one or more valves may be used to control an amount of fuel received by the burners. Further, an inducer fan or blower may be utilized to regulate an amount of air received by the burners. In this way, an amount of combustion and/or an amount of thermal energy produced by the furnace may be controlled. Unfortunately, during operation of the furnace, the furnace and/or the HVAC system may generate undesirable vibrations and/or may output acoustic waves that may result in noise (e.g., audible noise, thermoacoustic noise).

It is now recognized that furnace control techniques may enable a decrease in the generation of undesirable noise (e.g., audible noise, thermoacoustic noise) produced by the furnace. For example, present embodiments relate to a control system configured to detect a parameter indicative of noise generated by a furnace or burner, evaluate a noise output of the furnace based on the parameter, and adjust operation of the furnace based on a determination that the noise output is greater than a threshold noise level or intensity.

In accordance with present techniques, after a predetermined elapsed time subsequent to startup of the furnace, a sensor may detect a parameter (e.g., operating parameter) indicative of a noise level to a controller, and the controller may evaluate a noise output of the furnace based on the parameter. For example, the controller may compare a value of the parameter to a predetermined threshold value, where the predetermined threshold value may be associated with a threshold noise level or intensity. Based on a determination that the noise level is greater than a predetermined threshold noise intensity or level, the controller may adjust operation of the furnace to cause a reduction in the noise output by the furnace. For example, the controller may adjust one or more components of the furnace to adjust an air to fuel ratio of the air and fuel mixture ignited by the burner. For example, the controller may send a signal to actuate a valve to adjust a flow of fuel to the burner, thereby increasing or decreasing a flow rate of the fuel supplied to the burner. Additionally or alternatively, the controller may send a signal to a blower to adjust an amount of air directed to the burner and/or a flow rate of combustion products drawn through a heat exchanger of the furnace. By adjusting operation of the furnace (e.g., the air to fuel ratio) in this manner, present embodiments may enable a reduction in an amount of noise (e.g., vibrations, audible noise, thermoacoustic noise) generated during operation of the furnace. In this way, the furnace system may operate with reduced noise output, thereby decreasing audible noise that may otherwise be perceived by occupants of a space conditioned by the HVAC system.

Turning now to the drawings, FIG. 1 illustrates an embodiment of a heating, ventilation, and/or air conditioning (HVAC) system for environmental management that employs one or more HVAC units in accordance with the present disclosure. As used herein, an HVAC system includes any number of components configured to enable regulation of parameters related to climate characteristics, such as temperature, humidity, air flow, pressure, air quality, and so forth. For example, an “HVAC system” as used herein is defined as conventionally understood and as further described herein. Components or parts of an “HVAC system” may include, but are not limited to, all, some of, or individual parts such as a heat exchanger, a heater, an air flow control device, such as a fan, a sensor configured to detect a climate characteristic or operating parameter, a filter, a control device configured to regulate operation of an HVAC system component, a component configured to enable regulation of climate characteristics, or a combination thereof. An “HVAC system” is a system configured to provide such functions as heating, cooling, ventilation, dehumidification, pressurization, refrigeration, filtration, or any combination thereof. The embodiments described herein may be utilized in a variety of applications to control climate characteristics, such as residential, commercial, industrial, transportation, or other applications where climate control is desired.

In the illustrated embodiment, a building 10 is air conditioned by a system that includes an HVAC unit 12 in accordance with present embodiments. The building 10 may be a commercial structure or a residential structure. As shown, the HVAC unit 12 is disposed on the roof of the building 10; however, the HVAC unit 12 may be located in other equipment rooms or areas adjacent the building 10. The HVAC unit 12 may be a single package unit containing other equipment, such as a blower and/or integrated air handler. In other embodiments, the HVAC unit 12 may be part of a split HVAC system, such as the system shown in FIG. 3, which includes an outdoor HVAC unit 58 and an indoor HVAC unit 56.

The HVAC unit 12 is an air-cooled device that implements a refrigeration cycle to provide conditioned air to the building 10. Specifically, the HVAC unit 12 may include one or more heat exchangers across which an air flow is passed to condition the air flow before the air flow is supplied to the building. In the illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU) that conditions a supply air flow, such as environmental air and/or a return air flow from the building 10. After the HVAC unit 12 conditions the air, the air is supplied to the building 10 via ductwork 14 extending throughout the building 10 from the HVAC unit 12. For example, the ductwork 14 may extend to various individual floors or other sections of the building 10. In certain embodiments, the HVAC unit 12 may be a heat pump that provides both heating and cooling to the building with one refrigeration circuit configured to operate in different modes.

A control device 16, one type of which may be a thermostat, may be used to designate the temperature of the conditioned air. The control device 16 also may be used to control the flow of air through the ductwork 14. For example, the control device 16 may be used to regulate operation of one or more components of the HVAC unit 12 or other components, such as dampers and fans, within the building 10 that may control flow of air through and/or from the ductwork 14. In some embodiments, other devices may be included in the system, such as pressure and/or temperature transducers or switches that sense the temperatures and pressures of the supply air, return air, and so forth. Moreover, the control device 16 may include computer systems that are integrated with or separate from other building control or monitoring systems, and even systems that are remote from the building 10.

FIG. 2 is a perspective view of an embodiment of the HVAC unit 12. In the illustrated embodiment, the HVAC unit 12 is a single package unit that may include one or more independent working fluid circuits and components that are tested, charged, wired, piped, and ready for installation. The HVAC unit 12 may provide a variety of heating and/or cooling functions, such as cooling only, heating only, cooling with dehumidification, and/or heating with a furnace. As described above, the HVAC unit 12 may directly cool and/or heat an air flow provided to the building 10 to condition a space in the building 10.

As shown in the illustrated embodiment of FIG. 2, a cabinet 24 encloses the HVAC unit 12 and provides structural support and protection to the internal components from environmental and other contaminants. In some embodiments, the cabinet 24 may be constructed of galvanized steel and insulated with aluminum foil faced insulation. Rails 26 may be joined to the bottom perimeter of the cabinet 24 and provide a foundation for the HVAC unit 12. In certain embodiments, the rails 26 may provide access for a forklift and/or overhead rigging to facilitate installation and/or removal of the HVAC unit 12. In some embodiments, the rails 26 may fit into “curbs” on the roof to enable the HVAC unit 12 to provide air to the ductwork 14 from the bottom of the HVAC unit 12 while blocking elements such as rain from leaking into the building 10.

The HVAC unit 12 includes heat exchangers 28 and 30 in fluid communication with one or more working fluid circuits. Tubes within the heat exchangers 28 and 30 may 30 may circulate a working fluid (e.g., refrigerant), such as R-454B and/or R32, through the heat exchangers 28 and 30. The tubes may be of various types, such as multichannel tubes, conventional copper or aluminum tubing, and so forth. Together, the heat exchangers 28 and 30 may implement a thermal cycle in which the working fluid undergoes phase changes and/or temperature changes as it flows through the heat exchangers 28 and 30 to produce heated and/or cooled air. For example, the heat exchanger 28 may function as a condenser where heat is released from the working fluid to ambient air, and the heat exchanger 30 may function as an evaporator where the working fluid absorbs heat to cool an air flow. In some embodiments, the HVAC unit 12 may operate in a heat pump mode where the roles of the heat exchangers 28 and 30 may be reversed. That is, the heat exchanger 28 may 28 may function as an evaporator and the heat exchanger 30 may function as a condenser. While the illustrated embodiment of FIG. 2 shows the HVAC unit 12 having two of the heat exchangers 28 and 30, in other embodiments, the HVAC unit 12 may include one heat exchanger or more than two heat exchangers.

The heat exchanger 30 is located within a compartment 31 that separates the heat exchanger 30 from the heat exchanger 28. Fans 32 draw air from the environment through the heat exchanger 28. Air may be heated and/or cooled as the air flows through the heat exchanger 28 before being released back to the environment surrounding the HVAC unit 12. A blower assembly 34, powered by a motor 36, draws air through the heat exchanger 30 to heat or cool the air. The heated or cooled air may be directed to the building 10 by the ductwork 14, which may be connected to the HVAC unit 12. Before flowing through the heat exchanger 30, the conditioned air flows through one or more filters 38 that may remove particulates and contaminants from the air. In certain embodiments, the filters 38 may be disposed on the air intake side of the heat exchanger 30 to prevent contaminants from contacting the heat exchanger 30.

The HVAC unit 12 also may include other equipment for implementing the thermal cycle. Compressors 42 increase the pressure and temperature of the working fluid before the working fluid enters the heat exchanger 28. The compressors 42 may be any suitable type of compressors, such as scroll compressors, rotary compressors, screw compressors, or reciprocating compressors. In some embodiments, the compressors 42 may include a pair of hermetic direct drive compressors arranged in a dual stage configuration 44. However, in other embodiments, any number of the compressors 42 may be provided to achieve various stages of heating and/or cooling. As may be appreciated, additional equipment and devices may be included in the HVAC unit 12, such as a solid-core filter drier, a drain pan, a disconnect switch, an economizer, pressure switches, phase monitors, and humidity sensors, among other components.

The HVAC unit 12 may receive power through a terminal block 46. For example, a high voltage power source may be connected to the terminal block 46 to power the equipment. The operation of the HVAC unit 12 may be governed or regulated by a control board 48. The control board 48 may include control circuitry connected to a thermostat, sensors, and alarms. One or more of these components may be referred to herein separately or collectively as the control device 16. The control circuitry may be configured to control operation of the equipment, provide alarms, and monitor safety switches. Wiring 49 may connect the control board 48 and the terminal block 46 to the equipment of the HVAC unit 12.

FIG. 3 illustrates a residential heating and cooling system 50, also in accordance with present techniques. The residential heating and cooling system 50 may provide heated and cooled air to a residential structure, as well as provide outside air for ventilation and provide improved indoor air quality (IAQ) through devices such as ultraviolet lights and air filters. In the illustrated embodiment, the residential heating and cooling system 50 is a split HVAC system. In general, a residence 52 conditioned by a split HVAC system may include working fluid conduits 54 (e.g., refrigerant conduits) that operatively couple the indoor unit 56 to the outdoor unit 58. The indoor unit 56 may be positioned in a utility room, an attic, a basement, and so forth. The outdoor unit 58 is typically situated adjacent to a side of residence 52 and is covered by a shroud to protect the system components and to prevent leaves and other debris or contaminants from entering the unit. The working fluid conduits 54 transfer working fluid between the indoor unit 56 and the outdoor unit 58, typically transferring primarily liquid working fluid in one direction and primarily vaporized working fluid in an opposite direction.

When the system shown in FIG. 3 is operating as an air conditioner, a heat exchanger 60 in the outdoor unit 58 serves as a condenser for re-condensing vaporized working fluid flowing from the indoor unit 56 to the outdoor unit 58 via one of the working fluid conduits 54. In these applications, a heat exchanger 62 of the indoor unit functions as an evaporator. Specifically, the heat exchanger 62 receives liquid working fluid, which may be expanded by an expansion device, and evaporates the working fluid before returning it to the outdoor unit 58.

The outdoor unit 58 draws environmental air through the heat exchanger 60 using a fan 64 and expels the air above the outdoor unit 58. When operating as an air conditioner, the air is heated by the heat exchanger 60 within the outdoor unit 58 and exits the unit at a temperature higher than it entered. The indoor unit 56 includes a blower or fan 66 that directs air through or across the indoor heat exchanger 62, where the air is cooled when the system is operating in air conditioning mode. Thereafter, the air is passed through ductwork 68 that directs the air to the residence 52. The overall system operates to maintain a desired temperature as set by a system controller. When the temperature sensed inside the residence 52 is higher than the set point on the thermostat, or the set point plus a small amount, the residential heating and cooling system 50 may become operative to refrigerate additional air for circulation through the residence 52. When the temperature reaches the set point, or the set point minus a small amount, the residential heating and cooling system 50 may stop the refrigeration cycle temporarily.

In some embodiments, the indoor unit 56 may include a furnace system 70. For example, the indoor unit 56 may include the furnace system 70 when the residential heating and cooling system 50 is not configured to operate as a heat pump. The furnace system 70 may include a burner assembly and heat exchanger, among other components, inside the indoor unit 56. Fuel is provided to the burner assembly of the furnace system 70 where it is mixed with air and combusted to form combustion products. The combustion products may pass through tubes or piping in a heat exchanger, separate from heat exchanger 62, such that air directed by the blower or fan 66 passes over the tubes or pipes and extracts heat from the combustion products. The heated air may then be routed from the furnace system 70 to the ductwork 68 for heating the residence 52.

FIG. 4 is a perspective view of an embodiment of a furnace 100 (e.g., a furnace system), which may be incorporated with embodiments of the HVAC unit 12 and/or the heating and cooling system 50. For example, the furnace 100 may be an embodiment of the furnace system 70 discussed above. In some embodiments, the furnace 100 may be a ULN (ultra-low NOx) furnace. The furnace 100 may include a control system 102 having a controller 104 configured to control operation of one or more components of the furnace 100. In the illustrated embodiment, the furnace 100 includes a housing 106 in which or on which a number of components of the furnace 100 are disposed. For example, the furnace 100 includes a fuel valve 108 that may be controlled to adjust an amount of fuel (e.g., gas) directed through piping 110 to one or more burners 112 of the furnace 100. In some embodiments, multiple fuel valves 108 corresponding to each of the burners 112 may be employed.

The fuel valve(s) 108 may be controllable to vary an amount of fuel delivered to the burners 112. For example, positions of the fuel valve(s) 108 may be incrementally adjusted (e.g., in 1% increments), such as between 30% open (e.g., lower limit setting) and 100% open (e.g., upper limit setting). Thus, in some embodiments, the furnace 100 may be a variable capacity furnace. In other embodiments, the furnace 100 may be configured for single stage operation (e.g., the fuel valve 108 is either opened or closed) or two stage operation (e.g., with the fuel valve 108 fully opened, partially opened at a single partially opened setting, or closed). The percentage opening of the fuel valve 108 may be described as a “firing rate” of the burner 112 and/or the furnace 100. It should be appreciated that the present techniques may be incorporated with embodiments of the furnace 100 configured for variable capacity operation, single stage operation, or other multi-stage operation.

The burners 112 are configured to combust a mixture of the fuel (e.g., gas) and oxidant (e.g., air) to generate combustion products routed through a heat exchanger 114 (e.g., heat exchanger assembly) of the furnace 100. In general, the heat exchanger 114 may include one or more tubes (e.g., heat exchange tubes, conduits, pipes) configured to receive the combustion products generated by the burners 112 to place the combustion products in a heat exchange relationship with an air flow (e.g., supply air flow) directed thought the furnace 100. In some embodiments, the heat exchanger 114 may include a primary heat exchanger 116 (e.g., primary heat exchange tubes or coils) and a secondary heat exchanger 118 (e.g., secondary heat exchange tubes or coils) that are fluidly coupled to one another to enable flow of the combustion products therethrough. Further, in some embodiments, the tubes or coils associated with the primary heat exchanger 116 may differ in size, shape, or material from the tubes or coils associated with the secondary heat exchanger 118.

A supply air fan 120 (e.g., circulating fan, supply air fan) of the furnace 100, driven by a motor 122 (e.g., electric blower motor), may draw a supply air flow 124 into the furnace 100, for example through a filter of the furnace 100. The supply air fan 120 may direct (e.g., force) the supply air flow 124 across the heat exchanger 114 (e.g., the primary heat exchanger 116 and the secondary heat exchanger 118). That is, the supply air fan 120 may direct the supply air flow 124 across tubes of the heat exchanger 114. Heat from the combustion products flowing through the heat exchanger 114 may be transferred to the supply air flow 124 to generate a heated supply air flow 126 that is discharged from the furnace 100 via an outlet 128 of the furnace 100. For example, the outlet 128 may be fluidly coupled to a duct associated with a residence or building conditioned by the furnace 100.

The furnace 100 also includes a vent 130 (e.g., piping, such as polyvinyl chloride [PVC] piping or acrylonitrile butadiene styrene [ABS] plastic piping) fluidly coupled to the heat exchanger 114 (e.g., tubes of the heat exchanger 114). The vent 130 is configured to discharge the combustion products from the furnace 100. To this end, the furnace 100 may include a draft inducer fan 132 configured to draw the combustion products through the heat exchanger 114 (e.g., through tubes of the heat exchanger 114) and to discharge the combustion products from the furnace 100 via the vent 130. Operation of the draft inducer fan 132 may also draw air into the furnace 100 toward the burners 112 to mix with fuel and generate the air and fuel mixture that is ignited by the burners 112. In some instances, the draft inducer fan 132 may be operated upon initial startup of the furnace 100 and prior to operation of the burners 112. For example, the draft inducer fan 132 may be initially operated to remove remaining combustion products and/or existing air within the tubes of the heat exchanger 114 and may draw fresh air into the furnace 100 for mixture with fuel prior to combustion. In some embodiments, an operational setting of the draft inducer fan 132 may correspond to an operational setting of the fuel valve 108.

The control system 102 of the furnace 100 may be employed to control operation of one or more components of the furnace 100, such as one or more of the components described above. In the illustrated embodiment, the control system 102 includes the controller 104 disposed within the housing 106 of the furnace 100, but it should be understood that one or more components of the control system 102 may be disposed on the housing 106 (e.g., on an external surface of the housing 106), in another location separate from the furnace 100, or at a different location within the housing 106. Further, the control system 102 may include additional and/or alternative features, such as sensors, actuators, a user interface, communication circuitry, and so forth. It should be appreciated that embodiments of the control system 102 may be configured to enable and implement any of the techniques described herein to effectuate control of the furnace 100 and enable a reduction in vibrations and/or acoustic waves that may be generated during operation of the furnace 100.

To further illustrate, FIG. 5 is a schematic of an embodiment of the furnace 100, illustrating the control system 102 and the controller 104. The furnace 100 includes similar elements and element numbers as those described above with reference to FIG. 4. Additionally, the illustrated embodiment includes various sensors 150 that may be incorporated with the control system 102 to enable one or more of the functionalities described herein. The sensors 150 (e.g., sensors) are configured to detect or measure a parameter (e.g., operating parameter) and/or condition (e.g., operating condition) of the furnace 100. In some embodiments, one or more of the sensors 150 may be configured to detect a parameter indicative of, representative of, and/or associated with noise (e.g., audible noise, thermoacoustic noise, sound) generated and/or output by the furnace 100. Details of the control system 102, components thereof, and operation of the control system 102 is described further below.

As mentioned above, the controller 104 may be configured to control and/or adjust operation of one or more components of the furnace 100. In some embodiments, the controller 104 may be a component of or may include the control board 48. In other embodiments, the controller 104 may be a standalone controller, a dedicated controller, a group of controllers, multiple, separate controllers, a dedicated furnace controller, or another suitable controller included in an HVAC system having the furnace 100. In any case, the controller 104 is configured to control components of the furnace 100 in accordance with the techniques discussed herein. The controller 104 includes processing circuitry 152, such as a microprocessor, which may execute software for controlling the components of the furnace 100. The processing circuitry 152 may include multiple microprocessors, one or more “general-purpose” microprocessors, one or more special-purpose microprocessors, and/or one or more application specific integrated circuits (ASICS), or some combination thereof. For example, the processing circuitry 152 may include one or more reduced instruction set (RISC) processors.

The controller 104 may also include a memory device 154 (e.g., a memory) that may store information, such as executable instructions, control software, look up tables, configuration data, etc. The memory device 154 may include a volatile memory, such as random access memory (RAM), and/or a nonvolatile memory, such as read-only memory (ROM). The memory device 154 may store a variety of information and may be used for various purposes. For example, the memory device 154 may store processor-executable instructions including firmware or software for the processing circuitry 152 to execute, such as instructions for controlling components of the furnace 100 (e.g., fuel valve 108, supply air fan 120, draft inducer fan 132). Indeed, it should be appreciated that the memory device 154 may include executable instructions for performing any of the techniques disclosed herein. In some embodiments, the memory device 154 is a tangible, non-transitory, machine-readable-medium that may store machine-readable instructions for the processing circuitry 152 to execute. The memory device 154 may include ROM, flash memory, a hard drive, or any other suitable optical, magnetic, or solid-state storage medium, or a combination thereof. The memory device 154 may store data, instructions, and any other suitable data. For example, the memory device 154 may include a database configured to store one or more reference values, operating parameter values, calculated values, historical values, and/or any other suitable data to enable operation of the furnace 100 in accordance with the presently disclosed techniques.

In some embodiments, the controller 104 may include one or more timers 156 (e.g., one or more clocks). For example, the controller 104 may include executable instructions stored on the memory device 154, and the processing circuitry 152 may be configured to execute the executable instructions to operate one or more of the timers 156 to enable monitoring and/or tracking of one or more time durations associated with operations of the furnace 100 utilizing the present techniques, as described in greater detail below. In some embodiments, time durations and/or time duration thresholds associated with the one or more timers 156 may be stored in the memory device 154, such as in a database.

The controller 104 is also communicatively coupled to one or more of the sensors 150 of the furnace 100 (e.g., control system 102). As mentioned above, the one or more sensors 150 are configured to detect one or more operating parameters of the furnace 100 and provide feedback and/or data indicative of the operating parameters to the controller 104. Based on the data and/or feedback received from one or more of the sensors 150, the controller 104 may adjust operation of the furnace 100, such as to enable a reduction in noise output by the furnace 100. To this end, the controller 104 may also be communicatively coupled to one or more components of the furnace 100, such as the fuel valve 108, the supply air fan 120, the air flow valve 162, the draft inducer fan 132, and so forth.

In operation, the furnace 100 may receive a combustion air flow 158 and a flow of fuel 160. In particular, the flow of fuel 160 supplied to the furnace 100 may be controlled via operation of the fuel valve 108, as discussed above. In some embodiments, the furnace 100 may include an air flow valve 162 configured to control flow of the combustion air flow 158 directed into the furnace 100. Additionally or alternatively, the draft inducer fan 132 may be controlled to regulate flow of the combustion air flow 158 into the furnace 100. Within the furnace 100, the combustion air flow 158 and the flow of fuel 160 may be mixed to generate an air and fuel mixture 164 that may be ignited and combusted by the burners 112 to generate combustion products 166 that are directed through the heat exchanger 114. In some embodiments, the furnace 100 may include a premixing chamber 168 configured to receive and mix the combustion air flow 158 and the flow of fuel 160 to form the air and fuel mixture 164 upstream of the burners 112. Such embodiments may be recognized as pre-mixed furnaces and/or furnaces having pre-mix burners. In other embodiments, the burners 112 may be configured to separately receive the combustion air flow 158 and the flow of fuel 160 and to mix the combustion air flow 158 and the flow of fuel 160 to generate the air and fuel mixture 164 within the burner 112.

In any case, the air and fuel mixture 164 may be ignited via an igniter 144 of the burner 112. In some embodiments, a pulse may be sent (e.g., via the controller 104) through the igniter 144 to instruct the igniter 144 to produce a spark adjacent to or within the burner 112. In some embodiments, the air and fuel mixture 164 may be ignited by one burner 112 proximate the igniter 144, and the air and fuel mixture 164 may be sequentially ignited within adjacent burners 112. In other embodiments, one or more of the burners 112 may include another mechanism or feature configured to ignite the air and fuel mixture 164, such as a hot surface igniter or a pilot light. In the illustrated embodiment, the air and fuel mixture 164 may be drawn from the premixing chamber 168 and into the burners 112 for ignition to form the combustion products 166. By maintaining robust flames, such as flames outside of bodies of the burners 112, the burners 112 may produce the combustion products 166 at a desired temperature, composition, and/or efficiency.

As discussed above, the draft inducer fan 132 may draw the combustion products 166 through the heat exchanger 114 and may discharge the combustion products 166 from the furnace 100 (e.g., to an external environment) via the vent 130. To heat the supply air flow 124, the supply air fan 120 may operate to force the supply air flow 124 across the heat exchanger 114 to enable heat exchange with the combustion products 166 within the heat exchanger 114 to generate the heated supply air flow 126. The supply air fan 120 may also force the heated supply air flow 126 to exit the furnace 100 via the outlet 128. From the outlet 128, the heated supply air flow 126 may be directed to an interior space 170 (e.g., within a building) to condition the interior space 170.

In accordance with the present techniques, the furnace 100 may include one or more sensors 150 configured to detect one or more parameters associated with operation of the furnace 100. For example, one or more of the sensors 150 may be configured to detect a parameter indicative of and/or associated with a level or volume (e.g., intensity, sound volume) of noise (e.g., acoustic noise, thermoacoustic noise, vibration) output and/or emitted by the furnace 100. Additionally or alternatively, one or more of the sensors 150 may be configured to detect another operating parameter of the furnace 100, such as a temperature of the combustion air flow 158, a temperature of ambient air and/or an ambient environment (e.g., surrounding the furnace 100), a temperature within the interior space 170, a temperature of the heated supply air flow 126, a pressure of the combustion products 166, a flow rate of the combustion products 166, and so forth.

As discussed in further detail below, the sensors 150 may be positioned in any suitable location on and/or in the furnace 100. One or more of the sensors 150 may include microphone (e.g., acoustic wave sensor) configured to detect a sound level (e.g., sound volume) or frequency output (e.g., acoustic wave, pressure wave) by one or more components of the furnace 100. Additionally or alternatively, one or more of the sensors 150 may include an accelerometer configured to detect vibrations within the furnace 100. As mentioned above, the sensors 150 may be communicatively coupled to the controller 104 to send signals indicative of the detected operating parameter (e.g., a noise level, vibration level, or frequency) to the controller 104. In this way, the controller 104 may evaluate the operating parameter and determine an appropriate adjustment to operation of the furnace 100, in some instances. For example, the controller 104 may compare the operating parameter detected by one of the sensors 150 to a predetermined value (e.g., threshold value, range of values). In some embodiments, the predetermined value may be indicative of and/or associated with an acoustic level (e.g., intensity, volume) that results in audible sound heard by an occupant of the interior space 170 or other person associated with the furnace 100. Additionally or alternatively, the predetermined value may be selected based on a type and/or an installed location (e.g., within the furnace 100) of the corresponding sensor 150. In some embodiments, the controller 104 may be configured to detect and/or evaluate a pattern of an acoustic wave or vibration to determine whether the furnace 100 is operated with a sound output greater than a desired level. Upon a determination that the measured parameter (e.g., noise level, vibration level, and/or frequency) is above a predetermined threshold value and/or outside a range of values (e.g., range of frequency values), the controller 104 may adjust operation of the furnace 100 to enable a reduction in audible sound output by the furnace 100. For example, the controller 104 may adjust operation of the furnace 100 to adjust an air to fuel ratio of the air and fuel mixture 164 mixed and combusted by the furnace 100.

Various configurations and installations of the sensors 150 may be implemented in accordance with the present techniques. For example, a first sensor 172 may be positioned on an outer surface 174 of the housing 106 of the furnace 100 and may be configured to detect or measure an operating parameter indicative of noise, vibration, and/or frequency (e.g., acoustic frequency) produced by or in the furnace 100. In this way, the first sensor 172 may detect a noise level, vibrational level, or frequency external to the furnace 100 (e.g., the housing 106). Thus, the measured parameter may be more representative of a noise or sound that may be audible to an occupant within the interior space 170 and/or a space adjacent or proximate to the furnace 100.

Additionally or alternatively, one or more second sensors 176 may be positioned internal to the furnace 100, such as within the housing 106 of the furnace 100. The second sensors 176 may also be configured to measure and/or detect an operating parameter indicative of noise, vibration, and/or frequency (e.g., acoustic frequency) produced by or in the furnace 100, such as acoustic noise, vibration, and/or a frequency. For example, one or more of the second sensors 176 may be located in and/or mounted to a surface of a combustion chamber 178 of the furnace 100 in which the burners 112 are disposed. As such, the second sensors 176 may detect an operating parameter value, such as a noise level, a vibration level, and/or frequency, within the combustion chamber 178 that may be indicative of undesirable thermoacoustic noise generated by the furnace 100. Positioning the second sensors 176 within the combustion chamber 178 may result in detection and/or measurement readings from the second sensors 176 that are representative of acoustic noise, vibrations, and/or frequencies resulting from operation of the burners 112 instead of, for example, acoustic noise, vibrations, and/or frequencies generated by other sources, such as other equipment of an HVAC system having the furnace 100, environmental factors, occupants of the interior space 170, and so forth. In some embodiments, the second sensors 176 may be positioned within the combustion chamber 178 in a location that is protected or shielded from thermal energy generated by the burners 112. For example, the second sensors 176 may be positioned at a location away from the burners 112, for example, at an opposite side of the combustion chamber 178 relative to a position of the burners 112. Additionally or alternatively, the second sensors 176 may be designed and configured to resist or withstand heat. In further embodiments, an interior or exterior of the combustion chamber 178 may include heat resistant materials (e.g., insulating material, heat shield, insulating layer) disposed on or within the combustion chamber 178 that is configured to shield and protect the second sensors 176 from heat generated by the burners 112.

In some embodiments, one or more third sensors 180 may be positioned in and/or mounted to a surface of the premixing chamber 168 of the furnace 100. As described above, the premixing chamber 168 may receive the combustion air flow 158 and the flow of fuel 160 and may mix the combustion air flow 158 and the flow of fuel 160 therein to generate the air and fuel mixture 164 that is supplied to the combustion chamber 178 for combustion via the burner 112. In this way, the third sensors 180 may measure and/or detect an operating parameter indicative of vibrations and/or noise generated during operation of the furnace 100 while being adequately protected from thermal energy produced by the other components of the furnace 100 (e.g., within the combustion chamber 178).

In another aspect, one or more fourth sensors 182 may be positioned in and/or may be mounted to the vent 130 of the furnace 100. In this way, the fourth sensors 182 may measure and/or detect an operating parameter indicative of vibrations and/or noise that may be present within the vent 130, such as audible noise that may be emitted from the furnace 100 via the vent 130. For example, as combustion products 166 flow through the vent 130, the flow of combustion products 166 may cause undesirable noise or vibrations, such as impingement of the combustion products 166 against the vent 130. The position of the one or more fourth sensors 182 on and/or within the vent 130 may enable the control system 102 to detect audible noise and/or vibrations that may be more readily emitted from the furnace 100 via the vent 130. In some instances, upon a determination that an operating parameter detected by the fourth sensors 182 (e.g., a noise intensity or level, vibration level, and/or frequency being greater than a threshold value), the controller 104 may control or otherwise adjust the draft inducer fan 132, the air to fuel ratio of the air and fuel mixture 164, a damper in the vent 130, another component of the furnace 100, and/or a combination thereof to decrease undesirable noise, vibrations, and/or frequencies output by the furnace 100.

In some embodiments, a fifth sensor 184 configured to detect an operating parameter indicative of audible noise may be positioned in the interior space 170. For example, the fifth sensor 184 may also be configured to measure and/or detect a noise level, vibrations, and/or frequencies within the interior space 170 that may be generated by the furnace 100. For example, the fifth sensor 184 may be positioned in the interior space 170 on a wall, ceiling, or within an air duct configured to supply the heated supply air flow 126 to the interior space 170. The fifth sensor 184 may be communicatively coupled to the controller 104, such as via a wired or wireless connection, to send signals indicative of values of the detected operating parameter (e.g., a noise level, a frequency, and/or a vibration level).

It should be appreciated that the control system 102 may include any suitable number of sensors 150 positioned in one or more of the locations described above and/or in any other suitable location to detect parameter values indicative of audible sound or other acoustic waves generated during operation of the furnace 100. In this way, the sensors 150 may detect noise, acoustic waves, vibrations, and/or frequencies at various locations and may transmit signals indicative of the detected parameters to the controller 104. In response, the controller 104 may evaluate one or more values of the one or more parameters to determine whether and how to implement a control action to adjust a parameter and/or component of the furnace 100 to decrease undesirable noise or vibrations generated during operation of the furnace 100. Furthermore, positioning multiple and/or various sensors 150 at different locations may enable more precise determinations regarding a source of undesirable noise and/or vibrations generated by the furnace 100. In this way, through the detection and/or measurement of one or more operating parameters of the furnace 100 via multiple sensors 150, the controller 104 may more accurately estimate and/or determine a source of the emitted noise and/or vibrations, thereby enabling more effective adjustment of one or more operating parameters of the furnace 100 to enable reduced output of undesirable noise and/or vibrations.

FIG. 6 is a block diagram of an embodiment of the control system 102 of the furnace 100, in accordance with aspect of the present disclosure. As described above, the control system 102 includes the controller 104 configured to receive data and/or feedback from one or more sensors 150 and configured to adjust operation of the furnace 100 to enable reduced output of sound, acoustic waves, vibrations, and/or frequencies that may result in audible sounds perceptible by people during operation of the furnace 100.

The controller 104 may include a communication interface 200. The communication interface 200 may include wired or wireless interfaces (e.g., jacks, antennas, transmitters, receivers, transceivers, wire terminals, etc.) for conducting data communications with various systems, devices, or networks, such as the sensors 150 and/or components of the furnace 100. For example, the communication interface 200 may include an Ethernet card and port for sending and receiving data via an Ethernet-based communications network and/or a Wi-Fi transceiver for communicating via a wireless communications network. In some embodiments, the communication interface 200 may include a network interface that enables the components of the furnace 100 to communicate via various protocols such as EtherNet/IP, ControlNet, DeviceNet, or any other communication network protocol. Additionally or alternatively, the communication interface 200 may enable the components of the furnace 100 to communicate via mobile telecommunications technology, Bluetooth®, near-field communications technology, and the like. In such embodiments, the burner 112, the air flow valve 162, the fuel valve 108, the sensors 150, and the controller 104 may wirelessly communicate data between each other.

In some embodiments, the controller 104 may include and/or may be configured to communicate with one or more user devices 202, such as via the communication interface 200. In some embodiments, the one or more user devices 202 may include an electronic device of a user. For example, the user device 202 may include a mobile device, a smartphone, a laptop computer, a desktop computer, a personal digital assistant (PDA), a tablet, and/or any other electronic device with communication capabilities. In some embodiments, one or more of the sensors 150 may be integrated into the user device 202. For example, the user device 202 may include one of the sensors 150 configured to measure and/or detect a parameter indicative of and/or assisted with a noise level, vibration level, and/or a frequency, and the user device 202 may send a signal indicative of a value of the parameter to the controller 104.

In accordance with the present techniques, the controller 104 may be in communication with the fuel valve 108, the air flow valve 162, the draft inducer fan 132, and/or any other suitable components of the furnace 100, such as via the communication interface 200. The controller 104 may be configured to control and/or adjust operation of one or more components of the furnace 100 (e.g., the fuel valve 108, the air flow valve 162, or the draft inducer fan 132) perform one or more of the techniques described herein. In some embodiments, the controller 104 may control operation of the fuel valve 108, the air flow valve 162, and/or the draft inducer fan 132 to achieve, adjust, and/or maintain an air to fuel ratio of the air and fuel mixture 164. For example, the controller 104 may be configured to adjust operation of one or more components of the furnace 100 to achieve a preset or predetermined air to fuel ratio of the air and fuel mixture 164. In some embodiments, the preset air to fuel ratio may be stored in a database 204 of the controller 104. The preset air to fuel ratio may be provided by a user via the one or more user devices 202. In further embodiments, the preset air to fuel ratio may be selected (e.g., by the controller 104) from a plurality of preset air to fuel ratios stored in the database 204 based at least partially on an ambient temperature, a parameter of the furnace 100, a heating set point (e.g., communicated by a thermostat) an operating mode or stage of the furnace 100 (e.g., startup operation), another suitable parameter, or any combination thereof. For example, upon receipt of a call for heating, the controller 104 may select a particular preset air to fuel ratio based on a difference between a heating set point (e.g., as indicated by a thermostat or user device 202) and the detected and/or current temperature of the interior space 170 (e.g., detected by one of the sensors 150). Based on the particular preset air to fuel ratio selected by the controller 104, the controller 104 may adjust and/or control operation of components of the furnace 100 to cause the furnace 100 to generate the air to fuel mixture 164 at the particular preset air to fuel ratio.

In some embodiments, the air to fuel ratio selected and/or determined by the controller 104 may be dependent on a concentration of combustion gas (e.g., combustion products 166, CO, CO₂, nitrogen-based gases) produced by the furnace 100. For example, a particular preset air to fuel ratio may be selected based at least partially on data provided by one of the sensors 150 positioned in the vent 130 that is configured to measure a concentration or presence a particular compound or component within the combustion products 166. Furthermore, one preset air to fuel ratios may be selected to enable more efficient operation of the furnace 100.

The controller 104 is shown to be in communication with the one or more sensors 150, such as via the communication interface 200. As discussed above, the sensors 150 may include one or more a sound sensors, one or more audio sensors (e.g., a microphone, sound volume sensor), one or more vibration sensors (e.g., an accelerometer), one or more temperature sensors, one or more pressure sensors, one or more flow rate sensors, another suitable sensor, and/or or any other suitable sensor configured to detect an operating parameter of the furnace 100, such as sound or vibration. In some embodiments, as discussed above, one or more of the sensors 150 may be positioned in the combustion chamber 178, the premixing chamber 168, the heat exchanger 114, the interior space 170, the vent 130, another location within the housing 106, or another suitable location to detect noise and/or vibrations generated by the furnace 100, or any combination thereof. In some embodiments, multiple sensors 150 may be positioned within the furnace 100. One or more of the sensors 150 may be configured to detect an intensity (e.g., amount) of noise, an intensity of vibration, a frequency, and/or any other suitable parameter generated by the furnace 100. The one or more sensors 150 may generate an electrical signal indicative of sensed data associated with the parameter detected by the sensor 150.

The controller 104 further includes the database 204, as mentioned above. The database 204 may store information related to parameters detected by the one or more sensors 150, in some embodiments. For example, the database 204 may store values of one or more parameters that are indicative of a threshold amount or intensity of noise or sound generated by the furnace 100. That is, for any of the parameters described herein, the database 204 may store a corresponding threshold value indicative of an undesirable (e.g., audible) noise or sound level or intensity. As described in further detail below, in some embodiments the controller 104 may be configured to receive data indicative of an operating parameter value from one of the sensors 150 and to compare the operating parameter value to a corresponding threshold value indicative of noise or sound (e.g., audible sound) generated by the furnace 100. In response to a determination that the operating parameter value exceeds the corresponding threshold value, the controller 104 may adjust operation of the furnace 100 to enable a reduction in the noise or sound output by the furnace 100. For example, the controller 104 may adjust operation of the furnace 100 to adjust an air to fuel ratio of the furnace 100 and thereby cause a reduction in noise or sound output by the furnace 100. In some embodiments, the controller 104 may be configured to verify the reduction in sound output by the furnace 100, such as based on additional data (e.g., an updated operating parameter value) received from the one or more sensors 150.

To this end, the controller 104 may include processing circuitry 206 having at least one processor 208 and a memory 210. The processing circuitry 206 and/or the at least one processor 208 may be an embodiment of and/or may be similar to the processing circuitry 152 described above. Additionally, the memory 210 may be an embodiment of and/or may be similar to the memory device 154 described above. For example, the at least one processor 208 may be implemented as a general-purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, and/or other suitable electronic processing components. The memory 210 (e.g., memory, memory unit, storage device, etc.) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described herein. The memory 210 may be or include volatile memory or non-volatile memory. The memory 210 can include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present application. According to some embodiments, the memory 210 is communicably connected to the at least one processor 208 via the processing circuitry 206 and includes computer code for executing (e.g., by the processing circuitry 206 and/or the at least one processor 208) one or more processes described herein.

The memory 210 may include a data receiving module 212 configured to communicate with the one or more sensors 150 to receive the sensed data. For example, the sensed data may be indicative of one or more operating parameter values associated with an intensity of noise or sound, an intensity of vibration, a frequency, and/or other suitable parameter detected by one or more of the sensors 150. In some embodiments, one or more of the operating parameter values may be indicative of an amount of sound (e.g., a sound level) emitted by the furnace 100 during operation of the furnace 100. Additionally or alternatively, the data receiving module 212 may be configured to receive data related to other operating parameters of the furnace 100, such as a temperature, a pressure, a flow rate, an operating mode, an operating stage, an operating duration (e.g., duration of time), and so forth. Indeed, the data receiving module 212 may be configured to receive any suitable type of signal or communication.

The memory 210 further includes a regulating module 214. The regulating module 214 may be configured to evaluate the data received by the data receiving module 212. For example, the regulating module 214 may be configured to compare one or more operating parameter values detected by one or more of the sensors 150 to one or more corresponding threshold values (e.g., stored in the database 204). As examples, the regulating module 214 may compare a detected noise or sound value with a corresponding threshold sound value or level, compare a detected vibration value with a corresponding threshold vibration value or level (e.g., intensity), and/or compare a detected frequency value with a corresponding threshold frequency value or level (e.g. intensity) In some embodiments, the threshold values of each parameter may be associated with a particular level or intensity of sound or noise output by the furnace 100 during operation. As will be appreciated, the threshold values or levels (e.g., intensities) may be stored in the database 204. In some embodiments, the threshold values may be provided and/or adjusted by a user via the one or more user devices 202 in communication with the controller 104. For example, a user operating the user device 202 having one of the sensors 150 integrated therein may determine that a current noise level, vibration level, a frequency range, and/or other operating parameter value or level, as measured by the sensor 150 of the user device 202, is undesirable. As such, the user may assign, store, and/or designate the undesirable noise level, vibration level, and/or a frequency range, as measured by the sensor 150 of the user device 202, as a predetermined threshold noise level, vibration level, and/or a frequency to which detected values may be subsequently compared during evaluation of future detected values by the controller 104.

In some embodiments, the regulating module 214 may be configured to determine an adjustment to operation of the furnace 100, such as based on a parameter value detected and provided by the sensor 150 and/or based on comparison of the parameter value to a corresponding threshold value stored by the controller 104. In some embodiments, the regulating module 214 may be configured to determine an adjustment to an air to fuel ratio (e.g., of the air and fuel mixture 164) generated by the furnace 100. As will be appreciated, one or more operating parameter values of the furnace 100, such as operating parameter values associated with increased and/or audible sound levels, may be affected by the air to fuel ratio of the furnace 100. Accordingly, the regulating module 214 may be configured to adjust the air to fuel ratio to enable a reduction in the amount, intensity, and/or level of noise (e.g., audible sound) output by the furnace 100 during operation of the furnace 100. For example, upon a determination that an operating parameter value (e.g., sound output value, vibration value, frequency value, etc.) exceeds a corresponding threshold value, the regulating module 214 may determine an adjustment to operation of the furnace 100 in order to adjust the air to fuel ratio (e.g., of the air and fuel mixture 164) generated by the furnace 100 and reduce the level of sound output by the furnace 100. In some embodiments, the regulating module 214 may determine that a speed of the draft inducer fan 132 should be adjusted (e.g., increased, decreased) to enable a reduction in sound generated and/or output by the furnace 100. As another example, the regulating module 214 may determine that a firing rate of the furnace 100 (e.g., a position of the fuel valve 108) should be adjusted (e.g., reduced) to enable a reduction in sound generated and/or output by the furnace 100.

In another aspect, the regulating module 214 may be configured to improve efficiency of the furnace 100 via adjustment of one or more operating parameters of furnace 100 and/or via adjustment to operation of one or more components of the furnace 100. For example, the regulating module 214 may be configured to regulate the air to fuel ratio utilized by the furnace 100 based on other target parameters or operating modes. In some embodiments, upon determination that the furnace 100 is operating with an efficiency below a threshold value and/or is generating the combustion products 166 with characteristics and/or qualities outside of a desired range of corresponding characteristics and/or qualities, the controller 104 may adjust operation of the furnace 100 to achieve a desired efficiency and/or combustion products 166 quality (e.g., instead of based on a noise output of the furnace 100).

The regulating module 214 may be in communication with the database 204 to reference data stored in the database 204. For example, the database 204 may store one or more threshold values associated with one or more operating parameters of the furnace 100 (e.g., sound level or intensity, vibration amount, frequency) that may be detected by the one or more sensors 150. The threshold values may be associated with a level, intensity, or amount of noise, sound, or other thermoacoustic level (e.g., output level) of the furnace 100 that is desirable to mitigate and/or reduce. Based on receipt of an operating parameter value (e.g., from one of the sensors 150) for a particular operating parameter of the furnace 100, the regulating module 214 may reference the database 204 to obtain a corresponding threshold value associated with the particular operating parameter and compare the detected operating parameter value to the threshold value. In some embodiments, based on a determination that the detected operating parameter value meets or exceeds the corresponding threshold value, the regulating module 214 may determine that an adjustment to operation of the furnace 100 should be implemented, as discussed above. In some embodiments, the regulating module 214 may determine a particular operational adjustment to the furnace 100 (e.g., a particular component to be adjusted, a particular adjustment amount) based on a particular detected operating parameter (e.g., vibration, frequency, sound output), an amount of deviation between a detected operating parameter value and a corresponding threshold value, a location of the sensor 150 (e.g., within the furnace 100) providing the operating parameter value, an operating mode of the furnace 100, a demand or operating capacity of the furnace 100, or any combination thereof. For example, the regulating module 214 may determine a particular adjustment to an air to fuel ratio of the furnace 100 based on one or more of the factors described above.

In some embodiments, the database 204 may also store data related to operational adjustments that may be implemented by the controller 104, such as in response to data received from one or more of the sensors 150 that is indicative of a noise or sound output that exceeds a desired or threshold level. For example, the database 204 may store air to fuel ratio data. For example, the regulating module 214 may reference data in the database 204 and may utilize extracting techniques to determine an air to fuel ratio that should be implemented based on a particular value of a detected operating parameter (e.g., detected noise level, vibration level, and/or a frequency). Additionally or alternatively, the regulating module 214 may determine a particular air to fuel ratio of the furnace 100 to be implemented based on a predetermined relationship, which may be defined by an equation, arithmetic and/or logical operations, and/or other relational expression. For example, the regulating module 214 may be configured to execute an equation utilizing one or more operating parameter values (e.g., detected values, noise value, sound value, vibration value, and/or a frequency value) as inputs to determine a desired operational adjustment to the furnace, such as a desired air to fuel ratio to be implemented that is expected to reduce a noise or sound output by the furnace 100. Based on the air to fuel ratio determined by the regulating module 214, the controller 104 may adjust one or more components of the furnace 100 (e.g., the draft inducer fan 132, the fuel valve 108) to cause the furnace 100 to achieve and/or operate with the determined air to fuel ratio. As will be appreciated, adjusting the air to fuel ratio in accordance with the present techniques may enable a reduction in noise or sound output by the furnace 100 during operation of the furnace 100 while nevertheless enabling the furnace 100 to heat the supply air flow 124 to generate the heated supply air flow 126.

The memory 210 may also include an actuating module 216. The actuating module 216 may communicate with the regulating module 214 to receive data, information, and/or instructions regarding operational adjustments to be implemented with the furnace 100. For example, the regulating module 214 may determine an operational adjustment to one or more components of the furnace 100 that is expected to cause a reduction in a noise or sound output or generated by the furnace 100 and send data, information, and/or instructions corresponding to the operational adjustment to the actuating module 216. In response, the actuating module 216 may operate to implement the operational adjustment. For example, the regulating module 214 may determine that a speed of the draft inducer fan 132 should be increased in order to decrease sound or noise generated by the furnace 100, and the actuating module 216 may output instructions and/or a control signal to the draft inducer fan 132 to increase a speed of the draft inducer fan 132. In some embodiments, the actuating module 216 may control the draft inducer fan 132 to operate at a particular speed (e.g., increased speed, speed value) based on the data received from the regulating module 214. In some embodiments, the actuating module 216 may be configured to incrementally adjust operation of one or more components of the furnace 100 (e.g., incrementally adjust a speed of the draft inducer fan 132, such as until an operating parameter value indicative of undesirable noise falls below a threshold value.

As another example, the regulating module 214 may determine that an air to fuel ratio of the furnace 100 should be adjusted in order to decrease sound or noise generated by the furnace 100. In some embodiments, the regulating module 214 may determine a particular component of the furnace 100 that should be adjusted to achieve a desired air to fuel ratio, and the actuating module 216 may control the particular component accordingly. For example, in a non-modulating embodiment of the furnace 100, the actuating module 216 may output instructions and/or a control signal to adjust a speed of the draft inducer fan 132 to achieve the desired air to fuel ratio. In a modulating embodiment of the furnace, the actuating module 216 may output instructions and/or a control signal to adjust a speed of the draft inducer fan 132 and/or the air flow valve 162 and/or to adjust a position of the fuel valve 108 to achieve the desired air to fuel ratio. In this way, the actuating module 216 may adjust an amount of the fuel 160 and/or the combustion air flow 158 directed into the premixing chamber 168 to generate the air and fuel mixture 164 at the desired air to fuel ratio. For example, based on a determination that a reduced air to fuel ratio is desired, the actuating module 216 may send a signal to the draft inducer fan 132 and/or the air flow valve 162 to decrease a flow rate the combustion air flow 158, thereby decreasing the air to fuel ratio. Conversely, based on a determination that an increased air to fuel ratio is desired, the actuating module 216 may send a signal to the draft inducer fan 132 to increase the flow rate of the combustion air flow 158, thereby increasing the air to fuel ratio.

In accordance with the present techniques, the controller 104 is configured to cause adjustment to operation of the furnace 100 based on one or more detected operating parameters in order to reduce an intensity or level of noise or sound generated by the furnace 100 during operation of the furnace 100. In some embodiments, the controller 104 may be configured to operate the furnace 100 according to the operational adjustment determined by the controller 104 and subsequently evaluate additional (e.g., updated) feedback and/or data received from the one or more sensors 150. For example, after determining and implementing an operational adjustment to the furnace 100 (e.g., increased speed of the draft inducer fan 132), the controller 104 may thereafter receive additional data (e.g., additional operating parameter value) from the one or more sensors 150. Based on the additional data, the controller 104 may determine whether the operational adjustment to the furnace 100 caused a reduction in noise or sound generated by the furnace 100. For example, in some instances, the controller 104 may determine that an operating parameter value associated with sound generated by the furnace 100 falls below a corresponding threshold value indicative of undesirable noise generated by the furnace 100. In response, the controller 104 may control the furnace 100 to continue operating according to the operational adjustment (e.g., operate with the increased draft inducer fan 132 speed, operate with an adjusted air to fuel ratio). In this way, the furnace 100 may continue operating with reduced noise output. Additionally or alternatively, the controller 104 may continue monitoring data received from the one or more sensors 150 to determine whether the noise or sound generated by the furnace 100 remains below a threshold level, and in response to a determination that the noise or sound generated by the furnace 100 remains below the threshold level for a predetermined time period (e.g., elapsed time, tracked by the timer 156), the controller 104 may control the furnace 100 to revert to a previous operation (e.g., a default draft inducer fan 132 speed, operate with a default air to fuel ratio).

In some embodiments, based on a determination that a sound or noise generated by the furnace 100 exceeds a threshold or desirable level and/or based on a determination that an operating parameter value indicative of undesirable noise exceeds a corresponding threshold value, the controller 104 may be configured to generate an alert signal that may be output to a user. For example, the controller 104 may send an alert signal to one or more of the user devices 202. Additionally or alternatively, the controller 104 may be configured to output other alerts or signals to a user to indicate operational adjustment of the furnace 100, such as an alert indicative of an operational adjustment to the furnace 100. As an example, the controller 104 may output an alert indicative of whether the furnace 100 is operating in “quiet” mode, in a “low NOx” mode, in a “high efficiency” mode, and so forth. A particular alert output by the controller 104 may be selected based on operating parameters of the furnace 100, such as operating parameters implemented by the controller 104 (e.g., air to fuel ratio), operating parameters detected by the sensors 150 (e.g., noise or sound level), or both. In some embodiments, the user device 202 may be configured to receive an input from a user to adjust one or more operating parameters of the furnace 100 in response to output of the alert.

FIG. 7 is a flow chart of an embodiment of a method 310 for operating the furnace 100, in accordance with embodiments of the present disclosure. In some embodiments, the method 310 may be performed by the control system 102, such as the controller 104, the processing circuitry 152, the processing circuitry 206, the at least one processors 208, or any combination thereof. In other embodiments, the method 310 may be performed by any other controller of the furnace 100 and/or of an HVAC system having the furnace 100. Further, it should be appreciated that the method 310 may include one or more steps in addition to those described below and/or may include fewer steps than those described below. Additionally or alternatively, one or more steps of the method 310 may be performed simultaneously and/or in a different order than that described below.

As indicated by block 312, the method 310 may begin by initiating an ignition sequence of the furnace 100, whereby the flow of fuel 160 and the combustion air flow 158 are mixed (e.g., within the premixing chamber 168) to form the air and fuel mixture 164, which is ignited by the burner 112 to produce the combustion products 166. The ignition sequence may be initiated in response to a call for heating received by the controller 104. For example, the call for heating may be prompted by a temperature set point (e.g., received via a thermostat, via the user device 202) being above a detected temperature associated with the interior space 170.

The method 310 may proceed to block 314, whereby the furnace 100 may be operated for a burner warm-up period (e.g., warm-up operating mode) The controller 104 may operate the furnace 100 in a warm-up period for a predetermined amount or period of time (e.g., tracked by the timer 156) subsequent to the initiation of the ignition sequence at block 312. For example, the burner warm-up period may extend for approximately 1 minute, 2 minutes, 5 minutes, 10 minutes, or any other suitable time period. In additional or alternative embodiments, the warm-up period 314 may continue until a measured parameter value (e.g., temperature, pressure) of the furnace 100 increases, decreases, and/or otherwise exceeds a threshold parameter value. During the burner warm-up period, the controller 104 may operate the furnace 100 with one or more selected operating parameter values. For example, in order to enable desired operation of the furnace 100 after a period of inactivity, the controller 104 may actuate the fuel valve 108 to an open state (e.g., fully open state, threshold degree of opening) to increase flow of the fuel 160 to the burner 112 and thereby establish an adequate and/or robust flame, to initiate proper generation of the combustion products 166, to increase a temperature of the heat exchanger 114, and so forth. During the warm-up period, the controller 104 may not implement the features and/or techniques discussed above to reduce noise and/or sound generated by the furnace 100.

Following completion of the burner warm-up period at block 314, the method 310 may proceed to block 316. At block 316, the controller 104 may operate the furnace 100 according to a default air to fuel ratio (e.g., of the air and fuel mixture 164). For example, the controller 104 may operate the furnace 100 to achieve a particular default air to fuel ratio, such as based on a heating demand of the furnace 100. That is, the fuel valve 108, the air flow valve 162, and/or the draft inducer fan 132 fan of the furnace 100 may be controlled to achieve and/or maintain a default or preset air to fuel ratio. In some embodiments, the preset air to fuel ratio may be stored in the database 204 of the controller 104. In other embodiments, the preset air to fuel ratio may be provided by a user via the user device 202. In further embodiments, the preset air to fuel ratio may be at least partially based on an ambient (e.g., outdoor) temperature, a parameter of an HVAC system having the furnace 100, a temperature set point of the interior space 170, a target efficiency of the furnace 100, another suitable parameter, or any combination thereof. Additionally, the preset air to fuel ratio may be determined and/or selected based on a target or desired composition (e.g., chemical composition) of the combustion products 166 generated by the furnace 100.

At block 318, the control system 102 may detect one or more operating parameters associated with a noise and/or sound output by the furnace 100. To this end, the controller 104 may receive data from one or more of the sensors 150 configured to detect the operating parameter(s). As mentioned above, the sensors 150 may be positioned one or more of the burners 112, within the housing 106 of the furnace 100, and/or proximate the furnace 100. The sensors 150 may include a sound sensor or audio sensor, such as a microphone (e.g., sound volume sensor), a vibration sensor, such as an accelerometer, or any other measurement device configured to detect an operating parameter indicative of audible sound output (e.g., vibration, frequency, acoustics). In some embodiments, the sensor 150 may be positioned in the combustion chamber 178, the premixing chamber 168, the heat exchanger 114, the interior space 170, the vent 130, another location within the housing 106, or any location suitable to measure undesirable noise generated by the furnace 100. In some embodiments, multiple sensors 150 may be placed within the furnace 100. Further, the detected operating parameters measured by the sensors 150 may be transmitted to the data receiving module 212. In some embodiments, the sensors 150 may measure or detect operating parameters continuously or intermittently (e.g., periodically). Similarly, the controller 104 may be configured to monitor the operating parameter values detected by the sensors 150 continuously or intermittently.

Referring now to block 320, the controller 104 may compare one or more operating parameter values detected by the one or more sensors 150 to a corresponding threshold value (e.g., predetermined value). For example, a corresponding threshold value for a particular operating parameter may be a value indicative of and/or associated with a level of sound or noise output that is undesirable. In some embodiments, the controller 104 may compare a single operating parameter value (e.g., single detected value) to the corresponding threshold value. In other embodiments, the controller 104 may compare an average value of an operating parameter to the corresponding threshold value, where the average value is calculated based on multiple detected values of the operating parameter over a predetermined period of time (e.g., 10 seconds, 20 seconds, 30 seconds, etc.). In some embodiments, the sensed data may be compared by the controller 104 (e.g., the regulating module 214) subsequent to lapse of preterminal time period (e.g., operating time, determined by the timer 156) and/or subsequent to a predetermined number of operating cycles (e.g., furnace cycles). The predefined time period and/or the predefined number of cycles may be stored in the database 204 and referenced by the controller 104. Alternatively, the predefined time period and/or the predefined number of cycles may be specified by a user via the user device 202.

Operation of the furnace 100 may be controlled based on the comparison of the operating parameter value with the corresponding threshold value. For example, at block 322, the controller 104 may determine whether an operating parameter value detected by the sensor 150 exceeds (e.g., is greater than, is less than) a corresponding threshold value. In some embodiments, the controller 104 may determine whether an operating parameter value (e.g., frequency value) is outside of (e.g., above, below) a range of values. As discussed above, the corresponding threshold value may be indicative of a value above or below which a noise or sound output level generated by the furnace 100 is greater than a desirable level (e.g., an audible level). Additionally or alternatively, a corresponding range of values (e.g., range of threshold values) of a particular operating parameter may be indicative of a range of values within which a noise or sound output level generated by the furnace 100 is equal to or less than an audible level or other suitable level. Therefore, a determination that an operating parameter value is outside of a corresponding threshold range of values may be indicative of sound output by the furnace 100 that exceeds an audible or desirable level (e.g., within the interior space 170).

In some embodiments, one or more of the corresponding threshold values for operating parameters detected by the sensors 150 may be adjusted by a user. Additionally or alternatively, the controller 104 may be configured to receive a user input (e.g., via the user device 202) indicative of a threshold sound level at and/or below which the user desires the furnace 100 to operate. That is, the user may input an upper limit (e.g., maximum) level of sound or noise that the furnace 100 should not exceed during operation. In such embodiments, the controller 102 may be configured to establish (e.g., via data stored in the database 204) one or more corresponding threshold values associated with corresponding operating parameters detected by the sensors 150. In this way, the controller 104 may be configured to adjust operation of the furnace 100 to cause the furnace 100 to operate without generating sound or noise that exceeds the upper limit level of sound designated by the user. In other embodiments, the predetermined noise level may be a fixed or preset noise level of the furnace 100.

In certain embodiments, the threshold sound level and/or corresponding threshold values of operating parameters associated with the threshold sound level may be determined based on a presence of occupants in the interior space 170 and/or in a space adjacent to the furnace 100. For example, upon a determination (e.g., by the controller 104, based on data from one of the sensors 150, such as an occupancy sensor) that the interior space 170 or a space adjacent to the furnace 100 is not occupied, the controller 104 may adjust the predetermined threshold sound level and/or corresponding threshold values of operating parameters associated with the threshold sound level to a relatively higher level or value. As such, the furnace 100 may operate with the default air to fuel ratio (e.g., a more efficient air to fuel ratio), as described with reference to block 316, while no occupants are detected within the interior space 170. In this way, the furnace 100 may operate with fewer restrictions and/or greater efficiency.

In some embodiments, the controller 104 may be configured to execute the steps at blocks 318, 320, and/or 322 for a predetermined period of time (e.g., tracked by the timer 156). That is, the controller 104 may be configured to compare one or more operating parameter values detected by the sensor 150 to the corresponding threshold value to determine whether one or more detected operating parameter values exceeds the corresponding threshold value during the predetermined period of time. In this way, the controller 104 may enable the furnace 100 to achieve a steady state operation and/or better verify whether operation of the furnace 100 (e.g., utilizing the default air to fuel ratio) causes the furnace 100 to operate with generated sound or noise that exceeds a desired amount or intensity. In some embodiments, the controller 104 may be configured to determine an average value of the one or more operating parameter values detected by the sensor 150 and compare the average value to the corresponding threshold value to determine whether the average value exceeds the corresponding threshold value during the predetermined period of time.

Based on a determination that the operating parameter value does not exceed the corresponding threshold value (e.g., the sound output by the furnace 100 does not exceed a threshold sound level, during a predetermined period of time) at block 322, the method 310 may proceed to block 324. At block 324, the controller 104 may continue operating the furnace 100 without an operational adjustment to reduce an amount or intensity of sound generated by the furnace 100. For example, the controller 104 may continue operating the furnace 100 utilizing the default air to fuel ratio descried above. That is, the fuel valve 108, the air flow valve 162, and/or the draft inducer fan 132 of the furnace 100 may be controlled to maintain the default air to fuel ratio. As described in detail above, the preset air to fuel ratio may be stored in the database 204. From block 324, the method 310 may return to block 318, whereby the control system 102 may continue monitoring operating parameter values detected by the sensors 150 to evaluate a level, intensity, or amount of sound generated by the furnace 100 in accordance with the present techniques. In some embodiments, the controller 104 may maintain operation of the furnace 100 with the default air to fuel ratio for a preset time period or a preset number of furnace 100 cycles at block 324 before returning to block 318. After the preset time period or preset number of furnace 100 cycles, the method 310 may return to block 318 to detect operating parameter values detected by the sensors 150 to evaluate a level, intensity, volume, or amount of sound generated by the furnace 100

If, at block 322, the controller 104 determines that the operating parameter value exceeds (e.g., meets or exceeds) the corresponding threshold value, the method 310 may proceed to block 326. At block 326, the controller 104 may determine an adjustment to the air to fuel ratio. That is, based on a determination that the data collected by the sensor 150 is indicative of a noise or sound output level that exceeds a predetermined threshold sound output level, the controller 104 may determine that an operational adjustment to the furnace 100 should be implemented. In particular, the controller 104 may determine an adjustment to the air to fuel ratio of the furnace 100 in order to enable a reduction in a level or amount of sound generated by the furnace 100. In some embodiments, the controller 104 may adjust (e.g., incrementally adjust) the air to fuel ratio until the operating parameter value falls below the corresponding threshold value (e.g., until the sound output level falls below the predetermined threshold sound output level).

As discussed in detail above, the controller 104 may determine an updated air to fuel ratio based on the air to fuel ratio data stored in the database 204. In some embodiments, a reference range of sound output levels and corresponding air to fuel ratio values may be stored and referenced to determine a particular updated air to fuel ratio to implement with the furnace 100. Similarly, a reference range of operating parameter values (e.g., sound values, vibration values, frequency values) and corresponding air to fuel ratio values may be stored and referenced to determine a particular updated air to fuel ratio.

After the air to fuel ratio adjustment (e.g., updated air to fuel ratio) and/or other operational adjustment of the furnace 100 is determined, the method 310 may proceed to block 328, whereby the controller 104 may adjust operation of the furnace 100 to implement the air to fuel ratio adjustment. For example, the controller 104 may generate and send one or more control signals to the fuel valve 108, the air flow valve 162, and/or the draft inducer fan 132 to adjust operation of the furnace 100 and utilize the updated air to fuel ratio. As discussed above, the controller 104 may control the furnace 100 to adjust a flow rate of the fuel 160 and/or a flow rate of the combustion air flow 158 directed into the furnace 100 to reduce the amount or level of sound generated by the furnace 100. It should be noted that, in embodiments of the furnace 100 that are non-modulating, the controller 104 may implement the air to fuel ratio adjustment by adjusting operation of the air flow valve 162 and/or the draft inducer fan 132 without adjusting operation of the fuel valve 108. The method 310 may then return to block 318, whereby the control system 102 may continue monitoring operating parameter values detected by the sensors 150 to evaluate a level or amount of sound generated by the furnace 100 in accordance with the present techniques. In some embodiments, the controller 104 may operate the furnace 100, at block 328, utilizing the updated air to fuel ratio for a preset time period (e.g., monitored by timer 156) and/or for a preset number of furnace 100 cycles. After the preset time period lapses or preset number of furnace 100 cycles are completed, the controller 104 may restart the method 310, in some embodiments.

FIG. 8 is a flow chart of an embodiment of a method 400 for operating the furnace 100, in accordance with embodiments of the present disclosure. The method 400 includes blocks 312, 314, 316, 318, 320, 322, 324, and 326 similar to those described above with reference to FIG. 7, which may be implemented in a similar manner. The illustrated embodiment also includes additional steps configured to enable more efficient operation of the furnace 100.

For example, subsequent to the step in block 326, whereby the controller 104 may determine an adjustment to the air to fuel ratio of the furnace 100 in order to enable a reduction in a level or amount of sound generated by the furnace 100, the method 400 may proceed to block 402. At block 402, the controller 104 may further determine whether an updated air to fuel ratio (e.g., including the air to fuel ratio adjustment) is outside of a reference range of air to fuel ratios. For instance, the reference range of air to fuel ratios may include a range of air to fuel ratios associated with more efficient operation of the furnace 100 (e.g., low NOx operation). For example, the reference range of air to fuel ratios may include air to fuel ratios that enable operation of the furnace 100 with reduced and/or more desirable emissions, such as a reduced amount of NOx compounds within the combustion products 166. In some embodiments, the reference range of air to fuel ratios may also be determined and/or selected based on a set point temperature for the interior space 170 (e.g., a desired amount of heating), an ambient temperature, and/or other operating parameters of the furnace 100 (e.g., detected by the sensors 150). It should be appreciated that the controller 104 may store (e.g., in the database 204) a plurality of reference ranges that may be referenced, utilized, and/or selected by the controller 104 at block 402 based on a particular operation and/or operating parameter of the furnace 100.

Based on a determination that an updated air to fuel ratio (e.g., incorporating the air to fuel ratio adjustment determined at block 326) is not outside of a reference range of air to fuel ratios, the method 400 may proceed to block 404. At block 404, the controller 104 may adjust operation of the furnace 100 to implement the air to fuel ratio adjustment and/or the updated air to fuel ratio. For example, the controller 104 may generate and send one or more control signals to the fuel valve 108, the air flow valve 162, and/or the draft inducer fan 132 to adjust operation of the furnace 100 and utilize the updated air to fuel ratio. As discussed above, the controller 104 may control the furnace 100 to adjust a flow rate of the fuel 160 and/or a flow rate of the combustion air flow 158 directed into the furnace 100 to achieve the updated air to fuel ratio and thereby reduce the amount or level of sound generated by the furnace 100. From block 404, the method 400 may return to block 318, whereby the control system 102 may continue monitoring operating parameter values detected by the sensors 150 to evaluate a level or amount of sound generated by the furnace 100 in accordance with the present techniques. In some embodiments, the controller 104 may maintain operation of the furnace 100 with the updated air to fuel ratio for a preset time period or a preset number of furnace 100 cycles at block 324 before returning to block 318. After the preset time period or preset number of furnace 100 cycles, the method 400 may return to block 318 to detect operating parameter values detected by the sensors 150 to evaluate a level or amount of sound generated by the furnace 100

If, at block 402, the controller 104 determines that the updated air to fuel ratio (e.g., incorporating the air to fuel ratio adjustment determined at block 326) is outside of a reference range of air to fuel ratios, the method 400 may proceed to block 406. At block 406, the controller 104 may determine an alternative air to fuel ratio adjustment and/or may determine an alternative updated air to fuel ratio to be implemented with the furnace 100. In particular, the controller 104 may determine the alternative air to fuel ratio adjustment based on the reference range of air to fuel ratios. For example, the controller 104 may be configured to select a particular air to fuel ratio within the reference range of air to fuel ratios that best approximates the air to fuel ratio adjustment determined at block 326. In some embodiments, the controller 104 may select an air to fuel ratio within the reference range that is closest to the air to fuel ratio adjustment determined at block 326. For example, upon a determination that the updated air to fuel ratio falls below the reference range of air to fuel ratios at block 404, the controller 104 may select a lowest air to fuel ratio of the reference range as the updated air to fuel ratio. Similarly, upon a determination that the updated air to fuel ratio exceeds the reference range of air to fuel ratios at block 404, the controller 104 may select a highest air to fuel ratio in the reference range as the updated air to fuel ratio. The method 400 may then proceed from block 406 to block 404, whereby the controller 104 may control the furnace 100 to adjust a flow rate of the fuel 160 and/or a flow rate of the combustion air flow 158 directed into the furnace 100 to achieve the selected, updated air to fuel ratio and thereby reduce the amount or level of sound generated by the furnace 100. In this way, the method 400 may enable a reduction in sound or noise output by the furnace 100, while also enabling more efficient operation of the furnace 100.

As discussed in detail above, present embodiments include a control system configured to detect a parameter indicative of noise generated by a furnace, evaluate a noise output of the furnace based on the parameter, and adjust operation of the furnace based on a determination that the noise output is greater than a threshold noise level. In particular, based on a determination that the detected and/or determined noise output is greater than a predetermined threshold noise level, the control system may adjust operation of the furnace to cause a reduction in the noise output by the furnace. For example, the controller may adjust one or more components of the furnace to adjust an air to fuel ratio of the air and fuel mixture ignited by the burner. By adjusting operation of the furnace (e.g., the air to fuel ratio) in this manner, present embodiments may enable a reduction in an amount of noise (e.g., vibrations, audible noise, thermoacoustic noise) generated during operation of the furnace. In this way, the furnace system may operate with reduced noise output, thereby decreasing audible noise that may otherwise be perceived by occupants of a space conditioned by the furnace.

While only certain features and embodiments have been illustrated and described, many modifications and changes may occur to those skilled in the art, such as variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, such as temperatures and pressures, mounting arrangements, use of materials, colors, orientations, and so forth, without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode, or those unrelated to enablement. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

NOISE ABATEMENT SYSTEMS AND METHODS FOR A FURNACE

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