Systems and Methods for Providing Retroactive Wireless Connectivity to HVAC Systems

TECHNICAL FIELD

The present disclosure is generally in the field of wireless communication systems for providing wireless connectivity to non-communicating HVAC systems.

BACKGROUND

Heating, ventilation, and air conditioning (HVAC) systems may be communicating or non-communicating. In a non-communicating system, the thermostat acts as a switch, and completes a circuit to deliver voltage to a component of the HVAC system, e.g., an indoor unit such as an air handler or furnace, and/or an outdoor unit such as an air conditioning (AC) unit, to cause the component to turn on or off until a temperature set point is reached. Typically, HVAC systems run on a 24 Volt power supply. In a communicating system, the thermostat may search for components of the HVAC system, e.g., via a Bluetooth connection, and once paired with the component, the component may communicate its capabilities and/or internal operations parameters, which may allow for optimal performance of the HVAC system. Currently, non-communicating components may not communicate with communicating components.

The foregoing background information is provided to reveal information believed by the applicant to be of possible relevance to the present disclosure. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a wireless communication system for providing wireless connectivity between a communicating indoor unit and a non-communicating outdoor unit constructed in accordance with the principles of the present disclosure.

FIG. 2 illustrates some example components that may be included in the wireless connectivity device of the system of FIG. 1 in accordance with the principles of the present disclosure.

FIG. 3 illustrates a wireless communication system for providing wireless connectivity between a non-communicating indoor unit and a communicating outdoor unit constructed in accordance with the principles of the present disclosure.

FIG. 4 illustrates some example components that may be included in the wireless connectivity device of the system of FIG. 3 in accordance with the principles of the present disclosure.

FIG. 5 illustrates a wireless communication system for providing wireless connectivity between a non-communicating indoor unit and a non-communicating outdoor unit constructed in accordance with the principles of the present disclosure.

FIG. 6 illustrates some example components that may be included in the wireless connectivity device of the system of FIG. 5 in accordance with the principles of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed to systems and methods for providing wireless connectivity to a system, e.g., an HVAC system, including at least one non-communicating unit, e.g., an outdoor unit such as an AC unit or heat pump and/or an indoor unit such as an air handler or a furnace (as well as any other type of HVAC unit). A non-communicating unit does not have electronic communication capabilities and thus cannot communicate data to other units in the HVAC system. Instead, the non-communicating unit may simply be instructed to turn on or off. For example, a circuit electrically coupled to the non-communicating unit may be completed, e.g., via a command signal transmitted by a thermostat, such that voltage may be transmitted to the non-communicating unit to power on. Moreover, the circuit may be broken to cease delivery of voltage to thereby power off the non-communicating unit. In some digital systems, the command signals further may include a temperature set point along with the on/off command. For example, the indoor unit may send a command signal to the outdoor unit instructing the outdoor unit to turn on and to operate in a manner to achieve a predetermined temperature, such as by providing air conditioned to a certain temperature, etc. In contrast, a communicating unit may have the capability to measure and communicate data, e.g., data indicative of its capabilities and/or internal operations parameters, to facilitate optimization of the HVAC system.

In accordance with the principles of the present disclosure, the systems described herein may include a wireless connectivity device that may be mechanically and operatively coupled to or otherwise integrated with the non-communicating unit, to thereby provide communication capabilities to the non-communicating unit. Beyond simply providing basic communication to the non-communicating unit, the wireless connectivity device may further be used to determine or monitor system operation and diagnostic services. Moreover, the wireless connectivity device may provide demand response interactions between third party utility providers and the HVAC system. For example, state and/or local regulations may at times require limitations of electricity usage, such as by prohibiting thermostats from being lowered beyond a predetermined temperature, and utility providers may provide incentives to homeowners in exchange. Through the wireless connectivity device, with permission, utility providers may access data indicative of internal operations of the HVAC system, and send appropriate commands to devices of the HVAC system to automatically limit usage.

Therefore, the use of the wireless connectivity device improves upon conventional HVAC systems by providing for remote monitoring and control of HVAC systems including non-communicating units, which would otherwise be impossible in such conventional systems. As one example, a homeowner may use an application of a mobile device (such as a smartphone, laptop computer, tablet, etc.) that is connected to the Internet to view data about the non-communicating unit or control the non-communicating unit. Continuing the same example, the homeowner may be able to remotely control the operation of a legacy HVAC unit that would otherwise not have communication capabilities to set a temperature within a home (reference to a home is only exemplary and other types of buildings may also be applicable) via the application. As another example, a technician may be provided diagnostic information about the non-communicating HVAC unit and may be able to remotely diagnose the non-communicating unit before arriving at the location of the home. In some instances, the technician may be able to send a signal to resolve an issue with the unit or, at the very least, may have knowledge of the issue with the unit prior to arriving at the location of the home such that the technician may arrive at the home with the correct tools and/or parts to perform maintenance on the unit. As yet another example, if a home includes non-communicating units and one of the units is replaced with a newer communicating unit, a wireless connectivity device may be provided in the non-communicating unit to allow the homeowner to control both the new unit and the older non-communicating unit.

Some representative embodiments will be described more fully hereinafter with example reference to the accompanying drawings that illustrate embodiments of the disclosure. Embodiments may take many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those appropriately skilled in the art.

In accordance with one aspect of the present disclosure, a wireless connectivity device for an HVAC system is provided. The wireless connectivity device may include one or more sensors that may be operatively coupled to a non-communicating unit of the HVAC system, and to measure one or more internal operations parameters of the non-communicating unit, a communication module, such as a cellular module, that may wirelessly communicate data between the wireless connectivity device and the HVAC system, at least one processor, and memory having instructions that, when executed by the at least one processor, causes the at least one processor to determine a state of internal operations of the non-communicating unit based on the measured one or more internal operations parameters, e.g., the real-time operating conditions of the non-communicating unit based on at least one of, for example, current, pressure, temperature, vibration, or noise associated with the non-communicating unit.

For example, the wireless connectivity device may be configured to be mechanically and operatively coupled to the non-communicating unit, e.g., via a wired connection or wireless connection. Alternatively, the wireless connectivity device may be integrated with the non-communicating unit, e.g., built into the hardware of the non-communicating unit at the time of manufacture. The communication module may communicate data between the wireless connectivity device and the HVAC system via at least one of a WiFi, Bluetooth, or cellular connection. The communication module may include a wired communication bus, or alternatively, a wireless communication bus.

The processor may be programmed to determine the state of internal operations of the non-communicating unit by comparing the measured one or more internal operations parameters with one or more baseline internal operations parameters. Accordingly, the processor may be programmed to adjust operations of the non-communicating unit if the measured one or more internal operations parameters is outside of a predetermined threshold range of the one or more baseline internal operations parameters. The one or more sensors may include at least one of a current sensor that may measure current associated with the non-communicating unit, a pressure sensor that may measure pressure associated with the non-communicating unit, a temperature sensor that may measure temperature associated with the non-communicating unit, an accelerometer that may measure vibration associated with the non-communicating unit, or an audio sensor that may measure noise associated with the non-communicating unit.

The wireless connectivity device may be communicatively coupled to a cloud storage for storing information indicative of the state of internal operations of the non-communicating unit received from the wireless connectivity device. The cloud storage may share the information indicative of the state of internal operations of the non-communicating unit with one or more third parties, e.g., the manufacturer of the non-communicating unit, or an HVAC contractor or other persons with permission to access the data including the user/homeowner. Accordingly, the wireless connectivity device may control operations of the non-communicating unit responsive to one or more commands received from the one or more third parties. In some embodiments, the non-communicating unit may be an outdoor unit, and the wireless connectivity device may be communicatively coupled to, e.g., a thermostat, which may in turn be communicatively coupled to a mobile application for receiving user input. Alternatively, the wireless connectivity device may be communicatively coupled to the mobile application. In some embodiments, the non-communicating unit may be an indoor unit, and the wireless connectivity device may be communicatively coupled to, e.g., a mobile application programmed to communicate user input to the wireless connectivity device. Moreover, the non-communicating unit may be communicatively coupled to a thermostat. Alternatively, the wireless connectivity device further may include a thermostat communicatively coupled to the mobile application.

In accordance with another aspect of the present disclosure, an HVAC system is provided. The HVAC system may include an indoor unit, an outdoor unit, and a wireless connectivity device that is operatively coupled to at least one of the indoor unit or the outdoor unit. The wireless connectivity unit may include one or more sensors that may measure one or more internal operations parameters of the at least one of the indoor unit or the outdoor unit, and a communication module that may wirelessly communicate data between the wireless connectivity device and the HVAC system. The HVAC system further may include at least one processor, and memory having instructions that, when executed by the at least one processor, causes the at least one processor to determine a state of internal operations of the at least one of the indoor unit or the outdoor unit based on the measured one or more internal operations parameters.

The processor may be programmed to adjust operations of the at least one of the indoor unit or the outdoor unit if the measured one or more internal operations parameters is outside of a predetermined threshold range. The wireless connectivity device may be communicatively coupled to a cloud storage for storing information indicative of the state of internal operations of the non-communicating unit received from the wireless connectivity device. The cloud storage may share the information indicative of the state of internal operations of the at least one of the indoor unit or the outdoor unit with one or more third parties. Accordingly, the wireless connectivity device may control operations of the non-communicating unit responsive to one or more commands received from the one or more third parties.

The indoor unit may include at least one of an air handler or a furnace, and the outdoor unit may be an air conditioning unit or heat pump. In some embodiments, the indoor unit is communicating and the outdoor unit is non-communicating. Accordingly, the wireless connectivity device may be operatively coupled to the outdoor unit, and the processor may be programmed to determine a state of internal operations of the outdoor unit based on one or more measured internal operations parameters associated with the outdoor unit. Alternatively, the outdoor unit may be communicating and the indoor unit may be non-communicating. Accordingly, the wireless connectivity device may be operatively coupled to the indoor unit, and the processor may be programmed to determine a state of internal operations of the indoor unit based on one or more measured internal operations parameters associated with the indoor unit. In some embodiments, the outdoor unit is non-communicating and the indoor unit is non-communicating. Accordingly, the wireless connectivity device may be operatively coupled to the indoor unit and a second wireless connectivity device is operatively coupled to the indoor unit, such that the second wireless connectivity device is communicatively coupled to the wireless connectivity device.

While reference is made herein to HVAC systems, similar wireless connectivity may also be provided to systems that include other types of units, such as water heaters, for example.

Referring now to FIG. 1, an HVAC system with wireless connectivity capabilities is provided. System 100 may include communicating indoor unit 110, controller 120, non-communicating outdoor unit 130, wireless connectivity device 200, and/or cloud storage 160. Indoor unit 110, controller 120, wireless connectivity device 200, and/or cloud storage 160 may all be communicatively coupled via, e.g., network 150. Network 150 may include any one, or a combination of networks, such as a local area network (LAN), a wide area network (WAN), a telephone network, a cellular network, a cable network, a wireless network, and/or private/public networks, such as the Internet. For example, network 150 may support communication technologies, such as TCP/IP, Bluetooth, cellular, near-field communication (NFC), WiFi, WiFi direct, machine-to-machine communication, man-to-machine communication, and/or visible light communications. Although only one network 150 is shown in FIGS. 1, 3, and 5, as will be understood by a person having ordinary skill in the art, network 150 may encompass various communication networks for communication between different components of the systems described herein. As an example, the controller, e.g., thermostat, may communicate with the indoor unit, e.g., an air handling unit and/or furnace, via a WiFi connection over network 150, and the system components, e.g., the wireless communication device and/or other components with communications capabilities, may communicate with cloud storage 160 via a cellular connection over network 150, or alternatively, over a WiFi connection over network 150.

Indoor unit 110 may be, e.g. an air handling unit that regulates and circulates air as part of an HVAC system, and/or a furnace that generates heat from fuel source such as natural gas, oil, or electricity. For example, indoor unit 110 may include a filter, a blower, a heating element, and/or a cooling element for ventilating, heating, and/or cooling air. Indoor unit 110 generally may be disposed within a home, e.g., in a basement or attic or other appropriately sized location. Indoor unit 110 may be fluidicly coupled to outdoor unit 130 via, e.g., a duct system that permits air flow therebetween.

Controller 120, e.g., a thermostat, may be communicatively coupled to communicating indoor unit 110 for transmitting commands to indoor unit 110 and/or receiving data from indoor unit 110, e.g., data indicative of the capabilities and/or internal operation parameters of indoor unit 110. For example, controller 120 may be a smart thermostat such as an EcoNet® Smart Thermostat. Alternatively, controller 120 may be a standard programmable thermostat. Controller 120 may communicate with indoor unit 110 via a wired connection, or alternatively, via a wireless connection, e.g., WiFi or Bluetooth, over network 150.

In some instances, the controller 120 may be configured to auto-poll the wireless connectivity device 200 to obtain data about the non-communicating outdoor unit 130. For example, the controller 120 may request data from the wireless connectivity device 200 periodically at pre-determined intervals. This not only allows for data about the non-communicating outdoor unit 130 to be automatically obtained but also prevents data transmission bandwidth from being used when it is desired for such bandwidth to be used for data communications between other devices.

Outdoor unit 130 may be, e.g., an AC unit that cools air by removing heat from the air for circulation via, e.g., the blower of indoor unit 110. Outdoor unit 130 generally may be disposed outside a home, and may be operatively coupled to indoor unit 110 and/or controller 120 via a wired connection. Unlike traditional HVAC systems where a non-communicating outdoor unit may only be instructed by the HVAC system to turn on or off, e.g., via a 24 Volt power supply, system 100 further includes wireless connectivity device 200 that provides wireless communication capabilities to a non-communicating unit, e.g., outdoor unit 130. Accordingly, wireless connectivity device 200 may be mechanically and operatively coupled to, or otherwise integrated with outdoor unit 130. Moreover, wireless connectivity device 200 may be electrically powered, e.g., via an electric outlet and/or internal battery.

In addition, wireless connectivity device 200 may include one or more sensors that may measure one or more parameters associated with outdoor unit 130, e.g., internal operations parameters such as current, pressure, and temperature. For example, wireless connectivity device 200 may include three temperature sensors, two pressure sensors, and one current sensor. As will be understood by a person having ordinary skill in the art, wireless connectivity device 200 may include less or more than three temperature sensors, less or more than two pressure sensors, and less or more than one current sensor. In some embodiments, the one or more sensors further may include one or more accelerometers that may measure vibration, and/or one or more audio sensors that may detect noises associated with component parts of outdoor unit 130. Accordingly, additional internal operations parameters associated with outdoor unit 130 that may be measured by the one or more sensors include vibration and noise.

In some instances, the one or more sensors may be in electrical communication with the wireless connectivity device 200 such that the one or more sensors may be provided at various locations within the HVAC system physically separate from the wireless connectivity device 200. For example, the wireless connectivity device may be provided in a portion of the HVAC system including electronics used by the HVAC system and the one or more sensors may be provided proximate to components that the sensors are measuring.

The wireless connectivity device 200 may also be used to supplement an existing sensor suite of an HVAC system. For example, an HVAC system may already have temperature sensors used to capture temperature data for the HVAC system, but may not have a current sensor. The wireless connectivity device 200 may be provided with a current sensor to supplement the temperature sensors are capture additional information about the HVAC system.

As shown in FIG. 1, wireless connectivity device 200 may include communication module 204, e.g., a wireless transceiver, that may connect to and communicate data over network 150. Communication module 204 may provide any combination of, e.g., WiFi, Bluetooth, or cellular connections or any other wireless connections supported by network 150 described above, between wireless connectivity device 200 and the components of system 100. For example, communication module 204 may provide at least one of WiFi, Bluetooth, ZigBee, NFC, WiMAX, LTE, HSPA, EV-DO, UMTS, earlier 3G standards, satellite services, etc. In some embodiments, communication module 204 may include a wired communication bus, such as EcoNet®. Additionally or alternatively, communication module 204 may include wireless communication bus such as Bluetooth. Accordingly, communication module 204 may connect wireless connectivity device 200 with the other components of system 100, e.g., indoor unit 110, controller 120, and cloud storage 160, such that data may be communicated therebetween.

Moreover, in some embodiments, wireless connectivity device 200 may leverage an existing WiFi connection, e.g., a homeowner's WiFi internet network, to connect to cloud storage 160, rather than connecting via the cellular network of communication module 204, which may have associated costs such as monthly fees, and may be slower than the WiFi connection. Similarly, components of system 100 such as indoor unit 110 and/or controller 120, may wirelessly communicate via a homeowner's WiFi internet network, and may use the cellular network of communication module 204 as a backup if the WiFi internet network is unable to connect to cloud storage 160.

The use of the wireless connectivity device allows for the formation of a mesh network including both communicating units and non-communicating units in the HVAC system. This allows for multiple different types of units to communicate via a single shared network. This also allows for the communication range of units in the network to be increased. For example, a first non-communicating unit may include a wireless connectivity device 200 that allows the first non-communicating unit to communicate with other units via short-range wireless communications. A second unit may be within a distance of the first non-communicating unit allowing the first non-communicating unit to communicate with the second unit. However, a third unit may be a distance from the first non-communicating unit that is too far for the short-range wireless communications to be performed between the first non-communicating unit and the third unit. With the existence of the mesh network, the second unit may be able to relay messages between the first non-communicating unit and the third unit to allow for communications to be performed between the two units. Furthermore, the use of the mesh network allows for communications to be re-routed via other units if one of the units experiences a failure that prevents that particular unit from performing communications.

Controller 120 further may be communicatively coupled to wireless connectivity device 200 over network 150 for communicating with outdoor unit 130. Accordingly, controller 120 may transmit commands to wireless connectivity device 200 to thereby provide instructions to outdoor unit 130, and/or receive data from wireless connectivity device 200, e.g., data indicative of the capabilities and/or internal operations parameters of outdoor unit 130 measured by the one or more sensors of wireless connectivity device 200 operatively coupled to outdoor unit 130.

Moreover, controller 120 may include a user interface for receiving user input, e.g., a command to turn indoor unit 110 and/or outdoor unit 130 on or off and optionally a temperature set point, and generate and transmit one or more command signals indicative of the user input to indoor unit 110 and/or wireless connectivity device 200, e.g., via a WiFi connection over network 150. In some embodiments, controller 120 may be communicatively coupled to a mobile application running on a mobile device, e.g., via a WiFi or Bluetooth connection over network 150, such that controller 120 may receive user input via the mobile application. Accordingly, controller 120 may be operatively coupled to one or more temperature sensors that may measure temperature, e.g., within a room of a home, such that temperature may be monitored by controller 120, and controller 120 may instruct indoor unit 110 and/or outdoor unit 130 to operate until the temperature set point is achieved in accordance with the user input.

In addition, controller 120 and/or wireless connectivity device 200 may optimize performance of system 100 by taking into account capabilities and internal operations parameters of indoor unit 110 and/or outdoor unit 130. For example, controller 120 and/or wireless connectivity device 200 may take into account device capabilities including, but not limited to, max blower speed, max heating/cooling temperature, and/or power usage of indoor unit 110, and max cooling temperature and/or power usage of outdoor unit 130. Accordingly, controller 120 and/or wireless connectivity device 200 may adjust operations of indoor unit 110 and/or outdoor unit 130 responsive to the internal operations parameters of indoor unit 110 and/or outdoor unit 130, while considering the respective device capabilities.

Moreover, controller 120 may record and share internal operations parameters of indoor unit 110 and/or outdoor unit 130 with a third party, e.g., via cloud storage 160, which may be indicative of one or more operating issues of indoor unit 110 and/or outdoor unit 130, necessitating repair or replacement. The data may be reviewed remotely by a professional for identifying potential issues, thereby saving time otherwise required for the professional to conduct a home visit in order to identify the issue. In some embodiments, controller 120 may process the recorded data and execute diagnostic functions to identify potential issues associated with the operation of indoor unit 110 and/or outdoor unit 130. Moreover, controller 120 may communicate an alert to the user, e.g., by displaying the alert via the user interface of controller 120 or a mobile application communicatively coupled to controller 120, and/or share data indicative of the identified issues, e.g., via cloud storage 160.

Information shared between indoor unit 110, controller 120, and/or wireless connectivity device 200 may be stored on cloud storage 160 and may be bi-directional in nature. For example, in one case, information indicative of internal operations parameters associated with indoor unit 110 and/or outdoor unit 130 may be transferred from wireless connectivity device 200 to cloud storage 160. Such information stored on cloud storage 160 may be subsequently accessed and used by the components of system 100 and/or a third party.

Referring now to FIG. 2, components that may be included in wireless connectivity device 200 are described in further detail. Wireless connectivity device 200 may include one or more processors 202, communication module 204, and memory 206. As described above, communication module 204 allows wireless connectivity device 200 to communicate with indoor unit 110, controller 120, and cloud storage 160 over one or more communication networks of network 150. Communication module 204 may use any of various communication formats, such as, for example, an Internet communications format, or a cellular communications format.

Memory 206, which is one example of a non-transitory computer-readable medium, may be used to store operating system (OS) 208, sensors interface module 210, internal operations determination module 212, non-communicating device interface module 214, communicating device interface module 216, thermostat interface module 218, and cloud storage interface module 220. The modules are provided in the form of computer-executable instructions that may be executed by processor 202 for performing various operations in accordance with the disclosure. Memory 206 may include any one memory element or a combination of volatile memory elements (e.g., random access memory (RAM, such as DRAM, SRAM, SDRAM, etc.)) and non-volatile memory elements (e.g., ROM, hard drive, tape, CDROM, etc.). In the context of this document, a “non-transitory computer-readable medium” may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device.

Sensors interface module 210 may be executed by processor 202 for receiving and processing data measured by the one or more sensors of wireless connectivity device 200 operatively coupled to outdoor unit 130. For example, sensors interface module 210 may receive and process data indicative of at least one of current associated with outdoor unit 130 from one or more current sensors, e.g., current of the motor of outdoor unit 130, pressure associated with outdoor unit 130 from one or more pressure sensors, e.g., fluid pressure within the coils of outdoor unit 130, temperature associated with outdoor unit 130 from one or more temperature sensors, e.g., ambient temperature and/or temperature of electronic components of outdoor unit 130, vibration associated with outdoor unit 130 from one or more accelerometers, e.g., movement of mechanical components of outdoor unit 130, or noise associated with outdoor unit 130 from one or more audio sensors, e.g., noise emitted from the electronic and/or mechanical components of outdoor unit 130.

Internal operations determination module 212 may be executed by processor 202 for analyzing the data obtained and processed by sensors interface module 210 to determine the state of internal operations of outdoor unit 130, e.g., the real-time operating conditions of outdoor unit 130 based on at least one of current, pressure, temperature, vibration, or noise associated with outdoor unit 130. For example, based on the current data, internal operations determination module 212 may determine the amount of current outdoor unit 130 consumes, and compare it with a baseline and/or predetermined threshold amount associated with the baseline stored in memory 206 to determine if outdoor unit 130 is drawing less or more current than under normal and/or tolerable operating conditions. For example, if internal wires are broken and/or the motor of outdoor unit 130 is not working, the current data would indicate that outdoor unit 130 is drawing zero current. Moreover, if a rotor of outdoor unit 130 is locked, e.g., due to damage by a fallen tree on outdoor unit 130, the current data may indicate that outdoor unit 130 is drawing more current than expected.

Based on the pressure data, alone or in combination with the current data, internal operations determination module 212 may determine if refrigerant is leaking or overcharged. For example, internal operations determination module 212 may compare fluid pressure and/or current data with one or more baselines and/or predetermined thresholds stored in memory 206 to determine whether the fluid within the coil lines of system 100 is within an acceptable amount. Although the pressure data alone may be indicative of whether the fluid pressure levels within the coils are acceptable, as the fluid pressure within the coils may be different depending on whether outdoor unit 130 is running or not, the current data in combination with the pressure data may provide more information than pressure data alone. Based on the temperature data, internal operations determination module 212 may determine the ambient temperature based on temperature measurements obtained from both the low pressure side and the high pressure side of outdoor unit 130. The temperature data in combination with the pressure and/or current data may provide even more information that may be useful to, e.g., a contractor, to identify potential operational issues.

In addition, based on the vibration data, internal operations determination module 212 may determine whether outdoor unit 130 is vibrating more or less than under normal operating conditions by comparing the vibration data with a baseline and/or predetermined threshold amount stored in memory 206. Additionally, based on the audio data, internal operations determination module 212 may determine whether outdoor unit 130 emitting noise indicative of a potential issue, e.g., if the motor of outdoor unit 130 is making unusual sounds, by comparing the audio data with a baseline and/or predetermined threshold amount stored in memory 206.

Non-communicating device interface module 214 may be executed by processor 202 for communicating data between wireless connectivity device 200 and the non-communicating unit of system 100 that wireless connectivity device 200 is coupled to, e.g., outdoor unit 130. For example, non-communicating device interface module 214 may transmit commands to outdoor unit 130, e.g., to cause outdoor unit 130 to turn on or off and/or to operate until a temperature set point is achieved, responsive to user input. Moreover, non-communicating device interface module 214 may optimize operation of outdoor unit 130 by taking into account internal operations parameters of outdoor unit 130 as determined by internal operations determination module 212. For example, if a potential issue is identified by internal operations determination module 212, e.g., based on one or more of current, pressure, temperature, vibration, or audio measurements associated with outdoor unit 130, non-communicating device interface module 214 may adjust the operating parameters of outdoor unit 130, and/or cause outdoor unit 130 to power off until the potential issue is resolved. Moreover, based on known operational characteristics of outdoor unit 130, internal operations determination module 212 may cause outdoor unit 130 to operate in a manner such that the temperature set point is achieved in an energy efficient manner.

Communicating device interface module 216 may be executed by processor 202 for communicating data between wireless connectivity device 200 and a communicating unit of system 100, e.g., indoor unit 110. For example, communicating device interface module 216 may receive information indicative of the capabilities and/or internal operations parameters of indoor unit 110, such that cloud storage interface module 220 may communicate the information to cloud storage 160 for storage, as described in further detail below.

Thermostat interface module 218 may be executed by processor 202 for communicating data between wireless connectivity device 200 and controller 120, e.g., a thermostat. For example, thermostat interface module 218 may receive commands from controller 120, e.g., to power outdoor unit 130 on or off, such that non-communicating device interface module 214 may instruct outdoor unit 130 to turn on or off in accordance with the received commands.

Cloud storage interface module 220 may be executed by processor 202 for communicating data between wireless connectivity device 200 and cloud storage 160. For example, cloud storage interface module 220 may communicate information indicative of the capabilities and/or internal operations parameters of indoor unit 110 received by communicating device interface module 216, and/or information indicative of the internal operations parameters of outdoor unit 130 received and processed by sensors interface module 210 to cloud storage 160 for storage. As described above, the components of system 100 may subsequently access and receive data stored in cloud storage 160, e.g., via cloud storage interface module 220 and communication module 204.

Moreover, a third party with permission to access cloud storage 160 may access and download information stored in cloud storage 160. For example, a contractor may download information indicative of potential issues determined by internal operations determination module 212, and/or information indicative of the internal operations parameters of outdoor unit 130 received and processed by sensors interface module 210 such that the contractor may identify potential issues manually. Accordingly, the contractor may be made aware of potential issues prior to conducting an in-person inspection, and additionally may identify requisite repair tools and/or replacement parts prior to conducting the in-home visit for the repair and/or replacement, which will save valuable time and costs.

Referring now to FIG. 3, an alternative HVAC system with wireless connectivity capabilities is provided. System 300 may include non-communicating indoor unit 310, controller 320, communicating outdoor unit 330, wireless connectivity device 400, and/or cloud storage 160. Indoor unit 310, controller 320, wireless connectivity device 400, and/or cloud storage 160 may all be communicatively coupled via, e.g., network 150. Like indoor unit 110 of system 100, indoor unit 310 may be, e.g., an air handling unit that regulates and circulates air as part of an HVAC system, and/or a furnace that generates heat from fuel source such as natural gas, oil, or electricity, and like outdoor unit 130 of system 100, outdoor unit 330 may be, e.g., an AC unit that cools air by removing heat from the air for circulation. As described above, outdoor unit 330 may be operatively coupled to indoor unit 310 via a wired connection. Unlike system 100 where the indoor unit is communicating and the outdoor unit is non-communicating, in system 300, outdoor unit 330 is communicating and indoor unit 310 is non-communicating. Accordingly, outdoor unit 330 may communicate information indicative of its capabilities and internal operations parameters to the components of system 300, e.g., via a wired connection or wireless connection over network 150, whereas indoor unit 310 may be mechanically and operatively coupled to wireless connectivity device 400 to communicate with the components of system 300.

Wireless connectivity device 400 may constructed similar to wireless connectivity device 200, such that one or more sensors of wireless connectivity device 400 may be operatively coupled to indoor unit 310 to measure internal operations parameters of indoor unit 310, and communication module 404 of wireless connectivity device 400 may communicate information indicative of the internal operations parameters of indoor unit 310 to the components of system 300. For example, communication module 404 may provide any combination of, e.g., WiFi, Bluetooth, or cellular connections between wireless connectivity device 400 and the components of system 300. Unlike wireless connectivity device 200, which is operatively coupled to an outdoor unit, as wireless connectivity device 400 may be operatively coupled to indoor unit 310, wireless connectivity device 400 may function as a thermostat without the need for a separate thermostat.

As shown in FIG. 3, the thermostat functions of wireless connectivity device 400 may be controlled via controller 320, e.g., a mobile application running on a mobile device, communicatively coupled to wireless connectivity device 400 via a wireless connection such as WiFi or Bluetooth over network 150. Accordingly, wireless connectivity device 400 may receive user input via controller 320. Controller 320 further may provide commands to outdoor unit 330, and receive information from outdoor unit 330, wireless connectivity device 400, and cloud storage 160. Moreover, by coupling the one or more sensors of wireless connectivity device 400 to indoor unit 310, additional internal operations parameters of indoor unit 310 may be monitored, and thus more diagnostics may be provided by system 300. For example, wireless connectivity device 400 may monitor the cooling coils of indoor unit 310, and provide defrost control diagnostics.

Referring now to FIG. 4, components that may be included in wireless connectivity device 400 are described in further detail. As described above, wireless connectivity device 400 may be constructed similar to wireless connectivity device 200. For example, wireless connectivity device 400 may include one or more processors 402, communication module 404, and memory 406, which correspond with one or more processors 202, communication module 204, and memory 206. Accordingly, communication module 404 allows wireless connectivity platform 400 to communicate with outdoor unit 330, controller 320, and cloud storage 160. Moreover, like memory 206, memory 406 may be used to store operating system (OS) 408, sensors interface module 410, internal operations determination module 412, non-communicating device interface module 414, communicating device interface module 416, and cloud storage interface module 420. As outdoor unit 330 is the communicating unit in system 300, communicating device interface module 416 may communicate with outdoor unit 330.

Unlike memory 206, memory 406 may include mobile application interface module 418 instead of thermostat interface module 218. As the thermostat may be integrated with wireless connectivity device 400 that may be controlled via controller 320, e.g., a mobile application, mobile application interface module 418 may be executed by processor 402 for communicating data between wireless connectivity device 400 and controller 320. For example, mobile application interface module 418 may receive commands from controller 320, e.g., to power indoor unit 310 on or off, such that non-communicating device interface module 414 may instruct indoor unit 310 to turn on or off in accordance with the received commands.

Moreover, as described above, internal operations determination module 412 may provide additional diagnostic capabilities based on the received and processed data from sensors interface module 410 indicative of the state of internal operations of indoor unit 310. For example, by comparing the current and/or temperature data associated with indoor unit 310 with one or more baselines and/or predetermined thresholds associated therewith, internal operations determination module 412 may determine that indoor unit 310 is overcharged and that the cooling coils of indoor unit 310 are frozen, such that indoor unit 310 is unable to blow air, e.g., due to ice within indoor unit 310, to thereby provide indoor AC coil defrost control. In addition, based on at least the pressure data associated with indoor unit 310, internal operations determination module 412 may provide duct pressure monitoring, and/or detect a dirty filter, etc.

Referring now to FIG. 5, another alternative HVAC system with wireless connectivity capabilities is provided. System 500 may include non-communicating indoor unit 510, controller 520, non-communicating outdoor unit 530, one or more wireless connectivity devices 600, and/or cloud storage 160. Controller 520, one or more wireless connectivity devices 600, and/or cloud storage 160 may all be communicatively coupled via, e.g., network 150. Like indoor unit 110, 310, indoor unit 510 may be, e.g., an air handling unit that regulates and circulates air as part of an HVAC system, and/or a furnace that generates heat from fuel source such as natural gas, oil, or electricity, and like outdoor unit 130, 330, outdoor unit 530 may be, e.g., an AC unit that cools air by removing heat from the air for circulation. As described above, outdoor unit 530 may be operatively coupled to indoor unit 510 via a wired connection. Unlike systems 100, 300, both indoor unit 510 and outdoor unit 530 are non-communicating. Accordingly, both indoor unit 510 and outdoor unit 530 may each be mechanically and operatively coupled to or otherwise integrated with a wireless connectivity device, e.g., wireless connectivity device 600, to communicate with the components of system 500.

Wireless connectivity device 600 may constructed similar to wireless connectivity device 200, 400. For example, one or more sensors of the wireless connectivity device coupled to indoor unit 510 may be operatively coupled to indoor unit 510 to measure internal operations parameters of indoor unit 510, and the corresponding wireless communication module, e.g., communication module 604, of the wireless connectivity device may communicate information indicative of the internal operations parameters of indoor unit 510 to the components of system 500. Moreover, one or more sensors of the wireless connectivity device coupled to outdoor unit 530 may be operatively coupled to outdoor unit 530 to measure internal operations parameters of outdoor unit 530, and the corresponding wireless communication module, e.g., communication module 604, of the wireless connectivity device may communicate information indicative of the internal operations parameters of outdoor unit 530 to the components of system 500. For example, communication modules 604 may provide any combination of, e.g., WiFi, Bluetooth, or cellular connections between wireless connectivity devices 600 and the components of system 500.

Like wireless connectivity device 400, the wireless connectivity device operatively coupled to indoor unit 510 may function as a thermostat without the need for a separate thermostat. Accordingly, controller 520, e.g., a mobile application running on a mobile device, may be communicatively coupled to wireless connectivity devices 600 over network 150. Accordingly, controller 520 may transmit data indicative of user input to wireless connectivity devices 600, and information to cloud storage 160 for storage, and further may receive information from wireless connectivity devices 600 and cloud storage 160. Moreover, like wireless connectivity device 400, the wireless connectivity device operatively coupled to indoor unit 510 may monitor additional internal operations parameters of indoor unit 510, and thus provide more diagnostic capabilities.

Referring now to FIG. 6, components that may be included in wireless connectivity device 600 are described in further detail. As described above, wireless connectivity device 600 may be constructed similar to wireless connectivity device 200, 400. For example, wireless connectivity device 600 may include one or more processors 602, communication module 604, and memory 606, which correspond with one or more processors 202, 402, communication module 204, 404, and memory 206, 406. Accordingly, communication module 604 allows wireless connectivity platform 600 to communicate with another wireless connectivity device in system 500, controller 520, and cloud storage 160. Moreover, like memory 406, memory 606 may store operating system (OS) 608, sensors interface module 610, internal operations determination module 612, non-communicating device interface module 614, and cloud storage interface module 620.

Sensors interface module 610 and internal operations determination module 612 of the wireless connectivity device coupled to indoor unit 510 may operate in a similar manner to sensors interface module 410 and internal operations determination module 412, respectively, of wireless connectivity device 400 coupled to non-communicating indoor unit 310. Moreover, non-communicating device interface module 614 of the wireless connectivity device coupled to indoor unit 510 may communicate data between the wireless connectivity device and indoor unit 510, and non-communicating device interface module 614 of the wireless connectivity device coupled to outdoor unit 530 may communicate data between the wireless connectivity device and outdoor unit 530. Unlike memory 206, 406, memory 606 may include wireless connectivity device interface module 616 instead of communicating device interface module 216, 416. Wireless connectivity device interface module 616 may be executed by processor 602 for communicating data between one wireless connectivity device and another wireless connectivity device within system 500.

As described above, by coupling any of the wireless connectivity devices described herein to a non-communicating indoor unit, a non-communicating outdoor unit, or both, the wireless connectivity device may provide demand response interactions between third party utility providers and the HVAC system, such that the third party may effectively control the indoor unit and/or the outdoor unit. Accordingly, the third party may send commands to the one or more wireless connectivity devices to power on or off the associated indoor unit and/or outdoor unit to limit usage thereof, e.g., in accordance with state and/or local regulations.

Modifications and variations of the methods and devices described herein will be obvious to those skilled in the art from the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims.

Systems and Methods for Providing Retroactive Wireless Connectivity to HVAC Systems

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